4-cyl. diesel engine, Mechanics

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  3
• 1.3 Notes on installing
  5
• 1.4 Tightening torques
  7
• 1.5 Assembly mountings
  7
• 1.6 Renewing engine carrier rubber mounting
  8
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  9
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Dismantling and assembling engine
  11
• 1.2 Removing and installing ribbed belt
  26
• 1.3 Removing and installing toothed belt
  29
• 1.4 Checking semi-automatic toothed belt tensioning roller
  35
• 1.5 Removing single part injection pump sprocket
  36
• 2 Removing and installing sealing flange and pressure plate/flywheel/drive plate
  37
• 2.1 Removing and installing sealing flange and pressure plate/flywheel/drive plate
  37
• 2.2 Renewing crankshaft oil seal - pulley end -
  40
• 3 Removing and installing crankshaft
  42
• 3.1 Removing and installing crankshaft
  42
• 3.2 Crankshaft dimensions
  45
• 4 Dismantling and assembling pistons and conrods
  46
• 4.1 Dismantling and assembling pistons and conrods
  46
• 4.2 Checking piston projection at TDC
  53
• 4.3 Piston and cylinder dimensions
  54
• Cylinder head, Valve gear
  55
• 1 Removing and installing cylinder head
  55
• 1.1 Removing and installing cylinder head
  55
• 1.2 Removing and installing cylinder head
  60
• 1.3 Checking compressions
  62
• 2 Servicing valve gear
  65
• 2.1 Servicing valve gear
  65
• 2.2 Reworking valve seats
  71
• 2.3 Checking valve guides
  73
• 2.4 Renewing valve guides
  74
• 2.5 Renewing valve stem seals
  74
• 2.6 Removing and installing camshaft
  75
• 2.7 Checking hydraulic bucket tappets
  77
• 2.8 Replacing swirl chambers
  77
• Lubrication
  79
• 1 Removing and installing parts of the lubrication system
  79
• 1.1 Removing and installing parts of the lubrication system
  79
• 1.2 Checking oil pressure and oil pressure switch
  89
• 1.3 Removing and installing oil sump cap
  90
• Cooling system
  92
• 1 Removing and installing parts of cooling system
  92
• 1.1 Removing and installing parts of cooling system
  92
• 1.2 Parts of cooling system body side
  93
• 1.3 Parts of cooling system engine side
  97
• 1.4 Dismantling and assembling coolant pump
  100
• 1.5 Draining and filling cooling system
  101
• 1.6 Removing and installing radiator and radiator fan
  103
• Fuel supply system
  105
• 1 Removing and installing parts of fuel supply system
  105
• 1.1 Removing and installing parts of fuel supply system
  105
• 1.2 Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate
  106
• 1.3 Removing and installing fuel tank with its attachments, Caddy
  110
• 1.4 Servicing fuel filter
  115
• 1.5 Safety precautions when working on the fuel supply system
  117
• 1.6 Rules for cleanliness
  117
• 1.7 Removing and installing fuel tank
  117
• 1.8 Servicing accelerator mechanism
  119
• 1.9 Checking accelerator position sender
  124
• 1.10 Adjusting pedal position sender
  127
• Charging
  129
• 1 Charge air system with turbocharger
  129
• 1.1 Charge air system with turbocharger
  129
• 1.2 Safety precautions
  129
• 1.3 Rules for cleanliness
  129
• 1.4 Removing and installing turbocharger with attachments
  129
• 1.5 Removing and installing parts of charge air cooling system
  138
• 1.6 Exhaust gas turbocharger hose/pipe connections
  140
• 1.7 Removing and installing turbocharger
  142
• 2 Checking charge pressure system
  146
• 2.1 Checking charge pressure system
  146
• 2.2 Checking turbocharger
  146
• 2.3 Checking pressure unit for charge pressure regulating valve
  148
• 2.4 Removing and installing pressure unit for charge pressure regulating valve
  148
• 2.5 Checking charge pressure control
  149
• Exhaust system
  156
• 1 Removing and installing parts of exhaust system
  156
• 1.1 Removing and installing parts of exhaust system
  156
• 1.2 Front exhaust pipe and catalyst with its attachments
  157
• 1.3 Exhaust manifold, front exhaust pipe and catalyst with its attachments
  160
• 1.4 Silencer with mountings Caddy
  162
• 1.5 Silencer with mountings Polo Classic, Polo Estate
  165
• 2 Exhaust gas recirculation system, engine codes 1Y, AEY, AHB, AKW
  167
• 2.1 Exhaust gas recirculation system, engine codes 1Y, AEY, AHB, AKW
  167
• 2.2 Removing and installing parts of exhaust gas recirculation system
  168
• 2.3 Checking exhaust gas recirculation valve
  169
• 2.4 Checking exhaust gas recirculation
  169
• 2.5 Checking exhaust gas recirculation valve (N18)
  173
• 3 Exhaust gas recirculation system, engine codes AFN, AHU, ALE
  174
• 3.1 Exhaust gas recirculation system, engine codes AFN, AHU, ALE
  174
• 3.2 Removing and installing parts of exhaust gas recirculation system
  175
• 3.3 Vacuum hose connection diagram
  178
• 3.4 Checking exhaust gas recirculation valve (mechanical)
  180
• 3.5 Checking exhaust gas recirculation
  181