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  • Examplepage for repair manual 4-cyl. diesel engine with distributor injection pump
  • Examplepage for repair manual 2 4-cyl. diesel engine with distributor injection pump
  • Examplepage for repair manual 3 4-cyl. diesel engine with distributor injection pump

4-cyl. diesel engine with distributor injection pump

For Polo / Polo Sedan

Original Volkswagen repair manual


13,63 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.289 KB

159 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Servicing Diesel direct injection system and Engine control unit. Show more
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Repair manual Polo / Polo Sedan 4-cyl. diesel engine with distributor injection pump PDF download has the following content:

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
    4
  • 1.3 Securing engine to assembly stand
    8
  • 1.4 Notes on installing
    8
  • 1.5 Tightening torques
    9
  • 1.6 Assembly mountings
    10
  • 1.7 Additional information and removal instructions for vehicles with air conditioner
    11
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Dismantling and assembling engine
    12
  • 1.2 Removing and installing ribbed belt
    19
  • 1.3 Checking semi-automatic toothed belt tensioning roller
    21
  • 2 Removing and installing sealing flange and flywheel
    22
  • 2.1 Removing and installing sealing flange and flywheel
    22
  • 2.2 Renewing crankshaft oil seal -pulley end
    26
  • 2.3 Removing and installing sealing flange, pulley end
    29
  • 3 Removing and installing crankshaft
    32
  • 3.1 Removing and installing crankshaft
    32
  • 3.2 Crankshaft dimensions
    35
  • 4 Dismantling and assembling pistons and conrods
    36
  • 4.1 Dismantling and assembling pistons and conrods
    36
  • 4.2 Checking piston projection at TDC
    42
  • 4.3 Piston and cylinder dimensions
    43
  • Cylinder head, Valve gear
    44
  • 1 Removing and installing cylinder head
    44
  • 1.1 Removing and installing cylinder head
    44
  • 1.2 Removing, installing and tensioning toothed belt
    48
  • 1.3 Removing and installing cylinder head
    54
  • 1.4 Checking compression pressures
    60
  • 2 Servicing valve gear
    62
  • 2.1 Servicing valve gear
    62
  • 2.2 Reworking valve seats
    68
  • 2.3 Checking valve guides
    70
  • 2.4 Renewing valve stem seals
    71
  • 2.5 Removing and installing camshaft
    73
  • 2.6 Checking hydraulic bucket tappets
    76
  • Lubrication
    78
  • 1 Removing and installing parts of the lubrication system
    78
  • 1.1 Removing and installing parts of the lubrication system
    78
  • 1.2 Removing and installing sump
    86
  • 1.3 Checking oil pressure and oil pressure switch
    89
  • 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 Coolant hose connection diagram
    100
  • 1.5 Draining and filling cooling system
    102
  • 1.6 Removing and installing coolant pump
    105
  • 1.7 Removing and installing radiator
    107
  • 1.8 Removing and installing thermostat
    109
  • Fuel supply system
    111
  • 1 Removing and installing parts of fuel supply system
    111
  • 1.1 Removing and installing parts of fuel supply system
    111
  • 1.2 Removing and installing fuel tank with its attachments
    112
  • 1.3 Servicing fuel filter
    117
  • 1.4 Safety precautions when working on the fuel supply system
    120
  • 1.5 Rules for cleanliness
    120
  • 1.6 Removing and installing fuel tank
    121
  • 1.7 Removing and installing fuel delivery unit
    123
  • 1.8 Removing and installing fuel gauge sender
    125
  • 1.9 Servicing accelerator mechanism
    126
  • Mixture preparation, Injection
    127
  • 1 Servicing Diesel direct injection system
    127
  • 1.1 Servicing Diesel direct injection system
    127
  • 1.2 Safety precautions
    127
  • 1.3 Rules for cleanliness
    127
  • 1.4 Servicing injection pump
    128
  • 1.5 Dismantling and assembling intake manifold
    133
  • 1.6 Removing and installing injection pump
    135
  • 1.7 Removing and installing injectors
    140
  • 1.8 Checking injectors
    141
  • 1.9 Renewing injection timing device cover O-ring
    142
  • 2 Engine control unit
    143
  • 2.1 Engine control unit
    143
  • 2.2 Removing and installing engine control unit
    143
  • 2.3 Interrogating and erasing engine control unit fault memory
    143
  • 2.4 Adapting functions and components
    144
  • Exhaust system
    146
  • 1 Removing and installing parts of exhaust system
    146
  • 1.1 Removing and installing parts of exhaust system
    146
  • 1.2 Dismantling and assembling exhaust system
    146
  • 2 Exhaust gas recirculation system
    150
  • 2.1 Exhaust gas recirculation system
    150
  • 2.2 Removing and installing parts of exhaust gas recirculation system
    151
  • 2.3 Connection diagram for vacuum hoses
    152
  • 2.4 Checking exhaust gas recirculation valve (mechanical)
    153
  • Glow plug system
    154
  • 1 Checking glow plug system
    154
  • 1.1 Checking glow plug system
    154
  • 1.2 Checking glow plugs
    155
Manufacturer's designation 4-cyl. diesel engine with distributor injection pump
Manufacturer Volkswagen
Suitable for Polo / Polo Sedan (2002 - 2007)
Suitable car types 9N
Engine code ASY
Category Reparaturanleitung

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