THE CAR REPAIR SHOP
0
Home » Manuals » 4-cyl. diesel engine with distributor injection pump
  • 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
  • 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
Secure Payment via PayPal, credit card, direct debit and more
PayPal Logo SEPA Lastschrift Logo Giropay Logo Sofort Überweisung Logo

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

There are no reviews for this product at the moment.

Similar repair manuals

Basic equipment, From November 2001

Examplepage for repair manual Basic equipment, From November 2001

For Polo (2002 - 2005) / Polo (2005 - 2007) / Polo / Polo Sedan (2002 - 2007)

50,68 € Details

Brake systems

Examplepage for repair manual Brake systems

For Polo Sedan (2003 - 2005) / Polo (2005 - 2007)

13,85 € Details

4-cylinder diesel engine with unit injector

Examplepage for repair manual 4-cylinder diesel engine with unit injector

For Polo (2002 - 2005) / Polo (2005 - 2007)

15,24 € Details

Basic equipment (only for Polo Limousine), From July 2003

Examplepage for repair manual Basic equipment (only for Polo Limousine), From July 2003

For Polo Sedan (2003 - 2005) / Polo (2005 - 2007)

23,84 € Details

3-cylinder diesel engine

Examplepage for repair manual 3-cylinder diesel engine

For Polo (2002 - 2005) / Polo (2005 - 2007)

15,82 € Details

4-cyl. diesel engine with unit injector

Examplepage for repair manual 4-cyl. diesel engine with unit injector

For Polo / Polo Sedan (2002 - 2007)

15,53 € Details

Running gear, axles, steering

Examplepage for repair manual Running gear, axles, steering

For Polo Sedan (2003 - 2005) / Polo (2005 - 2007)

15,89 € Details

Electrical system South Africa

Examplepage for repair manual Electrical system South Africa

For Polo (2005 - 2007)

27,58 € Details

Fault finding, Power transmission

Examplepage for repair manual Fault finding, Power transmission

For Polo / Polo Sedan (2002 - 2007) / Polo (2005 - 2007)

4,47 € Details

5-speed manual gearbox 02R

Examplepage for repair manual 5-speed manual gearbox 02R

For Polo (2002 - 2005) / Polo (2005 - 2007) / Polo A05 (2010)

17,21 € Details

Our Best Sellers

Did you know? We also offer original spare parts.

car part 8W0807611A Schlieteil

8W0807611A

Schlieteil

66,85 €

Details
car part 2E0863439C Blende

2E0863439C

Blende

14,71 €

Details
car part n10255601 Klemmschel

n10255601

Klemmschel

1,98 €

Details
car part 3Q0713128 Modul

3Q0713128

Modul

96,34 €

Details
car part 06H103495AJ Abscheider

06H103495AJ

Abscheider

124,53 €

Details

Digijet-Einspritzanlage/ TSZ-H Zündanlage

Examplepage for repair manual Digijet-Einspritzanlage/ TSZ-H Zündanlage

For Polo / Polo Coupe / Polo Steilheck / Polo Stufenheck (1987 - 1994)

6,35 € Details

Nr. 526: Die Dieselmotoren-Baureihe EA288 mit Abgasnorm EU6

Examplepage for repair manual Nr. 526: Die Dieselmotoren-Baureihe EA288 mit Abgasnorm EU6

5,89 € Details

Standheizung, Zusatzheizung

Examplepage for repair manual Standheizung, Zusatzheizung

For Touareg (2011) / Touareg FL (2015 > )

6,64 € Details

image/svg+xml About Clonck

Original repair manuals und spare parts

Our repair manuals are original, come directly from Volkswagen and meet the highest quality standards.

In our original parts shop we sell high-quality original spare parts from car manufacturers. Use the search function to enter the desired part number (OE number) and order the required spare part quickly and easily.

Highest quality standards

At Clonck, we want to make car mechanics and car professionals happy. That's why you will only find professional and high-quality repair manuals at Clonck that will help you to repair your vehicle professionally.

Our partners

Autohaus Schmidt GmbH
Automag GmbH Filiale Laim
KFZ-VERLAG GmbH
Zimpel und Franke GmbH

Clonck: The car repair shop - also as app!

Clonck App Logo Play Store

Clonck: Fitting car parts for your car repair

4,5 90

With Clonck you can order the right original spare parts in no time.

  • Add your car model
  • Select assembly group
  • Enter vehicle identification number (VIN)
  • Access to over 5,000 original repair manuals
Start app now
Clonck App Preview Car Mobilephone Carparts