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  • Examplepage for repair manual 4-cyl. diesel engine with unit injector
  • Examplepage for repair manual 2 4-cyl. diesel engine with unit injector
  • Examplepage for repair manual 3 4-cyl. diesel engine with unit injector

4-cyl. diesel engine with unit injector

For Polo / Polo Sedan

Original Volkswagen repair manual


15,53 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

5.539 KB

185 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Charge air system with turbocharger, 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 unit injector 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
    2
  • 1 Removing and installing engine
    2
  • 1.1 Removing and installing engine
    2
  • 1.2 Notes on removing
    4
  • 1.3 Securing engine to assembly stand
    6
  • 1.4 Notes on installing
    6
  • 1.5 Tightening torques
    7
  • 1.6 Assembly mountings
    7
  • 1.7 Additional information and removal instructions for vehicles with air conditioner
    9
  • Crankshaft group
    10
  • 1 Dismantling and assembling engine
    10
  • 1.1 Dismantling and assembling engine
    10
  • 1.2 Removing and installing ribbed belt
    22
  • 2 Removing and installing sealing flange and flywheel
    25
  • 2.1 Removing and installing sealing flange and flywheel
    25
  • 2.2 Renewing crankshaft oil seal -pulley end
    28
  • 2.3 Removing and installing sealing flange, pulley end
    31
  • 3 Removing and installing crankshaft
    34
  • 3.1 Removing and installing crankshaft
    34
  • 3.2 Crankshaft dimensions
    38
  • 4 Dismantling and assembling pistons and conrods
    39
  • 4.1 Dismantling and assembling pistons and conrods
    39
  • 4.2 Checking piston projection at TDC
    45
  • 4.3 Piston and cylinder dimensions
    46
  • Cylinder head, Valve gear
    47
  • 1 Removing and installing cylinder head
    47
  • 1.1 Removing and installing cylinder head
    47
  • 1.2 Removing and installing cylinder head cover
    55
  • 1.3 Removing, installing and tensioning toothed belt
    57
  • 1.4 Removing and installing cylinder head
    64
  • 1.5 Checking compression pressures
    67
  • 2 Servicing valve gear
    69
  • 2.1 Servicing valve gear
    69
  • 2.2 Checking valve guides
    76
  • 2.3 Renewing valve stem seals
    78
  • 2.4 Removing and installing camshaft
    80
  • 2.5 Removing and installing camshaft oil seal
    84
  • Lubrication
    86
  • 1 Removing and installing parts of the lubrication system
    86
  • 1.1 Removing and installing parts of the lubrication system
    86
  • 1.2 Removing and installing sump
    98
  • 1.3 Checking oil pressure and oil pressure switch
    100
  • Cooling system
    102
  • 1 Removing and installing parts of cooling system
    102
  • 1.1 Removing and installing parts of cooling system
    102
  • 1.2 Parts of cooling system body side
    103
  • 1.3 Parts of cooling system engine side
    106
  • 1.4 Coolant hose connection diagram
    110
  • 1.5 Draining and filling cooling system
    112
  • 1.6 Removing and installing radiator
    115
  • 1.7 Removing and installing coolant pump
    116
  • 1.8 Removing and installing thermostat
    118
  • Fuel supply system
    120
  • 1 Removing and installing parts of fuel supply system
    120
  • 1.1 Removing and installing parts of fuel supply system
    120
  • 1.2 Removing and installing fuel tank with its attachments
    121
  • 1.3 Servicing fuel filter
    126
  • 1.4 Safety precautions when working on the fuel supply system
    128
  • 1.5 Rules for cleanliness
    129
  • 1.6 Removing and installing fuel cooler
    129
  • 1.7 Removing and installing fuel tank
    130
  • 1.8 Removing and installing fuel delivery unit
    132
  • 1.9 Removing and installing fuel gauge sender
    134
  • 1.10 Checking fuel pump
    135
  • 1.11 Servicing accelerator mechanism
    137
  • 1.12 Checking tandem pump
    138
  • 1.13 Removing and installing tandem pump
    140
  • Charging
    143
  • 1 Charge air system with turbocharger
    143
  • 1.1 Charge air system with turbocharger
    143
  • 1.2 Safety precautions
    143
  • 1.3 Rules for cleanliness
    143
  • 1.4 Removing and installing turbocharger with attachments
    143
  • 1.5 Removing and installing parts of charge air cooling
    152
  • Mixture preparation, Injection
    156
  • 1 Servicing Diesel direct injection system
    156
  • 1.1 Servicing Diesel direct injection system
    156
  • 1.2 Safety precautions
    156
  • 1.3 Rules for cleanliness
    156
  • 1.4 Servicing intake manifold flap
    157
  • 1.5 Servicing unit injector
    160
  • 1.6 Removing and installing O rings for unit injector
    162
  • 1.7 Removing and installing unit injector
    164
  • 2 Engine control unit
    168
  • 2.1 Engine control unit
    168
  • 2.2 Interrogating and erasing engine control unit fault memory
    168
  • 2.3 Adapting functions and components
    169
  • 2.4 Removing and installing engine control unit
    169
  • Exhaust system
    171
  • 1 Removing and installing parts of exhaust system
    171
  • 1.1 Removing and installing parts of exhaust system
    171
  • 1.2 Aligning exhaust system ensuring connections are stress-free
    173
  • 2 Exhaust gas recirculation system
    174
  • 2.1 Exhaust gas recirculation system
    174
  • 2.2 Removing and installing parts of exhaust gas recirculation system
    175
  • Ignition system
    177
  • 1 Checking glow plug system
    177
  • 1.1 Checking glow plug system
    177
  • 1.2 Checking glow plugs
    178
Manufacturer's designation 4-cyl. diesel engine with unit injector
Manufacturer Volkswagen
Suitable for Polo / Polo Sedan (2002 - 2007)
Suitable car types 9N
Engine code AXR
Category Reparaturanleitung

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