THE CAR REPAIR SHOP
0
Home » Manuals » 4-cyl. injection engine, 2005▸
  • Examplepage for repair manual 4-cyl. injection engine, 2005▸
  • Examplepage for repair manual 2 4-cyl. injection engine, 2005▸
  • Examplepage for repair manual 3 4-cyl. injection engine, 2005▸
  • Examplepage for repair manual 4-cyl. injection engine, 2005▸
  • Examplepage for repair manual 2 4-cyl. injection engine, 2005▸
  • Examplepage for repair manual 3 4-cyl. injection engine, 2005▸

4-cyl. injection engine, 2005▸

For Polo / Polo Sedan

Original Volkswagen repair manual


11,89 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

3.237 KB

135 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Parts of fuel system and Electronic power control (EPC). 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. injection engine, 2005▸ PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Removing and installing engine
    2
  • 1 Removing and installing engine
    2
  • 1.1 Notes on removing
    3
  • 1.2 Securing engine to assembly stand
    7
  • 1.3 Notes on installing
    7
  • 1.4 Assembly mounting
    8
  • Crankshaft group
    10
  • 1 Dismantling and assembling engine
    10
  • 1.1 Assembly overview
    10
  • 1.2 Removing and installing poly V-belt
    14
  • 2 Removing and installing front sealing flange
    17
  • 2.1 Exploded view sealing flanges and flywheel or drive plate
    17
  • 2.2 Renewing crankshaft oil seal
    18
  • 2.3 Removing and installing front sealing flange
    20
  • 3 Dismantling and assembling pistons and conrods
    24
  • 3.1 Assembly overview - Pistons and conrods
    24
  • 3.2 Checking pistons, piston rings and cylinder bores
    27
  • 3.3 Piston and cylinder dimensions
    29
  • 4 Removing and installing crankshaft
    30
  • 4.1 Exploded view crankshaft
    30
  • 4.2 Colour identification
    31
  • 4.3 Crankshaft dimensions
    32
  • Cylinder head, Valve gear
    33
  • 1 Removing and installing cylinder head
    33
  • 1.1 Exploded view cylinder head
    33
  • 1.2 Removing, installing and tensioning toothed belt
    35
  • 1.3 Checking semi-automatic toothed belt tensioning roller
    39
  • 1.4 Removing and installing cylinder head
    39
  • 1.5 Checking compression
    43
  • 2 Repairing valve gear
    46
  • 2.1 Exploded view valve gear
    46
  • 2.2 Reworking valve seats
    48
  • 2.3 Renewing camshaft oil seal
    50
  • 2.4 Removing and installing camshaft
    52
  • 2.5 Checking hydraulic bucket tappets
    55
  • 2.6 Checking valve guides
    56
  • 2.7 Renewing valve guides
    56
  • 2.8 Renewing valve stem seals
    57
  • Lubrication
    61
  • 1 Removing and installing parts of lubrication system
    61
  • 1.1 Engine oil
    61
  • 1.2 Assembly overview - Parts of lubrication system
    62
  • 1.3 Assembly overview - Oil filter bracket
    64
  • 1.4 Removing and installing sump
    65
  • 1.5 Checking oil pressure and oil pressure switch
    67
  • Cooling system
    70
  • 1 Removing and installing parts of cooling system
    70
  • 1.1 Assembly overview - parts of cooling system - engine side
    70
  • 1.2 Assembly overview - parts of cooling system - body side
    73
  • 1.3 Draining and filling coolant
    74
  • 1.4 Removing and installing coolant pump
    77
  • 1.5 Removing and installing thermostat
    78
  • 1.6 Removing and installing radiator fan V7 and radiator fan 2 V177
    80
  • 1.7 Removing and installing radiator
    81
  • 1.8 Checking cooling system for leaks
    82
  • Fuel supply system
    85
  • 1 Parts of fuel system
    85
  • 1.1 Assembly overview - fuel tank with attachments
    85
  • 1.2 Safety precautions when working on fuel supply system
    88
  • 1.3 Rules for cleanliness
    89
  • 1.4 Removing and installing fuel delivery unit
    89
  • 1.5 Removing and installing fuel gauge sender
    91
  • 1.6 Removing and installing fuel tank
    91
  • 1.7 Crash fuel shut-off
    93
  • 1.8 Checking fuel pump
    93
  • 2 Active charcoal filter system
    101
  • 2.1 Assembly overview - parts of active charcoal filter system
    101
  • 2.2 Checking fuel tank breather
    102
  • 3 Electronic power control (EPC)
    104
  • 3.1 Assembly overview
    104
  • Mixture preparation, Injection
    106
  • 1 Repairing ignition system
    106
  • 1.1 General notes on ignition system
    106
  • 1.2 Safety precautions
    106
  • 1.3 Assembly overview - ignition system
    106
  • 1.4 Spark plugs
    107
  • 2 Engine control unit
    108
  • 2.1 Removing and installing anti-theft engine control unit
    108
  • 2.2 Reading and erasing engine control unit fault memory
    110
  • Exhaust system
    111
  • 1 Removing and installing parts of exhaust system
    111
  • 1.1 Front exhaust pipe and catalytic converter with attachments
    111
  • 1.2 Silencer with mountings
    113
  • 1.3 Separating middle and rear silencers
    113
  • 1.4 Aligning exhaust system stress free
    114
  • Ignition system
    116
  • 1 Repairing injection system
    116
  • 1.1 General notes on injection
    116
  • 1.2 Safety precautions
    117
  • 1.3 Rules for cleanliness
    117
  • 1.4 Technical data
    118
  • 1.5 Dismantling and assembling intake manifold - upper part
    118
  • 1.6 Dismantling and assembling intake manifold - lower part
    120
  • 1.7 Fuel rail
    121
  • 1.8 Dismantling and assembling air cleaner
    122
  • 1.9 Removing and installing intake manifold
    122
  • 1.10 Removing and installing fuel rail with intake manifold flaps
    123
  • 1.11 Removing and installing injectors
    125
  • 1.12 Renewing Teflon seal on injector
    127
  • 1.13 Cleaning throttle valve module J338
    129
Manufacturer's designation 4-cyl. injection engine, 2005▸
Manufacturer Volkswagen
Suitable for Polo / Polo Sedan (2002 - 2007)
Suitable car types 9N
Engine code BBX
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 distributor injection pump

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

For Polo / Polo Sedan (2002 - 2007)

13,63 € 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 4L0898283A Teilesatz

4L0898283A

Teilesatz

56,38 €

Details
car part 1S0823363F Stuetze

1S0823363F

Stuetze

19,43 €

Details
car part 8V4809937A Schlauch

8V4809937A

Schlauch

7,39 €

Details
car part 1K0971813B9B9 Abdeckung

1K0971813B9B9

Abdeckung

11,77 €

Details
car part 1K0927904BA Leitg.Satz

1K0927904BA

Leitg.Satz

58,91 €

Details

4-Zyl. Einspritzmotor

Examplepage for repair manual 4-Zyl. Einspritzmotor

For New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)

21,00 € Details

Nr. 534: Der 1,4 l-3-Zylinder-TDI-Motor der Dieselmotoren-Baureihe EA288

Examplepage for repair manual Nr. 534: Der 1,4 l-3-Zylinder-TDI-Motor der Dieselmotoren-Baureihe EA288

5,89 € Details

4-Zyl.-Dieselmotor (1,5- und 1,6 l-Motor) 068.2 / 068.5 / 068.A / ADK

Examplepage for repair manual 4-Zyl.-Dieselmotor (1,5- und 1,6 l-Motor) 068.2 / 068.5 / 068.A / ADK

For Industriemotoren - Industrial Engines ()

8,15 € 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