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  • 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
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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

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