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  • Examplepage for repair manual 4-cyl. injection engine (toothed belt drive)
  • Examplepage for repair manual 2 4-cyl. injection engine (toothed belt drive)
  • Examplepage for repair manual 3 4-cyl. injection engine (toothed belt drive)

4-cyl. injection engine (toothed belt drive)

For Polo / Polo A05

Original Volkswagen repair manual


14,21 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

3.030 KB

167 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Pistons and conrods, Cylinder head, Parts of fuel supply system, Injection system and Engine control unit J623. Show more
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Repair manual Polo / Polo A05 4-cyl. injection engine 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
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing engine
    5
  • 1.2 Securing engine to assembly stand
    7
  • 1.3 Installing engine
    7
  • 1.4 Specified torques
    10
  • 1.5 Assembly mountings
    10
  • 1.6 Additional information and assembly work for vehicles with air conditioner
    11
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Assembly overview - parts l and ll
    12
  • 1.2 Assembly overview - part I, belt drive
    14
  • 1.3 Assembly overview - part II, cylinder block
    15
  • 1.4 Removing and installing poly-V belt
    17
  • 2 Cylinder block, sealing flange
    19
  • 2.1 Assembly overview
    19
  • 2.2 Pulling needle bearing out of and driving into crankshaft
    20
  • 2.3 Renewing crankshaft oil seal - belt pulley end
    21
  • 2.4 Poly V-belt pulley securing bolt tightening procedure
    23
  • 2.5 Removing and installing drive plate
    24
  • 2.7 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
    26
  • 2.8 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10017 )
    34
  • 2.9 Crankshaft dimensions
    41
  • 3 Pistons and conrods
    43
  • 3.1 Assembly overview
    43
  • 3.2 Piston and cylinder dimensions
    46
  • Cylinder head, valve gear
    47
  • 1 Cylinder head
    47
  • 1.1 Assembly overview
    47
  • 1.2 Checking valve timing
    49
  • 1.3 Removing, installing and tensioning toothed belt
    50
  • 1.4 Checking semi-automatic toothed belt tensioner
    55
  • 1.5 Removing and installing camshaft housing
    59
  • 1.6 Removing and installing cylinder head
    61
  • 1.7 Checking compression
    66
  • 2 Valve gear
    68
  • 2.1 Assembly overview
    68
  • 2.2 Reworking valve seats
    71
  • 2.3 Renewing camshaft oil seals
    72
  • 2.4 Checking valve guides
    74
  • 2.5 Renewing valve stem seals
    75
  • Lubrication
    77
  • 1 Parts of lubrication system
    77
  • 1.1 Engine oil:
    77
  • 1.2 Assembly overview
    77
  • 1.3 Removing and installing oil sump
    80
  • 1.4 Removing and installing oil pump
    81
  • 1.5 Checking oil pressure and oil pressure switch
    84
  • Cooling
    86
  • 1 Parts of cooling system
    86
  • 1.1 Assembly overview - parts of cooling system, body side
    86
  • 1.2 Assembly overview - parts of cooling system, body side
    88
  • 1.3 Assembly overview - parts of cooling system, engine side
    89
  • 1.4 Connection diagram for coolant hoses
    91
  • 1.5 Connection diagram for coolant hoses
    91
  • 1.6 Draining and adding coolant
    93
  • 1.7 Removing and installing radiator
    96
  • 1.8 Removing and installing coolant pump
    98
  • Fuel supply system
    100
  • 1 Parts of fuel supply system
    100
  • 1.1 Assembly overview - fuel tank with attachments
    100
  • 1.2 Safety regulations for working on fuel supply
    103
  • 1.3 Rules for cleanliness
    104
  • 1.4 Removing and installing fuel delivery unit
    104
  • 1.5 Removing and installing fuel gauge sender
    106
  • 1.6 Removing and installing fuel tank
    106
  • 1.7 Crash fuel shut-off
    108
  • 1.8 Checking fuel pump (engine codes AUA, AUB, BBY, BBZ, BKY and BUD)
    108
  • 1.9 Checking fuel pump (engine code CGGB)
    117
  • 1.10 Bleeding fuel system
    124
  • 2 Electronic power control (EPC)
    127
  • 2.1 Assembly overview
    127
  • 3 Activated charcoal filter system
    128
  • 3.1 Assembly overview - parts of activated charcoal filter system
    128
  • 3.2 Checking fuel tank breather
    129
  • Mixture preparation - injection
    130
  • 1 Injection system
    130
  • 1.1 General notes on injection
    130
  • 1.2 Assembly overview - parts of injection system
    130
  • 1.3 Assembly overview - intake manifold
    132
  • 1.4 Assembly overview - intake manifold
    133
  • 1.5 Assembly overview - fuel rail with injectors
    135
  • 1.6 Assembly overview - air filter
    135
  • 1.7 Assembly overview - air filter
    137
  • 1.8 Removing and installing air filter housing
    139
  • 1.9 Cleaning throttle valve module J338
    140
  • 1.10 Checking injectors
    141
  • 1.11 Checking intake air preheating
    142
  • 1.12 Safety precautions
    143
  • 1.13 Rules for cleanliness
    144
  • 1.14 Technical data
    145
  • 2 Engine control unit J623
    146
  • 2.1 Removing and installing engine (motor) control unit J623
    146
  • 2.2 Removing and installing anti-theft engine control unit J623
    146
  • Exhaust system
    150
  • 1 Parts of the exhaust system
    150
  • 1.1 Assembly overview - front exhaust system with attachments
    150
  • 1.2 Assembly overview - front exhaust system with attachments
    152
  • 1.3 Assembly overview - silencers with mountings
    154
  • 2 Exhaust gas recirculation system
    155
  • 2.1 Assembly overview
    155
  • Ignition system
    157
  • 1 Ignition system
    157
  • 1.1 General notes on ignition system
    157
  • 1.2 Assembly overview - parts of ignition system
    157
  • 1.3 Safety precautions
    159
  • 1.4 Test data, spark plugs
    160
Manufacturer's designation 4-cyl. injection engine (toothed belt drive)
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007) / Polo A05 (2010)
Suitable car types 9N1, 6R1
Engine code CGGB, AUA, AUB, BBY, BBZ, BKY
Category Reparaturanleitung

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