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  • Examplepage for repair manual 4-cyl. injection engine Mechanics (1.6 l engine)
  • Examplepage for repair manual 2 4-cyl. injection engine Mechanics (1.6 l engine)
  • Examplepage for repair manual 3 4-cyl. injection engine Mechanics (1.6 l engine)

4-cyl. injection engine Mechanics (1.6 l engine)

For Caddy Kasten/Kombi / Polo Classic / Polo Variant

Original Volkswagen repair manual


16,33 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.292 KB

196 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Accelerator mechanism, Checking electronic power control (EPC) and Secondary air system. Show more
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Repair manual Caddy Kasten/Kombi / Polo Classic / Polo Variant 4-cyl. injection engine Mechanics 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
    7
  • 1.4 Notes on installing
    8
  • 1.5 Tightening torques
    11
  • 1.6 Assembly mountings
    11
  • 1.7 Renewing bonded rubber bushes on subframe
    13
  • 1.8 Additional information and removal instructions for vehicles with air conditioner
    14
  • Crankshaft group
    16
  • 1 Dismantling and assembling engine
    16
  • 1.1 Dismantling and assembling engine
    16
  • 1.2 Removing and installing ribbed belt
    26
  • 2 Removing and installing sealing flange and pressure plate/drive plate
    28
  • 2.1 Removing and installing sealing flange and pressure plate/drive plate
    28
  • 2.2 Renewing crankshaft oil seal -belt pulley end
    31
  • 2.3 Removing and installing front sealing flange
    34
  • 2.4 Removing and installing drive plate
    36
  • 3 Removing and installing crankshaft
    39
  • 3.1 Removing and installing crankshaft
    39
  • 3.2 Colour markings
    43
  • 3.3 Crankshaft dimensions
    43
  • 4 Dismantling and assembling pistons and conrods
    44
  • 4.1 Dismantling and assembling pistons and conrods
    44
  • 4.2 Piston and cylinder dimensions
    50
  • Cylinder head, Valve gear
    51
  • 1 Removing and installing cylinder head
    51
  • 1.1 Removing and installing cylinder head
    51
  • 1.2 Removing, installing and tensioning toothed belt
    55
  • 1.3 Checking semi-automatic toothed belt tensioning roller
    58
  • 1.4 Removing and installing cylinder head
    59
  • 1.5 Checking compression pressures
    63
  • 2 Servicing valve gear
    64
  • 2.1 Servicing valve gear
    64
  • 2.2 Reworking valve seats
    70
  • 2.3 Replacing camshaft oil seal
    72
  • 2.4 Removing and installing camshaft
    75
  • 2.5 Checking hydraulic bucket tappets
    78
  • 2.6 Checking valve guides
    79
  • 2.7 Renewing valve guides
    80
  • 2.8 Renewing valve stem seals
    81
  • Lubrication
    84
  • 1 Removing and installing parts of the lubrication system
    84
  • 1.1 Removing and installing parts of the lubrication system
    84
  • 1.2 Removing and installing sump
    92
  • 1.3 Checking oil pressure and oil pressure switch
    94
  • Cooling system
    97
  • 1 Removing and installing parts of cooling system
    97
  • 1.1 Removing and installing parts of cooling system
    97
  • 1.2 Parts of cooling system body side
    98
  • 1.3 Parts of cooling system engine side
    101
  • 1.4 Coolant hose connection diagram
    111
  • 1.5 Draining and filling cooling system
    114
  • 1.6 Removing and installing radiator
    117
  • 1.7 Removing and installing coolant pump
    119
  • 1.8 Removing and installing thermostat
    121
  • Fuel supply system
    123
  • 1 Removing and installing parts of fuel supply system
    123
  • 1.1 Removing and installing parts of fuel supply system
    123
  • 1.2 Removing and installing fuel tank with its attachments and fuel filter
    124
  • 1.3 Safety precautions when working on the fuel supply system
    130
  • 1.4 Rules for cleanliness
    131
  • 1.5 Removing and installing fuel delivery unit
    131
  • 1.6 Removing and installing fuel gauge sender
    133
  • 1.7 Removing and installing fuel tank
    134
  • 1.8 Crash fuel shut-off
    135
  • 1.9 Checking fuel pump
    136
  • 2 Accelerator mechanism
    144
  • 2.1 Accelerator mechanism
    144
  • 2.2 Servicing accelerator mechanism
    144
  • 2.3 Adjusting throttle cable
    145
  • 3 Checking electronic power control (EPC)
    147
  • 3.1 Checking electronic power control (EPC)
    147
  • 3.2 Function of EPC system
    148
  • 3.3 Checking accelerator pedal position sender
    149
  • 3.4 Adjusting pedal position sender
    153
  • 4 Activated charcoal filter system
    155
  • 4.1 Activated charcoal filter system
    155
  • 4.2 Function
    155
  • 4.3 Servicing parts of the activated charcoal filter system
    156
  • 4.4 Checking fuel tank breather
    158
  • Exhaust system
    160
  • 1 Removing and installing parts of exhaust system
    160
  • 1.1 Removing and installing parts of exhaust system
    160
  • 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
    161
  • 1.3 Checking catalyst
    171
  • 2 Secondary air system
    173
  • 2.1 Secondary air system
    173
  • 2.2 Function
    173
  • 2.3 Removing and installing parts of the secondary air system
    174
  • 2.4 Checking secondary air pump motor
    178
  • 2.5 Checking combi-valve
    179
  • 2.6 Checking secondary air inlet valve
    181
  • 3 Exhaust gas recirculation system
    182
  • 3.1 Exhaust gas recirculation system
    182
  • 3.2 Servicing parts of exhaust gas recirculation system
    183
  • 3.3 Checking exhaust gas recirculation system
    186
  • 3.4 Checking potentiometer for exhaust gas recirculation
    188
Manufacturer's designation 4-cyl. injection engine Mechanics (1.6 l engine)
Manufacturer Volkswagen
Suitable for Caddy Kasten/Kombi (1996 - 2003) / Polo Classic / Polo Variant (1996 - 2002)
Suitable car types 9K, 6V
Engine code AKL, APF, AUR
Category Reparaturanleitung

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