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  • Examplepage for repair manual 3 4-cyl. injection engine with timing chain
  • Examplepage for repair manual 4-cyl. injection engine with timing chain
  • Examplepage for repair manual 2 4-cyl. injection engine with timing chain
  • Examplepage for repair manual 3 4-cyl. injection engine with timing chain

4-cyl. injection engine with timing chain

For Polo / Polo Sedan

Original Volkswagen repair manual


12,83 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.923 KB

148 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, Checking components and Engine control unit J623. Show more
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Repair manual Polo / Polo Sedan 4-cyl. injection engine with timing chain 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 Removing
    3
  • 1.2 Installing
    5
  • 1.3 Torque settings
    7
  • 1.4 Additional notes and assembly work for vehicles with air conditioner
    8
  • Crankshaft group
    10
  • 1 Dismantling and assembling engine
    10
  • 1.1 Assembly overview - parts l and ll
    10
  • 1.2 Part I Assembly overview - belt drive
    12
  • 1.3 Part II: Assembly overview - chain drive system
    13
  • 1.4 Removing and installing poly V-belt
    15
  • 1.5 Removing and installing valve timing housing
    16
  • 2 Cylinder block, sealing flange
    20
  • 2.1 Assembly overview
    20
  • 2.2 Renewing crankshaft oil seal - belt pulley end
    22
  • 2.3 Poly V-belt pulley securing bolt tightening procedure
    23
  • 2.5 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
    27
  • 2.6 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10017 )
    35
  • 2.7 Crankshaft dimensions
    42
  • 3 Pistons and conrods
    44
  • 3.1 Assembly overview
    44
  • 3.2 Checking piston
    45
  • 3.3 Checking cylinder bores
    46
  • 3.4 Piston and cylinder dimensions
    46
  • Cylinder head, valve gear
    47
  • 1 Cylinder head
    47
  • 1.1 Assembly overview
    47
  • 1.2 Checking valve timing
    50
  • 1.3 Adjusting valve timing
    51
  • 1.4 Removing and installing timing chain and chain drive for oil pump
    55
  • 1.5 Removing and installing camshaft housing
    63
  • 1.6 Removing and installing cylinder head
    67
  • 1.7 Checking compression
    70
  • 2 Valve gear
    72
  • 2.1 Assembly overview
    72
  • 2.2 Checking camshaft axial clearance
    74
  • 2.3 Reworking valve seats
    74
  • 2.4 Checking valve guides
    76
  • 2.5 Renewing valve stem seals
    76
  • Lubrication
    79
  • 1 Parts of lubrication system
    79
  • 1.1 Engine oil
    79
  • 1.2 Assembly overview
    79
  • 1.3 Removing and installing sump
    82
  • 1.4 Removing and installing oil pump
    83
  • 1.5 Checking oil pressure and oil pressure switch
    85
  • Cooling
    88
  • 1 Parts of cooling system
    88
  • 1.1 Assembly overview - parts of cooling system, body side
    88
  • 1.2 Assembly overview - parts of cooling system, engine side
    90
  • 1.3 Coolant hose schematic diagram
    92
  • 1.4 Draining and filling coolant
    93
  • 1.5 Removing and installing radiator
    95
  • 1.6 Removing and installing coolant pump
    96
  • Fuel supply system
    99
  • 1 Parts of fuel supply system
    99
  • 1.1 Assembly overview - fuel tank with attachments
    99
  • 1.2 Safety precautions when working on fuel supply system
    102
  • 1.3 Rules for cleanliness
    102
  • 1.4 Removing and installing fuel delivery unit
    102
  • 1.5 Removing and installing fuel gauge sender G
    104
  • 1.6 Removing and installing fuel tank
    105
  • 1.7 Assembly overview - fuel filter with attachments
    107
  • 1.8 Removing and installing fuel filter
    108
  • 1.9 Crash fuel shut-off
    109
  • 1.10 Checking fuel pump
    109
  • 1.11 Bleeding fuel system
    114
  • 2 Electronic power control (EPC)
    117
  • 2.1 Assembly overview
    117
  • 3 Activated charcoal filter system
    118
  • 3.1 Assembly overview
    118
  • 3.2 Checking fuel tank breather
    119
  • Mixture preparation - injection
    120
  • 1 Injection system
    120
  • 1.1 General notes on injection
    120
  • 1.2 Assembly overview - intake manifold
    120
  • 1.3 Assembly overview - fuel rail with injectors
    122
  • 1.4 Removing and installing injectors
    122
  • 1.5 Assembly overview - air filter
    123
  • 1.6 Removing and installing air filter housing
    125
  • 1.7 Cleaning throttle valve module J338
    126
  • 1.8 Safety precautions
    127
  • 1.9 Rules for cleanliness
    128
  • 1.10 Technical data
    128
  • 2 Checking components
    129
  • 2.1 Checking injectors for leaks and quantity injected
    129
  • 2.2 Checking fuel pressure regulator and holding pressure
    131
  • 3 Engine control unit J623
    134
  • 3.1 Removing and installing engine control unit J623
    134
  • 3.2 Vehicles with anti-theft secured engine control unit J623
    134
  • Exhaust system
    136
  • 1 Parts of the exhaust system
    136
  • 1.1 Assembly overview - catalytic converters and attachments
    136
  • 1.2 Assembly overview - silencers with mountings
    138
  • Ignition system
    139
  • 1 Ignition system
    139
  • 1.1 Assembly overview - ignition system
    139
  • 1.2 Removing and installing ignition coils with output stage
    140
  • 1.3 Safety precautions
    141
  • 1.4 Spark plug test data
    142
Manufacturer's designation 4-cyl. injection engine with timing chain
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007) / Polo Sedan (2003 - 2005)
Suitable car types 9N1, 9N2, 9N4
Engine code BTS
Category Reparaturanleitung

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