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  • Examplepage for repair manual 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.6 l engine, common rail)

4-cylinder diesel engine (1.6 l engine, common rail)

For Polo A05

Original Volkswagen repair manual


26,49 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

17.596 KB

342 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Pistons and conrods, Crankshaft, Cylinder head, Engine oil, Oil filter bracket, oil pressure, engine oil cooler and oil supply line, Oil supply line and turbocharger support, Rules for cleanliness, Repair instructions if tank has been filled with incorrect fuel, Parts of fuel supply system, Fuel gauge sender G 6, Mixture preparation, 1.6 l common rail and Filling/bleeding/checking the diesel direct injection system. Show more
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Repair manual Polo A05 4-cylinder diesel 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 and installing engine cover panel
    3
  • 1.2 Removing engine
    4
  • 1.3 Separating engine from gearbox
    12
  • 1.4 Securing engine on engine and gearbox support
    14
  • 1.5 Installing engine
    16
  • 1.6 Notes on installing
    18
  • 1.7 Assembly mountings
    20
  • 1.8 Setting up support bracket
    21
  • Crankshaft group
    24
  • 1 Removing and installing poly V-belt
    24
  • 1.1 Assembly overview - poly V-belt drive without air conditioning compressor
    24
  • 1.2 Assembly overview \- poly V-belt drive with tensioning element and air conditioner compressor
    25
  • 1.3 Removing and installing poly V-belt without air conditioner compressor
    25
  • 1.4 Removing and installing poly V-belt with tensioning element
    26
  • 1.5 Removing and installing tensioning element for poly V-belt
    27
  • 2 Dismantling and assembling engine
    31
  • 2.1 Assembly overview - ancillary bracket
    31
  • 2.2 Removing and installing ancillary bracket
    31
  • 2.3 Removing and installing vibration damper
    33
  • 2.4 Assembly overview - toothed belt drive
    34
  • 2.5 Removing and installing engine bracket
    36
  • 2.6 Assembly overview - crankcase
    41
  • 3 Removing and installing sealing flange and flywheel
    43
  • 3.1 Assembly overview - sealing flanges and flywheel
    43
  • 3.2 Removing and installing dual-mass flywheel
    44
  • 3.3 Renewing crankshaft sealing flange - flywheel end
    46
  • 3.4 Renewing crankshaft oil seal - pulley end
    54
  • 3.5 Removing and installing sealing flange - pulley end
    55
  • 4 Removing and installing engine speed sender G28
    58
  • 5 Pistons and conrods
    60
  • 5.1 Assembly overview - pistons and conrods
    60
  • 5.2 Measuring piston projection at „TDC“
    64
  • 5.3 Piston and cylinder dimensions
    65
  • 5.4 Measuring radial clearance of conrods
    65
  • 6 Crankshaft
    67
  • 6.1 Assembly overview - crankshaft
    67
  • Cylinder head, valve gear
    69
  • 1 Cylinder head
    69
  • 1.1 Assembly overview - cylinder head
    69
  • 1.2 Removing and installing Hall sender G40
    71
  • 1.3 Assembly overview - cylinder head cover
    74
  • 1.4 Removing and installing cylinder head cover
    75
  • 1.5 Removing and installing injector seal in cylinder head cover
    79
  • 1.6 Removing, installing and tensioning toothed belts
    82
  • 1.7 Removing and installing cylinder head
    96
  • 1.8 Removing and installing vacuum pump
    110
  • 1.9 Checking compression
    110
  • 2 Valve gear
    113
  • 2.1 Assembly overview - valve gear
    113
  • 2.2 Measuring axial clearance of camshaft
    114
  • 2.3 Measuring radial clearance of camshafts
    115
  • 2.4 Valves
    116
  • 2.5 Renewing valve stem seals with cylinder head removed
    119
  • 2.6 Removing and installing camshafts
    122
  • 2.7 Checking hydraulic compensation elements
    129
  • 2.8 Removing and installing camshaft oil seal
    130
  • Lubrication
    132
  • 1 Engine oil
    132
  • 1.1 Oil capacities
    132
  • 1.2 Checking engine oil level
    132
  • 2 Parts of lubrication system
    133
  • 2.1 Assembly overview - oil pump, sump
    133
  • 2.2 Removing and installing oil sump
    136
  • 2.3 Removing and installing oil pump
    140
  • 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
    141
  • 3.1 Assembly overview - oil filter bracket and engine oil cooler
    141
  • 3.2 Removing and installing oil filter bracket with engine oil cooler
    143
  • 3.3 Removing and installing engine oil cooler
    146
  • 3.4 Checking engine oil cooler for leaks
    149
  • 3.5 Checking oil pressure and oil pressure switch
    151
  • 3.6 Removing and installing oil pressure switch F1
    154
  • 4 Oil supply line and turbocharger support
    155
  • 4.1 Assembly overview - oil supply line and turbocharger support
    155
  • 4.2 Removing and installing oil supply line and turbocharger support
    156
  • Cooling
    160
  • 1 Cooling system
    160
  • 1.1 Assembly overview - parts of cooling system, body side
    161
  • 1.2 Assembly overview - cowling with radiator fan V7
    163
  • 1.3 Parts of cooling system, engine side
    164
  • 1.4 Assembly overview - coolant pump and 4/2-way valve with thermostat
    165
  • 1.5 Removing and installing 4/2-way valve with thermostat
    165
  • 1.6 Coolant hose schematic diagram
    170
  • 1.7 Removing and installing cowling with radiator fan V7
    171
  • 1.8 Removing and installing radiator and detaching charge air cooler from radiator
    172
  • 1.9 Removing and installing coolant temperature sender G62
    176
  • 1.11 Removing and installing coolant circulation pump 2 V178
    178
  • 1.12 Removing and installing coolant pump
    179
  • 1.13 Removing and installing front coolant pipe
    181
  • 1.14 Removing and installing right coolant pipes
    184
  • 2 Draining and replenishing coolant
    186
  • 2.1 Draining and filling coolant
    186
  • 2.2 Checking cooling system for leaks
    190
  • Fuel supply system
    193
  • 1 Safety precautions when working on fuel supply system
    193
  • 2 Rules for cleanliness
    194
  • 3 Repair instructions if tank has been filled with incorrect fuel
    195
  • 3.1 Step 1 (Engine was started with incorrect fuel)
    195
  • 3.2 Step 2 (Engine was not started with incorrect fuel)
    196
  • 3.3 Step 3 (There are metal particles in fuel delivery unit and fuel tank)
    197
  • 3.4 Step 4 (There are no metal particles in fuel delivery unit and fuel tank)
    198
  • 3.5 Step 5 (There are metal particles in high-pressure pump)
    198
  • 3.6 Step 6 (There are no metal particles in high-pressure pump)
    198
  • 4 Emptying fuel tank
    199
  • 4.1 Emptying fuel tank when fuel pump is intact
    199
  • 4.2 Emptying fuel tank if it is more than 3/4 full
    202
  • 4.3 Emptying fuel tank if it is less than 3/4 full
    203
  • 5 Parts of fuel supply system
    205
  • 5.1 Fuel tank
    205
  • 5.2 Removing and installing fuel delivery unit
    210
  • 6 Fuel gauge sender G 6
    213
  • 7 Repairing fuel supply
    215
  • 7.1 Assembly overview - fuel filter
    215
  • 7.2 Removing and installing fuel filter
    217
  • 7.3 Assembly overview - accelerator mechanism
    217
  • 8 Testing low-pressure fuel systems (fuel pump)
    219
  • 8.1 Distinguishing features of the various low-pressure fuel systems
    219
  • 8.2 Checking fuel pump , vehicles with 0.5 bar low-pressure fuel system
    222
  • 8.3 Checking fuel pump , vehicles with 6.0 bar low-pressure fuel system
    225
  • Turbocharging/supercharging
    237
  • 1 Charge air system with turbocharger
    237
  • 1.1 Safety precautions
    237
  • 1.2 Rules for cleanliness
    237
  • 1.3 Assembly overview - turbocharger with attachments
    238
  • 1.4 Removing and installing turbocharger
    241
  • 1.5 Assembly overview - parts of charge air cooling
    245
  • 1.6 Removing and installing charge air cooler
    247
  • 1.7 Removing and installing charge air pipe »hot« side
    247
  • 2 Checking charge air system
    249
  • 2.1 Checking charge air system for leaks
    249
  • 3 Vacuum system
    251
  • 3.1 Vacuum hose schematic diagram
    251
  • 3.2 Testing vacuum system
    252
  • Mixture preparation - injection
    253
  • 1 Safety precautions, rules for cleanliness, assembly instructions
    253
  • 1.1 Safety precautions
    253
  • 1.2 Rules for cleanliness
    253
  • 1.3 Instructions for working on fuel system
    254
  • 2 Mixture preparation, 1.6 l common rail
    256
  • 2.1 System layouts
    256
  • 2.2 Assembly overview - fuel system
    260
  • 2.3 Assembly overview - installation position of clamp
    266
  • 3 Removing and installing components of the diesel direct injection system
    267
  • 3.1 Removing and installing injectors
    267
  • 3.2 Removing and installing high-pressure lines
    272
  • 3.3 Removing and installing high-pressure pump
    278
  • 3.4 Removing and installing high-pressure accumulator
    282
  • 3.5 Removing and installing fuel pressure regulating valve N276
    286
  • 3.6 Removing and installing fuel pressure sender G247
    288
  • 4 Filling/bleeding/checking the diesel direct injection system
    291
  • 4.1 Filling/bleeding, checking high-pressure pump/fuel system
    291
  • 4.2 Checks on high-pressure accumulator
    295
  • 4.3 Checks on injector
    297
  • 4.4 Checking fuel system for leaks
    300
  • 4.5 Check pressure retention valve in fuel return line
    301
  • 5 Intake manifold
    303
  • 5.3 Removing and installing intake manifold (vehicles with intake manifold flap V157 )
    305
  • 5.5 Removing and installing throttle valve module J338
    312
  • 6 Air filter
    313
  • 6.1 Assembly overview - air filter
    313
  • 7 Engine control unit
    316
  • 7.1 Removing and installing engine control unit with no ant-theft protection
    316
  • 7.2 Removing and installing anti-theft engine control unit
    316
  • Exhaust system
    318
  • 1 Exhaust system
    318
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter
    318
  • 1.2 Removing and installing catalytic converter
    319
  • 1.3 Assembly overview - silencer
    324
  • 1.4 Aligning exhaust system free of stress
    326
  • 2 Exhaust gas recirculation system
    328
  • 2.1 Assembly overview - parts of exhaust gas recirculation system
    328
  • 2.2 Checking changeover for exhaust gas recirculation cooler
    329
  • 2.3 Removing and installing exhaust gas recirculation system
    330
  • Glow plug system
    334
  • 1 Removing, installing and checking glow plugs
    334
Manufacturer's designation 4-cylinder diesel engine (1.6 l engine, common rail)
Manufacturer Volkswagen
Suitable for Polo A05 (2010)
Suitable car types 6R1
Engine code CLNA
Category Reparaturanleitung

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