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  • Examplepage for repair manual 4-cylinder diesel engine with unit injector
  • Examplepage for repair manual 2 4-cylinder diesel engine with unit injector
  • Examplepage for repair manual 3 4-cylinder diesel engine with unit injector

4-cylinder diesel engine with unit injector

For Polo

Original Volkswagen repair manual


15,24 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

6.513 KB

181 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel, Crankshaft, Pistons and conrods, Cylinder head, Engine oil, Charge air system with turbocharger, Repairing diesel direct injection system and Exhaust system. Show more
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Repair manual Polo 4-cylinder diesel engine with unit injector 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 engine
    2
  • 1.2 Securing engine to assembly stand
    6
  • 1.3 Notes on installing
    7
  • 1.4 Assembly mountings
    8
  • 1.5 Additional notes and assembly work for vehicles with air conditioner
    9
  • Crankshaft group
    10
  • 1 Dismantling and assembling engine
    10
  • 1.1 Assembly overview - toothed belt drive
    10
  • 1.2 Assembly overview - poly V-belt drive
    11
  • 1.3 Removing and installing poly V-belt
    13
  • 1.4 Assembly overview - crankcase
    15
  • 2 Sealing flange and flywheel
    17
  • 2.2 Assembly overview - sealing flange and flywheel, engine code BMT
    19
  • 2.3 Renewing crankshaft oil seal - belt pulley end
    20
  • 2.4 Removing and installing sealing flange - belt pulley end
    21
  • 2.5 Renewing crankshaft sealing flange - flywheel end, engine code BMT
    23
  • 2.6 Removing and installing engine speed sender G28 , engine code BMT
    30
  • 3 Crankshaft
    32
  • 3.1 Assembly overview - crankshaft
    32
  • 3.2 Crankshaft dimensions
    33
  • 4 Pistons and conrods
    35
  • 4.1 Assembly overview - pistons and conrods
    35
  • 4.2 Separating new conrods
    36
  • 4.3 Checking pistons, piston rings and cylinder bores
    37
  • 4.4 Checking piston projection at TDC
    38
  • 4.5 Piston and cylinder dimensions
    40
  • Cylinder head, valve gear
    41
  • 1 Cylinder head
    41
  • 1.1 Assembly overview - cylinder head
    41
  • 1.2 Removing and installing cylinder head cover
    44
  • 1.3 Removing, installing and tensioning toothed belt
    45
  • 1.4 Removing and installing cylinder head
    54
  • 1.5 Checking compression
    58
  • 2 Valve gear
    61
  • 2.1 Assembly overview - valve gear
    61
  • 2.2 Checking valve guides
    64
  • 2.3 Renewing valve stem oil seals
    65
  • 2.4 Removing and installing camshaft
    66
  • 2.5 Removing and installing camshaft oil seal
    70
  • Lubrication
    73
  • 1 Engine oil
    73
  • 1.1 Oil capacities
    73
  • 1.2 Checking engine oil level
    73
  • 2 Parts of lubrication system
    74
  • 2.1 Assembly overview - parts of lubrication system
    74
  • 2.2 Removing and installing sump
    75
  • 2.3 Assembly overview - oil filter bracket
    77
  • 2.4 Checking oil pressure and oil pressure switch
    78
  • 2.5 Assembly overview - oil supply line
    79
  • 2.6 Removing and installing oil supply line
    80
  • Cooling
    83
  • 1 Parts of cooling system
    83
  • 1.1 Assembly overview - parts of cooling system, body side
    84
  • 1.2 Assembly overview - parts of cooling system, engine side
    87
  • 1.3 Coolant hose schematic diagram
    88
  • 1.4 Draining and filling coolant
    92
  • 1.5 Removing and installing radiator
    94
  • 1.6 Removing and installing coolant pump
    96
  • 1.7 Removing and installing thermostat
    97
  • 1.8 Checking cooling system for leaks
    99
  • 1.9 Checking oil cooler for leaks
    101
  • Fuel supply system
    104
  • 1 Removing and installing parts of fuel supply system
    104
  • 1.1 Safety precautions when working on fuel supply system
    104
  • 1.2 Rules for cleanliness
    105
  • 1.3 Assembly overview - fuel tank with attachments
    105
  • 1.4 Assembly overview - fuel filter
    108
  • 1.5 Removing and installing fuel cooler
    109
  • 1.6 Removing and installing fuel tank
    110
  • 1.7 Removing and installing fuel delivery unit
    111
  • 1.8 Removing and installing fuel gauge sender G
    113
  • 1.9 Checking fuel pump
    114
  • 1.10 Assembly overview - accelerator mechanism
    115
  • 1.11 Checking tandem pump
    116
  • 1.12 Removing and installing tandem pump
    119
  • Turbocharging/supercharging
    123
  • 1 Charge air system with turbocharger
    123
  • 1.1 Safety precautions
    123
  • 1.2 Rules for cleanliness
    124
  • 1.4 Hose connections with spring band ring
    125
  • 1.5 Assembly overview - turbocharger with attachments
    125
  • 1.6 Removing and installing turbocharger, engine code BMT
    130
  • 1.7 Assembly overview - parts of charge air cooling
    132
  • 1.8 Checking charge air system for leaks
    134
  • Mixture preparation - injection
    137
  • 1 Repairing diesel direct injection system
    137
  • 1.1 Safety precautions
    137
  • 1.2 Rules for cleanliness
    138
  • 1.3 Assembly overview - intake manifold with intake manifold flap
    138
  • 1.4 Assembly overview - air filter
    142
  • 1.5 Assembly overview - unit injector
    142
  • 1.6 Removing and installing unit injector O-rings
    143
  • 1.7 Removing and installing unit injector
    145
  • 2 Engine control unit
    149
  • 2.1 Reading and clearing engine control unit fault memory
    149
  • 2.2 Adapting functions and components
    149
  • 2.3 Removing and installing engine control unit
    150
  • Exhaust system
    155
  • 1 Exhaust system
    155
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter and silencers
    157
  • 1.2 Assembly overview - front exhaust pipe with particulate filter
    158
  • 1.3 Assembly overview - silencer (vehicle with particulate filter)
    160
  • 1.4 Removing and installing front exhaust pipe with particulate filter
    160
  • 1.5 Aligning exhaust system stress free
    163
  • 2 Exhaust gas recirculation system
    165
  • 2.1 Assembly overview - parts of exhaust gas recirculation
    165
  • 2.2 Assembly overview - exhaust gas recirculation cooler, engine code BMT
    169
  • 2.3 Removing and installing exhaust gas recirculation cooler, engine code BMT
    170
  • 2.4 Schematic diagram for vacuum hoses
    171
  • Glow plug system
    172
  • 1 Checking glow plug system
    172
  • 1.1 Removing, installing and checking glow plugs
    172
  • 1.2 Characteristics of ceramic glow plugs
    173
  • 1.3 Removing, installing and checking ceramic glow plugs
    173
Manufacturer's designation 4-cylinder diesel engine with unit injector
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007)
Suitable car types 9N1, 9N3
Engine code ASZ, ATD, AXR, BLT
Category Reparaturanleitung

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