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  • Examplepage for repair manual 4-cylinder injection engine (5-valve, turbocharger)
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  • Examplepage for repair manual 3 4-cylinder injection engine (5-valve, turbocharger)
  • Examplepage for repair manual 4-cylinder injection engine (5-valve, turbocharger)
  • Examplepage for repair manual 2 4-cylinder injection engine (5-valve, turbocharger)
  • Examplepage for repair manual 3 4-cylinder injection engine (5-valve, turbocharger)

4-cylinder injection engine (5-valve, turbocharger)

For Polo

Original Volkswagen repair manual


13,34 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.869 KB

155 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel, Crankshaft, Pistons and conrods, Cylinder head, Fuel tank, Repairing fuel supply system, Turbocharger and Checking components. Show more
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Repair manual Polo 4-cylinder 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
    2
  • 1 Removing and installing engine
    2
  • 1.1 Removing engine
    2
  • 1.2 Securing engine to assembly stand
    6
  • 1.3 Installing engine
    8
  • 1.4 Assembly mountings
    10
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Assembly overview
    11
  • 1.2 Removing and installing poly V-belt
    15
  • 2 Sealing flange and flywheel
    17
  • 2.1 Renewing crankshaft oil seal - pulley end
    18
  • 2.2 Removing and installing sealing flange - pulley end
    20
  • 2.3 Removing and installing flywheel
    23
  • 2.4 Removing and installing crankshaft sealing flange - flywheel end
    24
  • 3 Crankshaft
    26
  • 3.1 Assembly overview - crankshaft
    26
  • 3.2 Crankshaft dimensions
    27
  • 4 Pistons and conrods
    29
  • 4.1 Assembly overview - pistons and conrods
    29
  • 4.2 Checking pistons, piston rings and cylinder bores
    30
  • 4.3 Piston and cylinder dimensions
    32
  • Cylinder head, valve gear
    33
  • 1 Cylinder head
    33
  • 1.1 Assembly overview - cylinder head
    33
  • 1.2 Removing, installing and tensioning toothed belts
    35
  • 1.3 Removing and installing cylinder head
    40
  • 1.4 Checking compression
    44
  • 2.1 Assembly overview - valve gear
    48
  • 2.2 Valve dimensions
    50
  • 2.3 Reworking valve seats
    50
  • 2.4 Renewing camshaft oil seals
    52
  • 2.5 Checking hydraulic bucket tappets
    56
  • 2.6 Removing and installing camshafts
    56
  • 2.7 Checking valve guides
    61
  • 2.8 Renewing valve stem seals
    61
  • Lubrication
    64
  • 1 Parts of lubrication system
    64
  • 1.1 Engine oil
    64
  • 1.2 Assembly overview - parts of lubrication system
    64
  • 1.3 Assembly overview - oil filter bracket
    66
  • 1.4 Removing and installing sump
    67
  • 1.5 Checking oil pressure and oil pressure switch
    70
  • Cooling
    73
  • 1 Parts of cooling system
    73
  • 1.1 Parts of cooling system, body side
    73
  • 1.2 Parts of cooling system - engine side
    74
  • 1.3 Coolant hose schematic diagram
    76
  • 1.4 Draining and filling coolant
    77
  • 1.5 Removing and installing radiator
    80
  • 1.6 Removing and installing coolant pump
    82
  • 1.7 Removing and installing thermostat
    83
  • Fuel supply system
    86
  • 1 Fuel tank
    86
  • 1.1 Safety precautions when working on fuel supply system
    86
  • 1.2 Rules for cleanliness
    86
  • 1.3 Assembly overview - fuel tank with attachments
    87
  • 1.4 Removing and installing fuel tank
    89
  • 2 Repairing fuel supply system
    92
  • 2.1 Safety precautions when working on fuel supply system
    92
  • 2.2 Rules for cleanliness
    92
  • 2.3 Assembly overview - fuel delivery unit
    93
  • 2.4 Removing and installing fuel delivery unit
    93
  • 2.5 Removing and installing fuel gauge sender G
    95
  • 2.6 Checking fuel pump
    95
  • 3 Electronic power control (EPC)
    103
  • 3.1 Assembly overview
    103
  • 4 Activated charcoal filter system
    105
  • 4.1 Function
    105
  • 4.2 Assembly overview - parts of activated charcoal filter system
    105
  • 4.3 Schematic diagram of activated charcoal filter system
    107
  • 4.4 Checking fuel tank breather
    107
  • Turbocharging/supercharging
    109
  • 1 Turbocharger
    109
  • 1.1 Rules for cleanliness
    109
  • 1.2 Assembly overview part 1 - turbocharger
    110
  • 1.3 Assembly overview part 2 - turbocharger
    112
  • 1.4 Removing and installing turbocharger
    112
  • 2 Charge air system
    118
  • 2.1 Assembly overview - charge air cooler
    118
  • 2.2 Schematic diagram of turbocharging system
    119
  • 2.3 Checking charge pressure regulating valve vacuum unit
    119
  • 2.4 Checking overrun shut-off valve
    120
  • 2.5 Checking charge air system for leaks
    121
  • Mixture preparation - injection
    123
  • 1 Injection system
    123
  • 1.1 General notes on injection
    123
  • 1.2 Safety precautions
    123
  • 1.3 Rules for cleanliness
    124
  • 1.4 Technical data
    124
  • 1.5 Assembly overview - intake manifold
    125
  • 1.6 Assembly overview - fuel rail with injectors
    126
  • 1.7 Assembly overview - air filter
    127
  • 1.8 Removing and installing intake manifold
    127
  • 2 Checking components
    129
  • 2.1 Checking injectors
    129
  • 2.2 Checking fuel pressure regulator and holding pressure
    131
  • 3 Engine control unit
    135
  • 3.1 Removing and installing engine control unit
    135
  • 3.2 Removing and installing anti-theft engine control unit
    135
  • Exhaust system
    138
  • 1 Parts of exhaust system
    138
  • 1.1 Assembly overview - exhaust system
    138
  • 1.2 Separating centre and rear silencers
    140
  • 1.3 Removing and installing front exhaust pipe with catalytic converter
    141
  • 2 Secondary air system
    143
  • 2.1 Function
    143
  • 2.2 Assembly overview - secondary air system
    143
  • 2.3 Removing and installing secondary air pump motor V101
    144
  • 2.4 Checking combination valve
    144
  • Ignition system
    146
  • 1 Repairing ignition system
    146
  • 1.1 General notes on ignition system
    146
  • 1.2 Safety precautions
    146
  • 1.3 Assembly overview - parts of ignition system
    146
  • 1.4 Removing and installing ignition coils with output stage
    148
  • 1.5 Spark plug test data
    149
Manufacturer's designation 4-cylinder injection engine (5-valve, turbocharger)
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007)
Suitable car types 9N1, 9N3
Engine code BJX
Category Reparaturanleitung

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