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

4-cylinder injection engine (5-valve, turbocharger) Volkswagen R GmbH

For Polo

Original Volkswagen repair manual


13,27 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.817 KB

154 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 Volkswagen R GmbH 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
    22
  • 2.4 Removing and installing crankshaft sealing flange - flywheel end
    23
  • 3 Crankshaft
    25
  • 3.1 Assembly overview - crankshaft
    25
  • 3.2 Crankshaft dimensions
    26
  • 4 Pistons and conrods
    28
  • 4.1 Assembly overview - pistons and conrods
    28
  • 4.2 Checking pistons, piston rings and cylinder bores
    29
  • 4.3 Piston and cylinder dimensions
    31
  • Cylinder head, valve gear
    32
  • 1 Cylinder head
    32
  • 1.1 Assembly overview - cylinder head
    32
  • 1.2 Removing, installing and tensioning toothed belt
    34
  • 1.3 Removing and installing cylinder head
    39
  • 1.4 Checking compression
    43
  • 2.1 Assembly overview - valve gear
    47
  • 2.2 Valve dimensions
    49
  • 2.3 Reworking valve seats
    49
  • 2.4 Renewing camshaft oil seals
    51
  • 2.5 Checking hydraulic bucket tappets
    55
  • 2.6 Removing and installing camshafts
    55
  • 2.7 Checking valve guides
    60
  • 2.8 Renewing valve stem seals
    60
  • Lubrication
    63
  • 1 Parts of lubrication system
    63
  • 1.1 Engine oil
    63
  • 1.2 Assembly overview - parts of lubrication system
    63
  • 1.3 Assembly overview - oil filter bracket
    65
  • 1.4 Removing and installing oil sump
    66
  • 1.5 Checking oil pressure and oil pressure switch
    69
  • Cooling
    72
  • 1 Parts of cooling system
    72
  • 1.1 Parts of cooling system - body side
    72
  • 1.2 Parts of cooling system - engine side
    73
  • 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
    85
  • 1 Fuel tank
    85
  • 1.1 Safety precautions when working on fuel supply system
    85
  • 1.2 Rules for cleanliness
    85
  • 1.3 Assembly overview - fuel tank with attachments
    86
  • 1.4 Removing and installing fuel tank
    88
  • 2 Repairing fuel supply system
    91
  • 2.1 Safety precautions when working on fuel supply system
    91
  • 2.2 Rules for cleanliness
    91
  • 2.3 Assembly overview - fuel delivery unit
    92
  • 2.4 Removing and installing fuel delivery unit
    92
  • 2.5 Removing and installing fuel gauge sender G
    94
  • 2.6 Checking fuel pump
    94
  • 3 Electronic power control (EPC)
    102
  • 3.1 Assembly overview
    102
  • 4 Activated charcoal filter system
    104
  • 4.1 Function
    104
  • 4.2 Assembly overview - parts of activated charcoal filter system
    104
  • 4.3 Overview of activated charcoal filter system
    106
  • 4.4 Checking fuel tank breather
    106
  • Turbocharging/supercharging
    108
  • 1 Turbocharger
    108
  • 1.1 Rules for cleanliness
    108
  • 1.2 Assembly overview part 1 - turbocharger
    109
  • 1.3 Assembly overview part 2 - turbocharger
    111
  • 1.4 Removing and installing turbocharger
    111
  • 2 Charge air system
    117
  • 2.1 Assembly overview - charge air cooler
    117
  • 2.2 Schematic diagram of turbocharging system
    118
  • 2.3 Checking vacuum unit for charge pressure control valve
    118
  • 2.4 Checking overrun shut-off valve
    119
  • 2.5 Checking charge air system for leaks
    120
  • Mixture preparation - injection
    122
  • 1 Injection system
    122
  • 1.1 General notes on injection
    122
  • 1.2 Safety precautions
    122
  • 1.3 Rules for cleanliness
    123
  • 1.4 Technical data
    123
  • 1.5 Assembly overview - intake manifold
    124
  • 1.6 Assembly overview - fuel rail with injectors
    125
  • 1.7 Assembly overview - air filter
    126
  • 1.8 Removing and installing intake manifold
    126
  • 2 Checking components
    128
  • 2.1 Checking injectors
    128
  • 2.2 Checking fuel pressure regulator and holding pressure
    130
  • 3 Engine control unit
    134
  • 3.1 Removing and installing engine control unit
    134
  • 3.2 Removing and installing anti-theft engine control unit
    134
  • Exhaust system
    137
  • 1 Parts of exhaust system
    137
  • 1.1 Assembly overview - exhaust system
    137
  • 1.2 Separating centre and rear silencers
    139
  • 1.3 Removing and installing front exhaust pipe with catalytic converter
    140
  • 2 Secondary air system
    142
  • 2.1 Function
    142
  • 2.2 Assembly overview - secondary air system
    142
  • 2.3 Removing and installing secondary air pump motor V101
    143
  • 2.4 Checking combination valve
    143
  • Ignition system
    145
  • 1 Repairing ignition system
    145
  • 1.1 General notes on ignition system
    145
  • 1.2 Safety precautions
    145
  • 1.3 Assembly overview - parts of the ignition
    145
  • 1.4 Removing and installing ignition coils with output stage
    147
  • 1.5 Test data, spark plugs
    148
Manufacturer's designation 4-cylinder injection engine (5-valve, turbocharger) Volkswagen R GmbH
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007)
Suitable car types 9N1, 9N3
Engine code BBU
Category Reparaturanleitung

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