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  • Examplepage for repair manual 4-cylinder injection engine (direct injection)
  • Examplepage for repair manual 2 4-cylinder injection engine (direct injection)
  • Examplepage for repair manual 3 4-cylinder injection engine (direct injection)

4-cylinder injection engine (direct injection)

For Polo

Original Volkswagen repair manual


12,69 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.126 KB

146 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Pistons and conrods, Cylinder head, Safety precautions, Parts of fuel supply system, Checking components and Engine control unit J623. 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
    3
  • 1.2 Installing
    5
  • 1.3 Specified torques
    7
  • 1.4 Additional information 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 Assembly overview - part I, 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 (timing case)
    16
  • 2 Cylinder block, sealing flange
    20
  • 2.1 Assembly overview
    20
  • 2.2 Renewing crankshaft oil seal - pulley end
    22
  • 2.3 Poly V-belt pulley securing bolt tightening procedure
    23
  • 2.4 Renewing crankshaft sealing flange - flywheel end
    26
  • 2.5 Crankshaft dimensions
    33
  • 3 Pistons and conrods
    35
  • 3.1 Assembly overview
    35
  • 3.2 Checking piston
    36
  • 3.3 Checking cylinder bores
    37
  • 3.4 Piston and cylinder dimensions
    37
  • Cylinder head, valve gear
    38
  • 1 Cylinder head
    38
  • 1.1 Assembly overview
    38
  • 1.2 Checking valve timing
    41
  • 1.3 Adjusting valve timing
    42
  • 1.4 Removing and installing timing chain and chain drive for oil pump
    46
  • 1.5 Removing and installing camshaft housing
    53
  • 1.6 Removing and installing cylinder head
    57
  • 1.7 Checking compression
    60
  • 2 Valve gear
    62
  • 2.1 Assembly overview
    62
  • 2.2 Checking camshaft axial clearance
    64
  • 2.3 Reworking valve seats
    64
  • 2.4 Checking valve guides
    66
  • 2.5 Renewing valve stem seals
    66
  • Lubrication
    69
  • 1 Parts of lubrication system
    69
  • 1.1 Engine oil
    69
  • 1.2 Assembly overview
    69
  • 1.3 Removing and installing sump
    72
  • 1.4 Removing and installing oil pump
    73
  • 1.5 Checking oil pressure and oil pressure switch
    75
  • Cooling
    78
  • 1 Parts of cooling system
    78
  • 1.1 Assembly overview - parts of cooling system, body side
    78
  • 1.2 Assembly overview - parts of cooling system, engine side
    80
  • 1.3 Coolant hose schematic diagram
    82
  • 1.4 Draining and filling coolant
    83
  • 1.5 Removing and installing radiator
    85
  • 1.6 Removing and installing coolant pump
    86
  • Fuel supply system
    89
  • 1 Safety precautions
    89
  • 1.1 Safety precautions when working on fuel supply system
    89
  • 1.2 Releasing pressure in high-pressure area
    90
  • 2 Parts of fuel supply system
    91
  • 2.1 Assembly overview - fuel tank with attachments
    91
  • 2.2 Safety precautions when working on fuel supply system
    94
  • 2.3 Rules for cleanliness
    94
  • 2.4 Removing and installing fuel delivery unit
    94
  • 2.5 Removing and installing fuel gauge sender G
    96
  • 2.6 Removing and installing fuel tank
    97
  • 2.7 Crash fuel shut-off
    99
  • 2.8 Checking fuel pump
    99
  • 3 Electronic power control (EPC)
    106
  • 3.1 Function of EPC system
    106
  • 3.2 Assembly overview
    106
  • 4 Activated charcoal filter system
    108
  • 4.1 Function
    108
  • 4.2 Assembly overview
    108
  • 4.3 Checking fuel tank breather
    109
  • Mixture preparation - injection
    111
  • 1 Injection system
    111
  • 1.1 General notes on injection
    111
  • 1.2 Assembly overview - intake manifold
    111
  • 1.3 Assembly overview - fuel rail with injectors
    114
  • 1.4 Checking vacuum reservoir in intake manifold for leaks
    115
  • 1.5 Assembly overview - air filter
    116
  • 1.6 Removing and installing air filter
    117
  • 1.7 Cleaning throttle valve module J338
    117
  • 1.8 Removing and installing injectors
    118
  • 1.9 Removing and installing high-pressure pump
    121
  • 1.10 Safety precautions
    123
  • 1.11 Rules for cleanliness
    124
  • 1.12 Technical data
    124
  • 2 Checking components
    126
  • 2.1 Checking intake air preheating
    126
  • 3 Engine control unit J623
    127
  • 3.1 Removing and installing engine control unit J623
    127
  • 3.2 Removing and installing anti-theft engine control unit J623 (vehicles ► model year 2007)
    127
  • 3.3 Removing and installing anti-theft engine control unit J623 (vehicles model year 2007▸)
    129
  • Exhaust system
    131
  • 1 Parts of the exhaust system
    131
  • 1.1 Assembly overview - catalytic converters and attachments
    131
  • 1.2 Assembly overview - silencers with mountings
    133
  • 2 Exhaust gas recirculation system
    134
  • 2.1 Assembly overview - exhaust gas recirculation system
    134
  • 2.2 Removing and installing exhaust gas recirculation valve N18
    135
  • Ignition system
    137
  • 1 Ignition system
    137
  • 1.1 Assembly overview - ignition system
    137
  • 1.2 Removing and installing ignition coils with output stage
    138
  • 1.3 Safety precautions
    139
  • 1.4 Test data, spark plugs
    140
Manufacturer's designation 4-cylinder injection engine (direct injection)
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007)
Suitable car types 9N1, 9N3
Engine code AXU
Category Reparaturanleitung

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