Polo Mk5: Power unit
Also for this vehicle: Polo Mk3, Polo Mk4.
Steering & suspension
Body & interior
General
Transmission
Engine
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
4-cyl. injection engine with timing chain120 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons39 pages
Dismantling and assembling engine7 pages
Cylinder block, sealing flange23 pages
- Assembly overview
- Renewing crankshaft oil seal - belt pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Characteristics of the sealing flange and the assembly device T10017 and T10134
Renewing crankshaft sealing flange - flywheel end (assembly tool T10134)9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling sealing flange with sender wheel on assembly appliance T10134
- B - Attaching assembling tool T10134 with sealing flange to crankshaft flange
- C - Bolting assembly tool T10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly tool T10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Renewing crankshaft sealing flange - flywheel end (assembly tool T10017)9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A-Assembling sealing flange with sender wheel on assembly appliance T10017
- B-Assembling appliance T10017 with sealing flange on crankshaft flange
- C-Fitting assembly appliance T10017 onto crankshaft flange
- D-Pressing sender wheel onto crankshaft flange with assembly appliance T10017
- E - Checking sender wheel installation position on crankshaft
- F - Pressing sender wheel
Removing and installing crankshaft4 pages
Pistons and conrods5 pages
Engine cylinder head, valve gear14 pages
Engine lubrication › Parts of lubrication system6 pages
Fuel supply, gas operation17 pages
Parts of fuel supply system12 pages
- Assembly overview - fuel tank with attachments
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
- Removing and installing fuel tank
- Assembly overview - fuel filter with attachments
- Removing and installing fuel filter
- Crash fuel shut-off
- Checking fuel pump
- Bleeding fuel system
Mixture preparation system, electronic inj.,Gas19 pages
Injection system11 pages
Checking components5 pages
Checking injectors for leaks and quantity injected3 pages
- Checking fuel pressure regulator and holding pressure
Engine control unit J6233 pages
Exhaust system › Parts of the exhaust system3 pages
Ignition system, glow plug system › Ignition system5 pages
4-cyl. injection engine (toothed belt drive)130 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons34 pages
Dismantling and assembling engine5 pages
Cylinder block, sealing flange26 pages
- Assembly overview
- Pulling needle bearing out of and driving into crankshaft
- Renewing crankshaft oil seal - belt pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Removing and installing drive plate
- Characteristics of the sealing flange and the assembly deviceT10017 and T10134
Renewing crankshaft sealing flange - flywheel end (assembly toolT10134)9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Renewing crankshaft sealing flange - flywheel end (assembly toolT10017)9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A-Assembling sealing flange with sender wheel on assembly appliance T10017
- B-Assembling appliance T10017 with sealing flange on crankshaft flange
- C-Fitting assembly appliance T10017 onto crankshaft flange
- D-Pressing sender wheel onto crankshaft flange with assembly appliance T10017
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft dimensions
Engine cylinder head, valve gear22 pages
Engine lubrication › Parts of lubrication system6 pages
Engine cooling › Parts of cooling system7 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator
- Removing and installing coolant pump
Fuel supply, gas operation24 pages
Parts of fuel supply system19 pages
Activated charcoal filter system3 pages
Mixture preparation system, electronic inj.,Gas17 pages
Injection system14 pages
- General notes on injection
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Removing and installing air filter housing
- Cleaning throttle valve moduleJ338
- Checking injectors
- Checking intake air preheating
- Safety precautions
- Rules for cleanliness
- Technical data
Exhaust system5 pages
Parts of the exhaust system3 pages
- Assembly overview - front exhaust system with attachments
- Assembly overview - front exhaust system with attachments
- Assembly overview - silencers with mountings
Ignition system, glow plug system › Ignition system5 pages
4-cylinder injection engine (1.4 l direct injection engine, turbocharger and supercharger)132 pages
Technical data7 pages
Engine assy,cylinder block,crankcase5 pages
Enginecrankshaft group, pistons29 pages
Cylinder block (pulley end)8 pages
- Assembly overview - poly V-belt drive
- Assembly overview - cylinder block, belt pulley end
Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet)2 pages
- Removing and installing ancillary bracket
- Renewing crankshaft oil seal - pulley end
- Removing and installing crankshaft pulley
Cylinder block, gearbox end11 pages
- Assembly overview - cylinder block, gearbox end
Removing and installing sealing flange on gearbox side9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Engine cylinder head, valve gear25 pages
Cylinder head9 pages
Valve gear8 pages
Cover for timing chain4 pages
Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet)3 pages
Engine lubrication7 pages
Engine cooling13 pages
Coolant pump, regulation of cooling system5 pages
- Assembly overview - thermostat
- Removing and installing coolant pump (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
- Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
- Removing and installing coolant circulation pumpV50 (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
Exhaust turbocharger, G-charger13 pages
Mixture preparation system, electronic inj.,Gas21 pages
Senders and sensors4 pages
High-pressure pump3 pages
Exhaust system7 pages
Exhaust pipes, silencers4 pages
Cleansing exhaust emissions3 pages
Ignition system, glow plug system › Ignition system5 pages
4-cylinder diesel engine (1.6 l engine, common rail)419 pages
Technical data13 pages
- Engine number, engine data
General repair notes5 pages
Rules for cleanliness3 pages
- Testing vacuum system
Engine assy,cylinder block,crankcase14 pages
Enginecrankshaft group, pistons65 pages
Cylinder block (pulley end)15 pages
- Assembly overview - poly V-belt drive without air conditioning compressor
- Assembly overview - poly V-belt drive (vehicles with idler roller and air conditioner compressor)
- Assembly overview - poly V-belt drive (vehicles with tensioning element and air conditioner compressor)
- Removing and installing poly V-belt (vehicles without air conditioner compressor)
- Removing and installing poly V-belt (vehicles with idler roller)
- Removing and installing poly V-belt (vehicles with tensioning element)
Removing and installing tensioner for poly V-belt2 pages
- Removing and installing vibration damper
Ancillary bracket (removing and installing)3 pages
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing sealing flange - pulley end
Removing and installing poly V-belt6 pages
- Assembly overview - poly V-belt drive without air conditioning compressor
- Assembly overview - poly V-belt drive with tensioning element and air conditioner compressor
- Removing and installing poly V-belt without air conditioner compressor
- Removing and installing poly V-belt with tensioning element
- Removing and installing tensioning element for poly V-belt
Cylinder block, gearbox end13 pages
- Assembly overview - cylinder block, gearbox end
- Removing and installing flywheel (vehicles with dual-mass flywheel)
- Assembly overview - removing and installing flywheel (vehicles with single flywheel)
Removing and installing sealing flange on gearbox side9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- a) Securing seal with sender wheel on assembly toolT10134
- b) Securing assembling toolT10134 with sealing flange on crankshaft flange
- c) Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Removing and installing sealing flange and flywheel14 pages
- Assembly overview - sealing flanges and flywheel
- Removing and installing dual-mass flywheel
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- a) Securing seal with sender wheel on assembly toolT10134
- b) Securing assembling toolT10134 with sealing flange on crankshaft flange
- c) Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
- Removing and installing engine speed senderG28
Crankshaft4 pages
Assembly overview - crankshaft3 pages
Engine cylinder head, valve gear37 pages
Cylinder head15 pages
- Assembly overview - cylinder head
- Removing and installing Hall senderG40
- Assembly overview - cylinder head cover
- Removing and installing cylinder head cover
- Removing and installing injector seal in cylinder head cover
Removing, installing and tensioning toothed belts4 pages
- Removing and installing vacuum pump
- Checking compression
Valve gear16 pages
Toothed belt drive6 pages
- Assembly overview - toothed belt drive (Polo)
Removing, installing and tensioning toothed belt4 pages
Engine lubrication40 pages
Parts of lubrication system4 pages
Engine oil cooler3 pages
Oil filter, oil pressure switch7 pages
Oil filter bracket, oil pressure, engine oil cooler and oil supply line9 pages
Oil supply line and turbocharger support3 pages
Engine cooling43 pages
Cooling system15 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - cowling with radiator fanV7
- Parts of cooling system, engine side
- Assembly overview - coolant pump and 4/2-way valve with thermostat
- Removing and installing 4/2-way valve with thermostat
- Coolant hose schematic diagram
- Removing and installing cowling with radiator fanV7
- Removing and installing radiator and detaching charge air cooler from radiator
- Removing and installing coolant temperature senderG62
- Removing and installing coolant temperature sender at radiator outletG83
- Removing and installing coolant circulation pump 2V178
- Removing and installing coolant pump
- Removing and installing front coolant pipe
- Removing and installing right coolant pipes
Cooling system, coolant12 pages
Draining and replenishing coolant5 pages
Coolant pump, regulation of cooling system7 pages
- Coolers, radiator, radiator fan
Fuel supply, gas operation40 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
Repair instructions if tank has been filled with incorrect fuel7 pages
- Step 1 (Engine was started with incorrect fuel)
- Step 2 (Engine was not started with incorrect fuel)
- Step 3 (There are metal particles in fuel delivery unit and fuel tank)
- Step 4 (There are no metal particles in fuel delivery unit and fuel tank)
- Step 5 (There are metal particles in high-pressure pump)
- Step 6 (There are no metal particles in high-pressure pump)
Parts of fuel supply system9 pages
Testing low-pressure fuel systems (fuel pump)11 pages
- Distinguishing features of the various low-pressure fuel systems
Checking fuel pump, vehicles with 0.5 bar low-pressure fuel system4 pages
Checking fuel pump, vehicles with 6.0 bar low-pressure fuel system5 pages
Exhaust turbocharger, G-charger29 pages
Charge air system with turbocharger9 pages
- Safety precautions
- Rules for cleanliness
Assembly overview - turbocharger with attachments2 pages
- Removing and installing turbocharger
- Assembly overview - parts of charge air cooling
- Removing and installing charge air cooler
- Removing and installing charge air pipe »hot« side
Turbocharger5 pages
Assembly overview - turbocharger2 pages
Charge air system10 pages
- Assembly overview - charge air system
Removing and installing charge air cooler2 pages
Fitting charge air system hose connections5 pages
- Checking charge air system for leaks
Fuel preparation system Diesel injection91 pages
Injection system7 pages
Safety precautions, rules for cleanliness, assembly instructions5 pages
Injectors, high pressure accumulator15 pages
- Assembly overview - injectors
- Adapting correction values for injectors
Testing injectors3 pages
- Checking pressure retention valve in fuel return line.
- Removing and installing high-pressure accumulator (rail)
Removing and installing high-pressure lines4 pages
Mixture preparation, 1.6 l common rail6 pages
Removing and installing components of the diesel direct injection system12 pages
Removing and installing high-pressure lines4 pages
- Removing and installing high-pressure pump
- Removing and installing high-pressure accumulator
- Removing and installing fuel pressure regulating valve N276
- Removing and installing fuel pressure sender G247
Senders and sensors10 pages
- Removing and installing fuel pressure regulating valveN 276
- Checking fuel pressure regulating valve N 276
- Removing and installing fuel pressure senderG 247
- Checking fuel pressure senderG 247
- Checking fuel metering valveN 290,
Removing and installing pressure differential senderG 5054 pages
Filling/bleeding/checking the diesel direct injection system13 pages
Filling/bleeding, checking high-pressure pump/fuel system4 pages
Checks on high-pressure accumulator3 pages
Checks on injector3 pages
- Checking fuel system for leaks
- Check pressure retention valve in fuel return line
Lambda probe5 pages
Assembly overview - Lambda probe2 pages
Removing and installing Lambda probe2 pages
Intake manifold6 pages
- Assembly overview - intake manifold with attachments (vehicles with intake manifold flapV157)
- Assembly overview - intake manifold with attachments (vehicles without intake manifold flap)
- Removing and installing intake manifold (vehicles with intake manifold flapV157)
- Removing and installing intake manifold (vehicles without intake manifold flapV157)
- Removing and installing throttle valve moduleJ338
Air filter3 pages
Exhaust system41 pages
Exhaust system8 pages
Exhaust pipes, silencers6 pages
Assembly overview - exhaust system3 pages
Aligning exhaust system free of stress2 pages
Cleansing exhaust emissions8 pages
Assembly overview - cleansing exhaust emissions4 pages
Removing and installing particulate filter3 pages
Exhaust gas temperature regulation11 pages
- Assembly overview - exhaust gas temperature regulation
Removing and installing parts of exhaust gas temperature regulation6 pages
Removing and installing parts of exhaust gas temperature control system (Polo, right-hand drive)3 pages
Ignition system, glow plug system6 pages
3-cylinder injection engine (4-valve)87 pages
Engine assy,cylinder block,crankcase › Removing and installing engine4 pages
Enginecrankshaft group, pistons9 pages
Dismantling and assembling engine5 pages
Engine cylinder head, valve gear16 pages
Cylinder head10 pages
Engine lubrication › Parts of lubrication system7 pages
Fuel supply, gas operation20 pages
Parts of fuel supply system15 pages
Mixture preparation system, electronic inj.,Gas14 pages
Injection system11 pages
Engine control unitJ6233 pages
Exhaust system › Parts of the exhaust system3 pages
Ignition system, glow plug system › Ignition system5 pages
3-cylinder injection engine (2-valve)85 pages
Engine assy,cylinder block,crankcase › Removing and installing engine4 pages
Enginecrankshaft group, pistons9 pages
Dismantling and assembling engine5 pages
Engine cylinder head, valve gear13 pages
Engine lubrication › Parts of lubrication system7 pages
Fuel supply, gas operation20 pages
Parts of fuel supply system15 pages
Mixture preparation system, electronic inj.,Gas15 pages
Injection system12 pages
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Removing and installing air filter
- Cleaning throttle valve moduleJ338
- Checking injectors
- Check non-return valve for crankcase breather
- Safety precautions
- Rules for cleanliness
- Technical data
Engine control unitJ6233 pages
Exhaust system › Parts of the exhaust system3 pages
Ignition system, glow plug system › Ignition system5 pages
4-cylinder injection engine (1.2 l direct injection engine, turbocharger)125 pages
Technical data6 pages
Engine assy,cylinder block,crankcase5 pages
Enginecrankshaft group, pistons28 pages
Cylinder block (pulley end)6 pages
Cylinder block, gearbox end13 pages
- Assembly overview - cylinder block, gearbox end
Removing and installing crankshaft sealing flange on gearbox side9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- Mounting seal with sender wheel on assembly toolT10134
- Mounting assembly toolT10134 with sealing flange on crankshaft flange
- Bolting assembly toolT10134 onto crankshaft flange
- Pressing sender wheel onto crankshaft flange using assembly toolT10134
- Checking sender wheel installation position on crankshaft
- Re-pressing sender wheel
- Removing and installing ancillary bracket (top)
- Removing and installing ancillary bracket (bottom)
Pistons and conrods6 pages
- Assembly overview - pistons and conrods
Checking piston and cylinder bore3 pages
- Separating new conrod
Engine cylinder head, valve gear26 pages
Cylinder head8 pages
- Assembly overview - cylinder head
Removing and installing cylinder head cover and camshaft4 pages
- Removing and installing cylinder head
- Checking compression
Valve gear7 pages
Cover for timing chain3 pages
Chain drive8 pages
- Assembly overview - timing chain
- Checking valve timing
- Adjusting valve timing
Removing and installing timing chain and chain drive for oil pump4 pages
Engine lubrication9 pages
Engine cooling12 pages
Cooling system, coolant4 pages
Coolant pump, regulation of cooling system4 pages
Exhaust turbocharger, G-charger8 pages
Turbocharger5 pages
Mixture preparation system, electronic inj.,Gas20 pages
Exhaust system7 pages
Exhaust pipes, silencers4 pages
Cleansing exhaust emissions3 pages
Ignition system, glow plug system › Ignition system4 pages
- 3-cylinder diesel engine (1.2 l engine, common rail) › Engine assy,cylinder block,crankcase › Assembly mountings
4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH154 pages
- Self diagnosis, V.A.G Inspection Service › Read event memory
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons30 pages
Dismantling and assembling engine8 pages
Cylinder block, sealing flange14 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - pulley end
- Removing and installing crankshaft pulley
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Pistons and conrods5 pages
Engine cylinder head, valve gear18 pages
Engine lubrication › Parts of lubrication system6 pages
Engine cooling › Parts of cooling system10 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Checking cooling system for leaks
- Removing and installing cowling with radiator fanV7
- Removing and installing radiator fanV7
- Removing and installing radiator
- Removing and installing coolant pump
Fuel supply, gas operation38 pages
Parts of fuel supply system31 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
Emptying fuel tank3 pages
- Removing and installing fuel delivery unit
- Removing and installing external fuel gauge senderG with two cable connections
- Removing and installing interior fuel gauge senderG
- Removing and installing fuel tank
- Removing and installing fuel filter
- Crash fuel shut-off
- Bleeding fuel system
Parts of Autogas (LPG) fuel supply system10 pages
- Emptying the fuel tank (Autogas)
- Emptying the gas line
- Assembly overview - gas tank (Autogas)
- Removing and installing pressure relief valve
- Removing and installing inlet valve
- Gas gauge senderG707
- Removing and installing fuel gauge sender
- Removing and installing gas tank valveN495
- Removing and installing fuel tank (Autogas)
Activated charcoal filter system5 pages
Mixture preparation system, electronic inj.,Gas34 pages
Injection system22 pages
- General notes on injection
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Removing and installing injectors
- Removing and installing gas injectors
- Removing and installing gas rail sensorG401
- Assembly overview - air filter
- Removing and installing air filter housing
- Cleaning throttle valve moduleJ338
- Safety precautions
- Rules for cleanliness
- Technical data
Renewing filter on Autogas system3 pages
Removing and installing vaporiser on vehicles which can be operated with liquid gas3 pages
Checking components4 pages
Checking injectors for leaks and quantity injected3 pages
Engine control unitJ6233 pages
Gas mode control unitJ6595 pages
Exhaust system › Parts of the exhaust system4 pages
Ignition system, glow plug system › Ignition system5 pages
4-cylinder injection engine (1.4 l engine, BiFuel) Volkswagen R GmbH151 pages
Technical data2 pages
Self diagnosis, V.A.G Inspection Service › Reading fault memory for Autogas (LPG) system4 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons33 pages
Dismantling and assembling engine5 pages
Cylinder block, sealing flange25 pages
- Assembly overview
- Renewing crankshaft oil seal - belt pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Removing and installing drive plate
- Characteristics of the sealing flange and the assembly devicesT10017 and assembly deviceT10134
Renewing crankshaft sealing flange - flywheel end (assembly toolT10134)9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Renewing crankshaft sealing flange - flywheel end (assembly toolT10017)9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A-Assembling sealing flange with sender wheel on assembly appliance T10017
- B - Attaching assembling toolT10017 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10017 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10017
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft dimensions
Engine cylinder head, valve gear22 pages
Engine lubrication › Parts of lubrication system6 pages
Engine cooling › Parts of cooling system9 pages
- Assembly overview - parts of cooling system, body side
Assembly overview - parts of cooling system, engine side3 pages
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator
- Removing and installing coolant pump
Fuel supply, gas operation34 pages
Parts of fuel supply system29 pages
- Assembly overview - fuel tank with attachments
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel gauge sender
- Crash fuel shut-off
- Bleeding fuel system
Parts of Autogas (LPG) fuel supply system10 pages
- Emptying the fuel tank (Autogas)
- Emptying the gas line
- Assembly overview - gas tank (Autogas)
- Removing and installing pressure relief valve
- Removing and installing inlet valve
- Gas gauge senderG707
- Removing and installing fuel gauge sender
- Removing and installing gas tank valveN495
- Removing and installing fuel tank (Autogas)
Activated charcoal filter system3 pages
Mixture preparation system, electronic inj.,Gas26 pages
Injection system18 pages
- General notes on injection
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Removing and installing air filter housing
- Cleaning throttle valve moduleJ338
- Checking injectors
- Safety precautions
- Rules for cleanliness
- Technical data
Removing and installing vaporiser on vehicles which can be operated with liquid gas3 pages
Engine control unitJ6233 pages
- Removing and installing engine control unitJ623
- Removing and installing anti-theft engine control unitJ623
- Removing and installing anti-theft engine control unitJ623
Gas mode control unitJ6595 pages
Exhaust system › Parts of the exhaust system3 pages
Ignition system, glow plug system › Ignition system5 pages
Fuel supply system - Diesel engines57 pages
Technical data5 pages
Fuel supply, gas operation52 pages
What to do if fuel tank filled with incorrect fuel7 pages
- Step 1 (Engine was started with incorrect fuel)
- Step 2 (Engine was not started with incorrect fuel)
- Step 3 (There are filings in fuel delivery unit and fuel tank)
- Step 4 (There are no filings in fuel delivery unit or fuel tank)
- Step 5 (There are filings in high-pressure pump)
- Step 6 (There are no filings in high-pressure pump)
Fuel tank16 pages
Assembly overview - fuel tank3 pages
- Removing, installing and checking breather valve
Removing and installing fuel tank4 pages
Emptying fuel tank7 pages
- Emptying fuel tank when fuel pump is intact (CAYA, CAYB, CAYC)
- Emptying fuel tank when fuel pump is intact (CFWA)
- Emptying fuel tank when it is more than 3/4 full (CAYA, CAYB, CAYC)
- Emptying fuel tank if it is more than 3/4 full (CFWA)
- Emptying fuel tank when it is less than 3/4 full (CAYA, CAYB, CAYC)
- Emptying fuel tank if it is less than 3/4 full (CFWA)
Fuel delivery unit, fuel gauge sender9 pages
- Assembly overview - fuel delivery unit/fuel gauge sender (CAYA, CAYB, CAYC)
Removing and installing fuel delivery unit/fuel gauge sender3 pages
Removing and installing fuel gauge sender4 pages
- Detaching push-on connectors
Fuel filter8 pages
Assembly overview - fuel filter3 pages
Removing and installing fuel filter3 pages
- Fuel hoses in the engine compartment (CFWA)
Fuel pump9 pages
Checking fuel pump8 pages
- Checking fuel delivery rate of fuel system pressurisation pumpG6 (CAYA, CAYB, CAYC)
- Checking fuel delivery rate of fuel system pressurisation pumpG6 (CFWA)
- Checking fuel pressure of fuel pumpG6 for delivery rate (CFWA)
- Checking delivery pressure in the fuel return line (CFWA)
- Checking the current consumption of fuel pump for delivery rateG6 (CAYA, CAYB, CAYC)
- Checking current consumption of the fuel pump for delivery rateG6 (CFWA)
- Checking voltage supply of the fuel pump for delivery rateG6 (CAYA, CAYB, CAYC)
- Checking current consumption of the fuel pump for delivery rateG6 (CFWA)
Fuel supply system - Petrol engines32 pages
Technical data6 pages
- Engine data
Safety precautions during work on fuel supply system3 pages
Fuel supply, gas operation26 pages
Fuel delivery unit, fuel gauge sender3 pages
- Detaching push-on connectors
Activated charcoal filter system3 pages
Fuel pump7 pages