Workshop Manuals Factory service & repair Volkswagen
Volkswagen Polo Mk403 · Engine
03 · Engine

Engine - disassemble and assemble

Make
Volkswagen
Model
Polo Mk4
Section
4 - Cyl. injection engine › Enginecrankshaft group, pistons › Engine - disassemble and assemble
EngineEngine - disassemble and assemble
Engine - disassemble and assemble
Engine - disassemble and assemble – Volkswagen Polo Mk4  Note
All bearing and moving surfaces must be lubricated with oil before beginning assembly works.
Engine - disassemble and assemble – Volkswagen Polo Mk4   WARNING
Always replace self-locking nuts and screws subject to angular torque.
   
Engine - disassemble and assemble – Volkswagen Polo Mk4
Engine - disassemble and assemble – Volkswagen Polo Mk4  Note
t  Whenever considerable amounts of metal shavings and filings are found during engine repairs, this indicates that the crankshaft bearings or the connecting rod shells are damaged. In order to avoid future damage, proceed as follows:
t  Clean the lubrication channels carefully.
t  Replace the oil injector valves.
t  Replace oil radiator.
t  Replace the oil filter.
Part I
   
Engine - disassemble and assemble – Volkswagen Polo Mk4
1 - 50 Nm
2 - Engine support
3 - Mechanical distribution upper cover
4 - Timing belt
q   Mark the rotation direction before removing.
q   Check wear.
q   Do not bend.
q   Remove and install, adjust → Chapter.
5 - 20 Nm
6 - Washer
7 - 100 Nm
q   To remove and install, immobilise the camshaft gear with the Wrench -3415-.
8 - Camshaft gear
9 - Cylinder head cover
q   With cable guides.
10 - 10 Nm
11 - Key
q   Check the fitting.
12 - Camshaft
q   Check axial clearance → Fig.
q   Remove and install → Chapter.
q   Measure radial clearance with “Plastigage”: Wear limit: 0.1 mm.
q   Runout: max. 0.05 mm.
13 - Support
q   For Hall Sensor -G40-.
14 - Mechanical distribution rear cover
15 - 20 Nm
16 - Tensioning pulley
q   Check the timing belt semi-automatic tensioning pulley → Chapter.
17 - Sealing ring
q   Replace.
18 - Water pump
q   Check free movement.
q   In case of damage and leakage, cut and replace.
q   Remove and install → Chapter.
19 - 15 Nm
20 - Crankshaft gear
21 - 90 Nm 90°
q   Replace after each removal.
q   The thread and the head must be free from oil and grease.
q   To remove and install, use the Spanner -3415 -.
22 - Mechanical distribution lower cover
23 - Poly-V belt
q   Mark the rotation direction before removing.
q   Timing belt - remove and install → Chapter.
q   Poly-V belt travel → Chapter.
24 - Pulley/ vibration damper
q   The installation can only be made in one position.
q   Check position when installing the timing belt → Chapter.
25 - 40 Nm
26 - Tensioning element for Poly-V belts
q   For Poly-V belt.
q   Turn using a spanner to loosen the Poly-V belt → Chapter.
q   Timing belt - remove and install → Chapter.
27 - Support
28 - Mechanical distribution center cover

Part II
Engine - disassemble and assemble – Volkswagen Polo Mk4   WARNING
Always replace self-locking nuts and screws subject to angular torque.
   
Engine - disassemble and assemble – Volkswagen Polo Mk4
1 - 2 poles connector
q   For Knock sensor 1 -G61-.
q   Gilded contacts.
q   Do not invert.
2 - Knock sensor 1 -G61-
q   Gilded contacts.
3 - 20 Nm
q   Tightening torque influences Knock Sensor 1 -G61- operation.
4 - 2 poles connector
q   For Knock sensor 2 -G66-.
q   Gilded contacts.
q   Do not invert.
5 - Knock sensor 2 -G66-
q   Gilded contacts.
6 - Dipstick tube
7 - Oil dipstick
q   Oil level shall not exceed the Max. mark. !
q   Marks → Fig.
8 - Cooling system tube
q   Cooling system hose connection diagram → Chapter.
9 - 25 Nm
10 - Support
q   For the Ignition transformer -N152 -.
11 - Support
12 - 10 Nm
13 - Support
14 - 10 Nm
15 - Sealing ring
q   Replace.
16 - Oil filter support
q   Remove and install → Chapter.
17 - 15 Nm 90°
q   Substituir após cada remoção.
18 - Gasket
q   Replace.
19 - Engine speed sensor -G28-
20 - Sealing ring
q   Replace when damaged.
21 - 40 Nm
22 - 15 Nm
23 - Connection nozzle
24 - Thermostat valve for the cooling system
q   Check: heat the cooling system thermostat valve in a double boiler.
q   Opening start with approx. 87° C.
q   Minimum opening travel 7 mm.
q   Remove and install → Chapter.
25 - 45 Nm
26 - Compact support
q   To the Generator (Alternator) -C-, air conditioning compressor and Poly-V belt tensioning element.
q   Compact support - remove and install in vehicles with air conditioning: → Aeration system ; Rep. Gr.87.
27 - Engine block
q   Sealing flanges and engine flywheel - remove and install → Chapter.
q   Crankshaft - remove and install → Chapter.
q   Pistons and connecting rods - assemble and disassemble → Chapter.

   

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