Polo Mk4: Engine
Also for this vehicle: Polo Mk3, Polo Mk5.
Steering & suspension
Body & interior
Engine
General
Transmission
Heating & A/C
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4-cylinder injection engine116 pages
Engine assy,cylinder block,crankcase › Removing and installing engine7 pages
Enginecrankshaft group, pistons22 pages
Dismantling and assembling engine5 pages
Removing and installing sealing flanges and flywheel or drive plate14 pages
- Assembly overview
- Renewing crankshaft oil seal - pulley end
- Removing and installing drive plate
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 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
Dismantling and assembling pistons and conrods3 pages
Engine cylinder head, valve gear22 pages
Engine lubrication › Removing and installing parts of lubrication system6 pages
Engine cooling › Dismantling and assembling parts of cooling system7 pages
Fuel supply, gas operation21 pages
Removing and installing parts of fuel supply system16 pages
Active charcoal filter system3 pages
Mixture preparation system, electronic inj.,Gas19 pages
Repairing injection system10 pages
Checking components5 pages
- Checking injectors
Checking fuel pressure regulator and holding pressure2 pages
- Checking intake air preheating
Exhaust system5 pages
Removing and installing parts of exhaust system3 pages
Ignition system, glow plug system › Repairing ignition system5 pages
4 - Cyl. injection engine (4-valve, rolling rockers)179 pages
Engine assy,cylinder block,crankcase › Engine - remove and install13 pages
Enginecrankshaft group, pistons30 pages
Engine - disassemble and assemble8 pages
Poly-V belt - remove and install7 pages
Crank shaft rear flange - remove and install14 pages
Crank shaft rear flange, driving wheel side - replace10 pages
- Extract flange with rotor
- Operation sequence
- Introduce flange under pressure with rotor
- A-Install flange with rotor on Assembly tool T10017
- B-Install Assembly tool T10017 with flange on the crank shaft
- Operation sequence
- C-Thread Assembly tool T10017 to crank shaft flange
- D-Press rotor with Assembly tool T10017 onto crank shaft flange
- E-Check assembly position of crank shaft rotor
- F- retighten driving wheel
Crank shaft - remove and install6 pages
Identification of engine bearing caps3 pages
- Color marks
- Crank shaft specifications
Engine cylinder head, valve gear › Head - disassemble and assemble38 pages
- Distribution times - check
Tension pulley of indented belt - check4 pages
Indented belt - remove and install, adjust5 pages
Engine lubrication › Lubrication system components - remove and install11 pages
Engine cooling › Cooling system components - remove and install18 pages
Fuel supply, gas operation29 pages
Fuel supply system components - remove and install21 pages
- Fuel container with accessory parts and fuel filter - remove and install
- Safety measures for jobs on fuel supply system
- Cleaning rules
Fuel pump - check6 pages
- Test conditions
- Power supply and operation - check
- Fuel flow - check
- Test conditions
- Test sequence
- Fuel pump retaining valve - check
- Test conditions
- Test sequence
Engine power electronic regulation (E-gas electronic throttle) - check2 pages
Activated charcoal filter system.6 pages
Mixture preparation system, electronic inj.,Gas29 pages
Injection system - repair11 pages
Injection components - check7 pages
Fuel pressure regulator and retaining pressure - check3 pages
Engine command unit11 pages
Fault memory of engine command unit - consult and delete5 pages
Exhaust system › Removal and installation of exhaust system parts3 pages
Ignition system, glow plug system › Ignition system - repair5 pages
4 - Cyl. diesel engine (with distributor injection pump)150 pages
Engine assy,cylinder block,crankcase › Engine - remove and install14 pages
Enginecrankshaft group, pistons23 pages
Engine - disassemble and assemble9 pages
Poly-V pulley - remove and install5 pages
Semi-automatic tension pulley of indented belt - check3 pages
Crankshaft seal and engine steering wheel - remove and install7 pages
Pistons and rods - disassemble and assemble5 pages
Engine cylinder head, valve gear29 pages
Engine lubrication › Lubrication systems components - remove and install10 pages
Oil pressure switch and oil pressure - check6 pages
Engine cooling › Cooling system components - remove and install17 pages
Fuel supply, gas operation › Fuel supply system components - remove and install15 pages
Fuel preparation system Diesel injection26 pages
Direct injection system-Diesel - repair16 pages
Engine command unit10 pages
Engine command unit fault memory - check and erase5 pages
- Functions and components - adjust
Exhaust system9 pages
Exhaust system parts - remove and install4 pages
Exhaust system - remove and install3 pages
- Condition
- Operations sequence
- Operations sequence
- Operations sequence
Exhaust gas return system5 pages
Ignition system, glow plug system › Pre-heating system - check4 pages
4 - Cyl. diesel engine (with unit injectors)148 pages
Engine assy,cylinder block,crankcase › Engine - remove and install10 pages
Enginecrankshaft group, pistons20 pages
Engine - disassemble and assemble6 pages
Poly-V belt - remove and install5 pages
Crankshaft and engine wheel sealing - remove and install7 pages
Pistons and rods - disasemble and assemble5 pages
Engine cylinder head, valve gear25 pages
Engine lubrication › Lubrication system components - remove and install8 pages
Oil pressure and oil pressure switch - check4 pages
Engine cooling › Cooling system components - remove and install18 pages
Fuel supply, gas operation › Supply system components - remove and install28 pages
Exhaust turbocharger, G-charger › Over-supply system with turbo-compressor6 pages
Fuel preparation system Diesel injection20 pages
Diesel direct injection system - repair12 pages
Engine control unit7 pages
Engine control unit fault memory - check and erase5 pages
- Functions and components - adapt
- Engine control unit - remove and install
Ignition system, glow plug system › Pre-heating installation - check4 pages
4 - Cyl. injection engine260 pages
Engine assy,cylinder block,crankcase › Engine - remove and install8 pages
Enginecrankshaft group, pistons30 pages
Engine - disassemble and assemble5 pages
Engine - assembly and disassembly11 pages
Poly-V belt - remove and install7 pages
Crankshaft and flywheel flanges - remove and install7 pages
Engine cylinder head, valve gear67 pages
Engine cylinder head - remove and install18 pages
Timing belt - remove and install, adjust7 pages
Cylinder head - assembly and disassembly11 pages
- Toothed belt semi-automatic tensioning roller - check
Toothed belt - remove and install, adjust4 pages
- Removal
- Tensioner without adjustment
- Installation
- Tensioner without adjustment
Valve control mechanism - repair19 pages
Camshaft mechanism - repair19 pages
Valve seat - trim4 pages
Camshaft and cylinder head cover - remove and install4 pages
Engine lubrication › Lubrication system components - remove and install13 pages
Engine cooling › Cooling system components - remove and install21 pages
Fuel supply, gas operation58 pages
Supply system components - remove and install25 pages
- Fuel tank with assembly parts and fuel filter - remove and install
- Safety measures when working in the supply system
- Cleaning rules
Fuel pump (pre-supply pump) G6 - check6 pages
Fuel supply system components - remove and install23 pages
Engine power electronic adjustment (E-Gas electronic accelerator) components - repair .2 pages
Engine power electronic adjustment (electronic throttle) - check2 pages
Activated charcoal filter system6 pages
Mixture preparation system, electronic inj.,Gas46 pages
Injection - repair11 pages
- General notes on injection
- Component location - overview
- Injection components - remove and install
- Intake manifold (upper part) - disassemble and assemble
- Intake manifold (lower part) - disassemble and assemble
- Fuel distributor with injection valves - remove and install
- Air filter - disassemble and assemble
- Safety measures
- Cleaning rules
- Technical data
Injection system - repair12 pages
Injection components - check7 pages
Injection valves - check4 pages
- Checking conditions
- Checking sequence
- Check injected volume
- Checking conditions
Component checks5 pages
- Injection valves - check
Residual pressure and fuel pressure regulator - check3 pages
Engine control unit J62311 pages
Fault memory in the Engine control unit J623 - read and clear5 pages
Exhaust system › Exhaust system components - remove and install3 pages
Ignition system, glow plug system11 pages