Diesel engine ANY AYZ (aluminium cylinder block) Mechanics - Repair Manual
VW Lupo 1999 ->
Edition 06.2005
00 - Technical data
1 Technical data
1.1 Technical data
1.2 Engine number
1.3 Engine data
10 - Removing and installing engine
1 Removing and installing engine
1.1 Removing and installing engine
1.2 Notes on removing
1.3 Securing engine to assembly stand
1.4 Notes on installing
1.5 Tightening torques
1.6 Assembly mountings
13 - Crankshaft group
1 Dismantling and assembling engine
1.1 Dismantling and assembling engine
1.2 Removing and installing ribbed belt
2 Removing and installing counterbalance shaft and retaining frame
2.1 Removing and installing counterbalance shaft and retaining frame
2.2 Removing and installing counterbalance shaft
3 Removing and installing cylinder block, sealing flange and fly wheel
3.1 Removing and installing cylinder block, sealing flange and fly wheel
3.2 Renewing crankshaft oil seal -pulley end
3.3 Removing and installing sealing flange, pulley end
4 Dismantling and assembling pistons and conrods
4.1 Dismantling and assembling pistons and conrods
4.2 Checking piston projection at TDC
4.3 Piston and cylinder dimensions
15 - Cylinder head, Valve gear
1 Removing and installing cylinder head
1.1 Removing and installing cylinder head
1.2 Removing, installing and tensioning toothed belt
1.3 Dismantling and assembling intake manifold
1.4 Removing and installing cylinder head
1.5 Checking compression pressures
2 Servicing valve gear
2.1 Servicing valve gear
2.2 Reworking valve seats
2.3 Checking valve guides
2.4 Renewing valve guides
2.5 Renewing valve stem seals
2.6 Removing and installing camshaft
2.7 Removing and installing camshaft oil seal
17 - Lubrication
1 Removing and installing parts of the lubrication system
1.1 Removing and installing parts of the lubrication system
1.2 Removing and installing sump
1.3 Checking oil pressure and oil pressure switch
19 - Cooling system
1 Removing and installing parts of cooling system
1.1 Removing and installing parts of cooling system
1.2 Parts of cooling system body side.
1.3 Parts of cooling system engine side.
1.4 Coolant hose connection diagram.
1.5 Draining and filling cooling system.
1.6 Removing and installing radiator
1.7 Removing and installing coolant pump
1.8 Removing and installing thermostat.
20 - Fuel supply system
1 Removing and installing parts of fuel supply system
1.1 Removing and installing parts of fuel supply system
1.2 Removing and installing fuel tank with its attachments
1.3 Servicing fuel filter.
1.4 Safety precautions when working on the fuel supply system
1.5 Rules for cleanliness
1.6 Removing and installing fuel cooler.
1.7 Removing and installing fuel tank
1.8 Servicing accelerator mechanism.
1.9 Checking accelerator pedal position sender
1.10 Adjusting pedal position sender
1.11 Checking tandem pump
1.12 Removing and installing tandem pump
21 - Charging
1 Charge air system with turbocharger
1.1 Charge air system with turbocharger
1.2 Safety precautions.
1.3 Rules for cleanliness
1.4 Removing and installing turbocharger with attachments
1.5 Removing and installing parts of charge air cooling.
1.6 Hose connection diagram for charge pressure control
2 Checking charge pressure control.
2.1 Checking charge pressure control.
26 - Exhaust system
1 Removing and installing parts of exhaust system.
1.1 Removing and installing parts of exhaust system.
2 Exhaust gas recirculation system
2.1 Exhaust gas recirculation system
2.2 Removing and installing parts of exhaust gas recirculation system.
2.3 Vacuum hose connection diagram.
2.4 Checking exhaust gas recirculation valve (mechanical)
2.5 Checking exhaust gas recircu
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