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3-Cyl. injection engine (1.0 l)

For Polo [BR]

Original Volkswagen repair manual


29,09 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

39.149 KB

383 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Power-drive unit supports, Cylinder block (pulley side), Crankshaft, Toothed belt drive, Oil filter/Oil pressure switch F1, Cooling system/coolant, Radiator/Radiator fan, Fuel tank, Fuel supply unit/Fuel level sensor, Activated charcoal system, Accelerator activation, Injection valves, Air cleaner, Intake manifold and Lambda probe. Show more
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Repair manual Polo [BR] 3-Cyl. injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 \--- Change history ---
    1
  • 2 Safety instructions
    2
  • 2.1 Safety measures regarding work on the fuel supply
    2
  • 2.2 Safety measures in test drives using testing and measurement devices
    3
  • 2.3 Safety measures when working on the cooling system
    4
  • 2.4 Safety measures when working on the ignition system
    4
  • 3 Identification
    6
  • 3.1 Engine number/engine characteristics
    6
  • 4 Repair instructions
    8
  • 4.1 Cleanliness rules
    8
  • 4.2 General instructions
    8
  • 4.3 General repair instructions
    9
  • 4.4 Foreign bodies on the engine
    9
  • 4.5 Contact corrosion
    9
  • 4.6 Connection installation and fastening
    10
  • 4.7 Radiator and capacitor installation
    10
  • 4.8 Check the vacuum system
    10
  • Removing and installing engine
    11
  • 1 Engine - remove and install
    11
  • 1.1 Engine - removal
    11
  • 1.2 Engine - separate gearbox
    22
  • 1.3 Engine - secure to engine and gearbox support
    24
  • 1.4 Engine - installation
    26
  • 1.5 Engine - remove and install, summarized instructions
    29
  • 2 Power-drive unit supports
    32
  • 2.1 Power unit brackets - assembly overview
    32
  • 2.2 Power unit bracket (engine side) - remove and install
    35
  • 2.3 Drive-train mounting (gearbox side) - remove and install
    36
  • 2.4 Pendulum support (torque limiter) - remove and install
    39
  • 2.5 Support the engine in assembly position
    40
  • 2.6 Drive train mountings - adjust
    42
  • 2.7 Drive train mounting adjustment - check
    44
  • Crankshaft group
    45
  • 1 Cylinder block (pulley side)
    45
  • 1.1 Poly-V belt mechanism - assembly overview
    45
  • 1.2 Cylinder block (pulley side) - assembly overview
    47
  • 1.3 Poly-V belt - remove and install
    50
  • 1.4 Poly-V belt tensioner - remove and install
    52
  • 1.5 Engine console - remove and install
    53
  • 1.6 Crankshaft pulley (vibration damper) - remove and install
    57
  • 1.7 Crankshaft seal (pulley side) - replace
    60
  • 2 Cylinder block (gearbox side)
    63
  • 2.1 Cylinder block (gearbox side) - assembly overview
    63
  • 2.2 Flywheel - remove and install
    64
  • 2.3 Crankshaft flange (flywheel side) - replace
    66
  • 3 Crankshaft
    78
  • 3.1 Crankshaft - dimensions
    78
  • 4 Pistons and conrods - remove and install
    79
  • 4.1 Pistons and conrods - assembly overview
    79
  • 4.2 Pistons - remove and install
    82
  • 4.3 Pistons, rings, and cylinders - check
    83
  • 4.4 Conrod and cap (new part) - separate
    86
  • 4.5 Conrod radial clearance - check
    86
  • 4.6 Oil spray jet and valve - remove and install
    87
  • Cylinder head, valve gear
    89
  • 1 Engine cylinder head
    89
  • 1.1 Engine cylinder head - assembly overview
    89
  • 1.2 Cylinder head - remove and install
    92
  • 1.3 Cylinder head - remove and install, summarized instructions
    99
  • 1.4 Cylinder head cover with exhaust and inlet camshafts - remove and install
    101
  • 1.5 Cylinder compression - check
    104
  • 2 Toothed belt drive
    107
  • 2.1 Toothed belt - remove and install
    107
  • 2.2 Valve timing - check
    111
  • 2.3 Remove the camshaft toothed belt
    115
  • 3 Camshaft mechanism
    128
  • 3.1 Camshaft mechanism - assembly overview
    128
  • 3.2 Crankshaft - check axial clearance
    130
  • 3.3 Camshaft gasket (pulley side) - replace
    131
  • 3.4 Inlet camshaft regulator - remove and install
    138
  • 3.5 Exhaust camshaft sprocket - remove and install
    143
  • 3.6 Camshaft adjustment valve 1 N205 - remove and install
    147
  • 3.7 Valve stem sealant - replace
    148
  • 4 Inlet and exhaust valves
    159
  • 4.1 Valve guides - check
    159
  • 4.2 Valves - check
    160
  • 4.3 Valve dimensions
    160
  • Lubrication
    161
  • 1 Crankcase/oil pump
    161
  • 1.1 Crankcase/oil pump - assembly overview
    161
  • 1.2 Engine oil
    166
  • 1.3 Lower sump - remove and install
    167
  • 1.4 Upper crankcase - remove and install
    169
  • 1.5 Oil pump - remove and install
    173
  • 2 Engine crankcase ventilation
    176
  • 2.1 Engine crankcase ventilation - assembly overview
    176
  • 2.2 Crankcase ventilation device - remove and install
    177
  • 3 Oil filter/Oil pressure switch F1
    180
  • 3.1 Oil pressure switch 0.3...0.6 bar F1 - remove and install
    180
  • 3.2 Oil pressure and Oil pressure switch F1 - check
    181
  • 3.3 Oil filter - remove and install
    184
  • Cooling
    186
  • 1 Cooling system/coolant
    186
  • 1.1 Hose connection diagram for cooling system
    186
  • 1.2 Cooling system - check air-tightness
    186
  • 1.3 Coolant tank flap - check safety valve
    189
  • 1.4 Cooling system - drainage and replenishment
    191
  • 2 Water pump/coolant adjustment
    198
  • 2.1 Water pump/thermostatic valves - assembly overview
    198
  • 2.2 Thermostat valve - assembly overview
    201
  • 2.3 Water pump - remove and install
    204
  • 2.4 Thermostats - remove and install
    209
  • 2.5 Water pump toothed belt - remove and install
    215
  • 2.6 Water pump sprocket - remove and install
    216
  • 2.7 Coolant temperature sensor G62 - remove and install
    218
  • 3 Cooling system pipes
    221
  • 3.1 Coolant system line - assembly overview
    221
  • 3.2 Cooling system line - remove and install
    221
  • 4 Radiator/Radiator fan
    223
  • 4.1 Radiator/Radiator fan - assembly overview
    223
  • 4.2 Fan cowl and radiator fan - assembly overview
    224
  • 4.3 Radiator - remove and install
    225
  • 4.4 Fan housing - remove and install
    231
  • 4.5 Radiator fan V7 - remove and install
    233
  • Fuel supply system
    234
  • 1 Fuel tank
    234
  • 1.1 Fuel tank - assembly overview
    234
  • 1.2 Fuel tank - remove and install
    236
  • 1.3 Fuel tank - drain
    243
  • 2 Fuel supply unit/Fuel level sensor
    254
  • 2.1 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - assembly overview
    254
  • 2.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
    256
  • 2.3 Fuel gauge sensor G - remove and install
    261
  • 2.4 Installation opening cover - remove and install
    262
  • 3 Plug-in connectors
    264
  • 3.1 Plug-in connectors - disconnect
    264
  • 4 Fuel filter
    270
  • 4.1 Fuel filter - remove and install
    270
  • 5 Activated charcoal system
    272
  • 5.1 Activated charcoal filter system - assembly overview
    272
  • 5.2 Activated charcoal filter - remove and install
    274
  • 5.3 Fuel tank ventilation - check
    275
  • 6 Accelerator activation
    282
  • 6.1 Accelerator pedal module - assembly overview
    282
  • 6.2 Accelerator pedal module GX2 - remove and install
    282
  • 7 Fuel system pressurisation pump G6
    284
  • 7.1 Fuel system pressurisation pump G6 - check
    284
  • 8 Fuel lines
    303
  • 8.1 Fuel lines - remove and install
    303
  • Mixture preparation - injection
    308
  • 1 Injection system
    308
  • 1.1 Injection system - assembly overview
    308
  • 1.2 Combustion system - assembly overview
    311
  • 2 Injection valves
    314
  • 2.1 Fuel rail with injection valves - assembly overview
    314
  • 2.2 Injection valves - remove and install
    316
  • 2.3 Injection valves - check
    318
  • 3 Air cleaner
    325
  • 3.1 Air filter - assembly overview
    325
  • 3.2 Air filter - remove and install
    326
  • 4 Intake manifold
    328
  • 4.1 Intake manifold - assembly overview
    328
  • 4.2 Intake manifold - remove and install
    330
  • 4.3 Throttle butterfly valve control unit J338 - remove and install
    333
  • 4.4 Throttle valve control unit J338 - clean
    335
  • 5 Transmitters and sensors
    337
  • 6 Engine control unit J623
    339
  • 6.1 Engine control unit J623 - remove and install
    339
  • 7 Lambda probe
    341
  • 7.1 Lambda probe - assembly overview
    341
  • 7.2 Lambda Probe G39 - remove and install
    342
  • 7.3 Lambda Probe after the catalytic converter G130 - remove and install
    343
  • Exhaust system
    346
  • 1 Silencer/exhaust pipes
    346
  • 1.1 Silencer - assembly overview
    346
  • 1.2 Silencer/exhaust pipes - detach
    347
  • 1.3 Centre silencer with rear silencer - remove and install
    349
  • 1.4 Centre silencer - remove and install
    353
  • 1.5 Rear silencer - remove and install
    355
  • 1.6 Exhaust system - tension free alignment
    356
  • 1.7 Exhaust system - check tightness
    357
  • 1.8 Pipe clamp installation position
    357
  • 2 Exhaust system
    359
  • 2.1 Emission control - assembly overview
    359
  • 2.2 Catalytic converter - remove and install
    362
  • Ignition system
    365
  • 1 Ignition system
    365
  • 1.1 Ignition system - assembly overview
    365
  • 1.2 Ignition coils with final power stage - assembly overview
    367
  • 1.3 Spark plugs Q - technical data
    368
  • 1.4 Ignition coil with final power stage - remove and install
    368
  • 1.5 Knock sensor 1 G61 - remove and install
    372
  • 1.6 Hall Sensor G40 - remove and install
    373
  • 1.7 Engine speed sensor G28 - remove and install
    374
  • 1.8 Heater control unit J65 - remove and install
    376
Manufacturer's designation 3-Cyl. injection engine (1.0 l)
Manufacturer Volkswagen
Suitable for Polo [BR] (2018 >)
Suitable car types BZ1
Engine code CSEB
Category Reparaturanleitung

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