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  • Examplepage for repair manual 3-cylinder diesel engine
  • Examplepage for repair manual 2 3-cylinder diesel engine
  • Examplepage for repair manual 3 3-cylinder diesel engine

3-cylinder diesel engine

For Polo

Original Volkswagen repair manual


17,35 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

5.145 KB

210 Sites

Detailed technical data

Immediately readable

This repair manual contains: Self-diagnosis, Fault memory, Fault table: Fault codes 00515...01282, Measured value blocks, Removing and installing engine, Pistons and conrods, Cylinder head, Parts of fuel supply system and Charge air system with turbocharger. Show more
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Repair manual Polo 3-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Self-diagnosis
    2
  • 1 Self-diagnosis
    2
  • 1.1 Features of self-diagnosis
    2
  • 1.2 Technical data of self-diagnosis
    2
  • 2 Fault memory
    7
  • 2.1 Read fault memory
    7
  • 2.2 Erase fault memory
    8
  • 3 Fault table: Fault codes 00515...01282
    10
  • 4 Fault table: Fault codes 16485...18076
    13
  • 5 Final control diagnosis
    27
  • 5.1 Performing final control diagnosis
    27
  • 6 Measured value blocks
    30
  • 6.1 Safety precautions
    30
  • 6.2 Reading measured value block
    30
  • 6.3 Measured values at idling speed
    31
  • 6.4 Measured values at full throttle
    39
  • Removing and installing engine
    44
  • 1 Removing and installing engine
    44
  • 1.1 Notes on removing
    45
  • 1.2 Securing engine to assembly stand
    46
  • 1.3 Notes on installing
    47
  • 1.4 Assembly mountings
    48
  • 1.5 Additional notes and assembly work for vehicles with air conditioner
    49
  • Crankshaft group
    50
  • 1 Dismantling and assembling engine
    50
  • 1.1 Assembly overview
    50
  • 1.2 Removing and installing poly V-belt
    55
  • 2 Removing and installing sealing flange and flywheel
    58
  • 2.1 Assembly overview
    58
  • 2.2 Renewing crankshaft oil seal - pulley end
    59
  • 2.3 Removing and installing sealing flange - pulley end
    60
  • 3 Balancer shaft and retaining frame
    63
  • 3.1 Assembly overview
    63
  • 3.2 Removing and installing balancer shaft
    64
  • 4 Removing and installing crankshaft
    69
  • 4.1 Crankshaft dimensions
    70
  • 5 Pistons and conrods
    71
  • 5.1 Assembly overview - pistons and conrods
    71
  • 5.2 Checking piston projection at TDC
    73
  • 5.3 Piston and cylinder dimensions
    75
  • Cylinder head, valve gear
    76
  • 1 Cylinder head
    76
  • 1.1 Assembly overview - cylinder head
    76
  • 1.2 Removing, installing and tensioning toothed belts
    79
  • 1.3 Removing and installing cylinder head
    84
  • 1.4 Checking compression
    87
  • 2 Valve gear
    90
  • 2.1 Assembly overview - valve gear
    90
  • 2.2 Reworking valve seats
    92
  • 2.3 Checking valve guides
    94
  • 2.4 Renewing valve guides
    94
  • 2.5 Renewing valve stem seals
    95
  • 2.6 Removing and installing camshaft
    97
  • 2.7 Removing and installing camshaft oil seal
    101
  • Lubrication
    104
  • 1 Parts of lubrication system
    104
  • 1.1 Engine oil
    104
  • 1.2 Assembly overview - parts of lubrication system
    104
  • 1.3 Removing and installing sump
    109
  • 1.4 Checking oil pressure and oil pressure switch
    110
  • Cooling
    113
  • 1 Parts of cooling system
    113
  • 1.1 Assembly overview - parts of cooling system, body side
    113
  • 1.2 Assembly overview - parts of cooling system, engine side
    115
  • 1.3 Coolant hose schematic diagram
    116
  • 1.4 Draining and filling coolant
    117
  • 1.5 Removing and installing radiator
    120
  • 1.6 Removing and installing coolant pump
    121
  • 1.7 Removing and installing thermostat
    122
  • Fuel supply system
    124
  • 1 Parts of fuel supply system
    124
  • 1.1 Assembly overview - fuel tank with attachments
    124
  • 1.2 Assembly overview - fuel filter
    126
  • 1.3 Safety precautions when working on fuel supply system
    128
  • 1.4 Rules for cleanliness
    128
  • 1.5 Removing and installing fuel cooler
    128
  • 1.6 Removing and installing fuel tank
    129
  • 1.7 Accelerator mechanism
    130
  • 1.8 Checking accelerator position sender G79
    133
  • 1.9 Adjusting accelerator position sender G79
    136
  • 1.10 Checking tandem pump
    137
  • 1.11 Removing and installing tandem pump
    139
  • Turbocharging/supercharging
    142
  • 1 Charge air system with turbocharger
    142
  • 1.1 Safety precautions
    142
  • 1.2 Rules for cleanliness
    142
  • 1.3 Removing and installing turbocharger with attachments
    142
  • 1.4 Removing and installing parts of charge air cooling
    145
  • 1.5 Charge pressure control hose routing diagram
    147
  • 2 Checking charge pressure system
    148
  • 2.1 Checking charge pressure control
    148
  • 2.2 Checking charge pressure control valve vacuum unit
    152
  • 2.3 Removing and installing vacuum unit for charge pressure control valve
    153
  • Mixture preparation - injection
    154
  • 1 Repairing diesel direct injection system
    154
  • 1.1 Safety precautions
    154
  • 1.2 Rules for cleanliness
    154
  • 1.3 Fitting locations overview
    155
  • 1.4 Repairing intake manifold flap
    156
  • 1.5 Servicing unit injector
    156
  • 1.6 Removing and installing O-rings for unit injector
    157
  • 1.7 Removing and installing unit injector
    159
  • 2 Checking components and functions
    164
  • 2.1 Checking voltage supply for diesel direct injection system
    164
  • 2.2 Checking engine speed sender G28
    164
  • 2.3 Checking intake manifold pressure sender G71 and altitude sender F96
    165
  • 2.4 Checking coolant temperature sender G62
    168
  • 2.5 Checking brake light switch F and brake pedal switch F47
    169
  • 2.6 Checking clutch pedal switch F36
    170
  • 2.7 Checking intake manifold temperature sender G72
    172
  • 2.8 Checking fuel temperature sender G81
    173
  • 2.9 Checking air mass meter G70
    175
  • 2.10 Checking intake manifold flap change-over
    177
  • 2.11 Checking unit injector valves
    178
  • 2.12 Checking camshaft position Hall sender G40
    181
  • 3 Checking additional signals
    183
  • 3.1 Checking speed signal
    183
  • 3.2 Checking signal from/to air conditioning system
    184
  • 3.3 Checking speed signal
    187
  • 3.4 Checking cruise control system (CCS)
    187
  • 3.5 Checking data bus
    189
  • 4 Renewing, coding and adapting engine control unit
    191
  • 4.1 Renewing diesel direct injection system control unit J248
    191
  • 4.2 Coding diesel direct injection system control unit J248
    191
  • Exhaust system
    194
  • 1 Parts of exhaust system
    194
  • 1.2 Assembly overview - Silencer with mountings
    195
  • 2 Exhaust gas recirculation system
    196
  • 2.1 Assembly overview - parts of exhaust gas recirculation
    196
  • 2.2 Schematic diagram for vacuum hoses
    197
  • 2.3 Checking exhaust gas recirculation valve
    197
  • 2.4 Checking exhaust gas recirculation
    198
  • Glow plug system
    202
  • 1 Glow plug system
    202
  • 1.1 Checking glow plug system
    202
  • 1.2 Checking glow plugs
    203
Manufacturer's designation 3-cylinder diesel engine
Manufacturer Volkswagen
Suitable for Polo (1995 - 2002)
Suitable car types 6N
Engine code AMF
Category Reparaturanleitung

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