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  • Examplepage for repair manual 3-cylinder diesel engine (aluminium cylinder block)
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  • Examplepage for repair manual 3 3-cylinder diesel engine (aluminium cylinder block)
  • Examplepage for repair manual 3-cylinder diesel engine (aluminium cylinder block)
  • Examplepage for repair manual 2 3-cylinder diesel engine (aluminium cylinder block)
  • Examplepage for repair manual 3 3-cylinder diesel engine (aluminium cylinder block)

3-cylinder diesel engine (aluminium cylinder block)

For Lupo 3L

Original Volkswagen repair manual


14,65 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

4.725 KB

173 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Charge air system with turbocharger, Checking charge pressure control and Repairing diesel direct injection system. Show more
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Repair manual Lupo 3L 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
  • Removing and installing engine
    2
  • 1 Removing and installing engine
    2
  • 1.1 Notes on removing
    3
  • 1.2 Securing engine to assembly stand
    4
  • 1.3 Notes on installing
    5
  • 1.4 Torque settings
    6
  • 1.5 Assembly mountings
    7
  • Crankshaft group
    8
  • 1 Dismantling and assembling engine
    8
  • 1.1 Assembly overview
    8
  • 1.2 Removing and installing poly V-belt
    13
  • 2 Removing and installing balancer shaft and retaining frame
    14
  • 2.1 Removing and installing balancer shaft
    15
  • 3 Removing and installing cylinder block, sealing flange and flywheel
    20
  • 3.1 Renewing crankshaft oil seal on belt pulley end
    21
  • 3.2 Removing and installing sealing flange on pulley end
    22
  • 4 Dismantling and assembling pistons and conrods
    25
  • 4.1 Disconnecting conrod
    27
  • 4.2 Checking piston projection at TDC
    28
  • 4.3 Piston and cylinder dimensions
    29
  • Cylinder head, valve gear
    30
  • 1 Removing and installing cylinder head
    30
  • 1.1 Removing, installing and tensioning toothed belts
    33
  • 1.2 Dismantling and assembling intake manifold
    38
  • 1.3 Removing and installing cylinder head
    40
  • 1.4 Compression test
    44
  • 2 Repairing valve gear
    47
  • 2.1 Reworking valve seats
    49
  • 2.2 Checking valve guides
    51
  • 2.3 Renewing valve guides
    52
  • 2.4 Renewing valve stem seals
    52
  • 2.5 Removing and installing camshaft
    54
  • 2.6 Removing and installing camshaft oil seal
    58
  • Lubrication
    61
  • 1 Removing and installing parts of lubrication system
    61
  • 1.1 Engine oil
    61
  • 1.2 Removing and installing sump
    68
  • 1.3 Checking oil pressure and oil pressure switch
    69
  • Cooling
    71
  • 1 Removing and installing parts of cooling system
    71
  • 1.1 Parts of cooling system, body side
    71
  • 1.2 Parts of cooling system - engine side
    73
  • 1.3 Coolant hose schematic diagram
    74
  • 1.4 Draining and filling coolant
    75
  • 1.5 Removing and installing radiator
    78
  • 1.6 Removing and installing coolant pump
    79
  • 1.7 Removing and installing thermostat
    80
  • Fuel supply system
    82
  • 1 Removing and installing parts of fuel supply system
    82
  • 1.1 Removing and installing fuel tank with attached components
    82
  • 1.2 Repairing fuel filter
    84
  • 1.3 Safety precautions when working on fuel supply system
    85
  • 1.4 Rules for cleanliness
    85
  • 1.5 Removing and installing fuel cooler
    85
  • 1.6 Removing and installing fuel tank
    86
  • 1.7 Repairing throttle mechanism
    88
  • 1.8 Checking accelerator position sender G79
    90
  • 1.9 Adjusting accelerator position sender G79
    94
  • 1.10 Checking tandem pump
    95
  • 1.11 Removing and installing tandem pump
    97
  • Turbocharging/supercharging
    100
  • 1 Charge air system with turbocharger
    100
  • 1.1 Safety precautions
    100
  • 1.2 Rules for cleanliness
    100
  • 1.3 Removing and installing turbocharger with attachments
    100
  • 1.4 Removing and installing parts of charge air cooling
    103
  • 1.5 Charge pressure control hose routing diagram
    104
  • 2 Checking charge pressure control
    105
  • 2.1 Checking charge pressure control solenoid valve N75
    107
  • Mixture preparation - injection
    109
  • 1 Repairing diesel direct injection system
    109
  • 1.1 Safety precautions
    109
  • 1.2 Rules for cleanliness
    110
  • 1.3 Overview of fitting locations
    110
  • 1.4 Repairing intake manifold flap
    111
  • 1.5 Repairing unit injector
    113
  • 1.6 Removing and installing O-rings for unit injector
    113
  • 1.7 Removing and installing unit injector
    115
  • 2 Checking components and functions
    121
  • 2.1 Checking voltage supply for diesel direct injection system
    121
  • 2.2 Checking engine speed sender G28
    121
  • 2.3 Checking intake manifold pressure sender G71 and altitude sender F96
    122
  • 2.4 Checking coolant temperature sender G62
    124
  • 2.5 Checking brake light switch F and brake pedal switch F47
    126
  • 2.6 Checking clutch pedal switch F36
    127
  • 2.7 Checking intake manifold temperature sender G72
    129
  • 2.8 Checking fuel temperature sender G81
    130
  • 2.9 Checking air mass meter G70
    132
  • 2.10 Checking intake manifold flap change-over
    134
  • 2.11 Checking intake manifold flap motor V157
    136
  • 2.12 Checking unit injector valves
    137
  • 2.13 Checking camshaft position Hall sender G40
    139
  • 3 Checking additional signals
    141
  • 3.1 Checking speed signal
    141
  • 3.2 Checking signal from/to air conditioning system
    142
  • 3.3 Checking speed signal
    145
  • 3.4 Checking cruise control system (CCS)
    145
  • 3.5 Checking data bus
    147
  • 4 Renewing, coding and adapting engine control unit
    153
  • 4.1 Renewing engine control unit
    153
  • 4.2 Coding engine control unit
    153
  • 4.3 Adapting engine control unit to electronic immobilizer
    154
  • Exhaust system
    156
  • 1 Removing and installing parts of exhaust system
    156
  • 1.1 Front exhaust pipe with catalytic converters and attachments
    156
  • 1.2 Silencer with mountings
    157
  • 2 Exhaust gas recirculation system
    158
  • 2.1 Removing and installing parts of exhaust gas recirculation system
    158
  • 2.2 Schematic diagram for vacuum hoses
    160
  • 2.3 Checking exhaust gas recirculation valve
    160
  • 2.4 Checking exhaust gas recirculation
    161
  • Glow plug system
    165
  • 1 Checking glow plug system
    165
  • 1.1 Checking glow plugs
    166
Manufacturer's designation 3-cylinder diesel engine (aluminium cylinder block)
Manufacturer Volkswagen
Suitable for Lupo 3L (1999 - 2006)
Suitable car types 6E
Engine code AYZ
Category Reparaturanleitung

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