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  • Examplepage for repair manual 4-cylinder injection engine (direct injection)
  • Examplepage for repair manual 2 4-cylinder injection engine (direct injection)
  • Examplepage for repair manual 3 4-cylinder injection engine (direct injection)

4-cylinder injection engine (direct injection)

For Lupo 3L

Original Volkswagen repair manual


17,50 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

5.110 KB

212 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Electronic power control (EPC), Activated charcoal filter system and Checking components. Show more
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Repair manual Lupo 3L 4-cylinder injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Technical data
    1
  • 1.2 Engine number
    1
  • 1.3 Engine data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing and installing engine
    3
  • 1.2 Notes on removing
    4
  • 1.3 Securing engine to assembly stand
    7
  • 1.4 Notes on installing
    7
  • 1.5 Tightening torques
    9
  • 1.6 Assembly mountings
    9
  • 1.7 Additional information and removal instructions for vehicles with air conditioner
    10
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Dismantling and assembling engine
    12
  • 1.2 Removing and installing ribbed belt
    20
  • 2 Removing and installing cylinder block, sealing flange and flywheel
    22
  • 2.1 Removing and installing cylinder block, sealing flange and flywheel
    22
  • 2.2 Aluminium cylinder block
    22
  • 2.3 Renewing crankshaft oil seal -belt pulley end-
    25
  • 2.4 Renewing crankshaft sealing flange -flywheel end-
    27
  • 3 Dismantling and assembling pistons and conrods
    36
  • 3.1 Dismantling and assembling pistons and conrods
    36
  • 3.2 Piston and cylinder dimensions
    41
  • Cylinder head, Valve gear
    42
  • 1 Removing and installing cylinder head
    42
  • 1.1 Removing and installing cylinder head
    42
  • 1.2 Checking valve timing
    48
  • 1.3 Checking semi-automatic toothed belt tensioning roller
    51
  • 1.4 Removing, installing and tensioning toothed belts
    54
  • 1.5 Removing and installing camshaft housing
    61
  • 1.6 Removing and installing cylinder head
    64
  • 1.7 Checking compression pressures
    67
  • 2 Servicing valve gear
    69
  • 2.1 Servicing valve gear
    69
  • 2.2 Reworking valve seats
    78
  • 2.3 Removing and installing camshaft adjuster and exhaust camshaft sprocket
    80
  • 2.4 Renewing camshaft oil seals
    87
  • 2.5 Checking valve guides
    90
  • 2.6 Renewing valve guides
    91
  • 2.7 Renewing valve stem seals
    92
  • Lubrication
    95
  • 1 Removing and installing parts of the lubrication system
    95
  • 1.1 Removing and installing parts of the lubrication system
    95
  • 1.2 Removing and installing oil sump
    101
  • 1.3 Removing and installing oil pump
    104
  • 1.4 Checking oil pressure and oil pressure switch
    107
  • Cooling system
    109
  • 1 Removing and installing parts of cooling system
    109
  • 1.1 Removing and installing parts of cooling system
    109
  • 1.2 Parts of cooling system body side
    110
  • 1.3 Checking coolant temperature sender -radiator outlet-
    113
  • 1.4 Parts of cooling system engine side
    115
  • 1.5 Coolant hose connection diagram
    120
  • 1.6 Draining and filling cooling system
    122
  • 1.7 Removing and installing radiator
    124
  • 1.8 Removing and installing coolant pump
    126
  • 1.9 Dismantling and assembling coolant distribution housing
    128
  • Fuel supply system
    130
  • 1 Removing and installing parts of fuel supply system
    130
  • 1.1 Removing and installing parts of fuel supply system
    130
  • 1.2 Removing and installing fuel tank with its attachments and fuel filter
    131
  • 1.3 Safety precautions when working on the fuel supply system
    135
  • 1.4 Rules for cleanliness
    136
  • 1.5 Removing and installing fuel delivery unit
    136
  • 1.6 Removing and installing fuel tank
    138
  • 1.7 Checking fuel pump
    140
  • 1.8 Removing and installing high-pressure pump
    146
  • 2 Electronic power control (EPC)
    148
  • 2.1 Electronic power control (EPC)
    148
  • 2.2 Function of EPC system
    148
  • 2.3 Servicing parts of electronic power control (EPC)
    149
  • 3 Activated charcoal filter system
    150
  • 3.1 Activated charcoal filter system
    150
  • 3.2 Function
    150
  • 3.3 Servicing parts of the activated charcoal filter system
    151
  • 3.4 Checking fuel tank breather
    153
  • Mixture preparation, Injection
    155
  • 1 Servicing injection
    155
  • 1.1 Servicing injection
    155
  • 1.2 General notes on injection
    155
  • 1.3 Removing and installing parts of the injection system
    156
  • 1.4 Dismantling and assembling intake manifold
    161
  • 1.5 Dismantling and assembling fuel rail with injectors
    169
  • 1.6 Dismantling and assembling air cleaner
    172
  • 1.7 Removing and installing injectors
    175
  • 1.8 Safety precautions
    180
  • 1.9 Rules for cleanliness
    181
  • 1.10 Technical data
    181
  • 2 Checking components
    182
  • 2.1 Checking components
    182
  • 2.2 Removing and installing fuel pressure regulator and fuel metering valve
    182
  • 2.3 Checking fuel pressure regulator and holding pressure
    184
  • 2.4 Removing and installing engine control unit
    187
  • 2.5 Interrogating and erasing engine control unit fault memory
    188
  • 2.6 Adapting functions and components
    189
  • Exhaust system
    191
  • 1 Removing and installing parts of exhaust system
    191
  • 1.1 Removing and installing parts of exhaust system
    191
  • 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
    191
  • 2 Exhaust gas recirculation system
    199
  • 2.1 Exhaust gas recirculation system
    199
  • 2.2 Servicing parts of exhaust gas recirculation system
    200
  • Ignition system
    202
  • 1 Servicing ignition system
    202
  • 1.1 Servicing ignition system
    202
  • 1.2 General notes on ignition system
    202
  • 1.3 Removing and installing parts of the ignition system
    203
  • 1.4 Safety precautions
    205
  • 1.5 Test data, spark plugs
    206
Manufacturer's designation 4-cylinder injection engine (direct injection)
Manufacturer Volkswagen
Suitable for Lupo 3L (1999 - 2006)
Suitable car types 6E
Engine code ARR
Category Reparaturanleitung

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