Diesel engines 1.7 and 1.9 l car Volkswagen Polo 3
Diesel engines AKW, ANV 1.7 SDI, AEY 1.9 SDI, AFN, AHU and ALE 1.9 TDI, 1Y 1.9 D
Engine code The engine code is stamped between the fuel injection pump and the vacuum pump on the cylinder block (Fig. 6.1). Additionally, the engine code is also pasted on the...
Engine code The engine code is stamped between the fuel injection pump and the vacuum pump on the cylinder block (Fig. 6.1). Additionally, the engine code is also pasted on the...
Disassembling the engine
The engine elements are shown in Fig. 6.2 a-c. Fig. 6.2 a. Engine components: 1, 9, 11, 13, 22 - Bolts; 2 - Washer; 3, 8, 32 - Tension rollers; 4 - Tension lever; 5 - Retainer; 6...
The engine elements are shown in Fig. 6.2 a-c. Fig. 6.2 a. Engine components: 1, 9, 11, 13, 22 - Bolts; 2 - Washer; 3, 8, 32 - Tension rollers; 4 - Tension lever; 5 - Retainer; 6...
Timing belt drive with single pulley injection pump
Removal 1. Remove the ribbed belt. 2. Remove the ribbed belt tensioner roller, if installed. 3. Remove the upper part of the timing belt cover and the cylinder head cover. 4....
Removal 1. Remove the ribbed belt. 2. Remove the ribbed belt tensioner roller, if installed. 3. Remove the upper part of the timing belt cover and the cylinder head cover. 4....
Timing belt drive with double pulley injection pump
Engine 1Y Removal 1. Remove the ribbed belt. 2. If installed, remove the ribbed belt tensioner roller. 3. Remove the upper part of the timing belt cover and the cylinder head...
Engine 1Y Removal 1. Remove the ribbed belt. 2. If installed, remove the ribbed belt tensioner roller. 3. Remove the upper part of the timing belt cover and the cylinder head...
Sealing flange and flywheel / drive disc / pressure disc
The sealing flange and flywheel/drive plate/pressure plate are shown in Fig. 6.12. Fig. 6.12. Sealing flange and flywheel / drive disk / pressure disk: 1, 14 - Seals; 2 - Key; 3,...
The sealing flange and flywheel/drive plate/pressure plate are shown in Fig. 6.12. Fig. 6.12. Sealing flange and flywheel / drive disk / pressure disk: 1, 14 - Seals; 2 - Key; 3,...
Crankshaft
The crankshaft is shown in Fig. 6.13. Fig. 6.13. Crankshaft: 1 - Bearing inserts 1, 2, 4 and 5; 2, 7 - Bolts; 3 - Main caps; 4 - Bearing insert 3; 5, 10 - Thrust half rings (axial...
The crankshaft is shown in Fig. 6.13. Fig. 6.13. Crankshaft: 1 - Bearing inserts 1, 2, 4 and 5; 2, 7 - Bolts; 3 - Main caps; 4 - Bearing insert 3; 5, 10 - Thrust half rings (axial...
Connecting rod and piston group
The piston and connecting rod are shown in Fig. 6.14. Fig. 6.14. Piston and connecting rod: 1 - Piston rings; 2 - Piston; 3 - Piston pin; 4 - Retaining ring; 5 - Connecting rod; 6...
The piston and connecting rod are shown in Fig. 6.14. Fig. 6.14. Piston and connecting rod: 1 - Piston rings; 2 - Piston; 3 - Piston pin; 4 - Retaining ring; 5 - Connecting rod; 6...
Checking the piston protrusion at TDC
The piston protrusion at TDC is produced when installing a new piston (Fig. 6.17). Depending on the piston protrusion, the cylinder head gasket is installed (tables 6.3 a,b)....
The piston protrusion at TDC is produced when installing a new piston (Fig. 6.17). Depending on the piston protrusion, the cylinder head gasket is installed (tables 6.3 a,b)....
Cylinder head
The cylinder head is shown in Fig. 6.19. Fig. 6.19. Cylinder head: 1, 4, 6, 19, 29, 31 - Bolts; 2 - Upper part of the timing belt protective cover; 3 - Timing belt; 5 - Camshaft...
The cylinder head is shown in Fig. 6.19. Fig. 6.19. Cylinder head: 1, 4, 6, 19, 29, 31 - Bolts; 2 - Upper part of the timing belt protective cover; 3 - Timing belt; 5 - Camshaft...
Compression check
4.1. Engines AEY, AFN, ANV, AHU, AKW, ALE 1. Disconnect the wiring connector from the shut-off valve on the high-pressure fuel pump. 2. Disconnect the wiring connector from the...
4.1. Engines AEY, AFN, ANV, AHU, AKW, ALE 1. Disconnect the wiring connector from the shut-off valve on the high-pressure fuel pump. 2. Disconnect the wiring connector from the...
Gas distribution mechanism
The elements of the gas distribution mechanism are shown in Fig. 6.25. Fig. 6.25. Elements of the gas distribution mechanism: 1 - Camshaft main caps; 2 - Nut; 3 - Camshaft; 4 -...
The elements of the gas distribution mechanism are shown in Fig. 6.25. Fig. 6.25. Elements of the gas distribution mechanism: 1 - Camshaft main caps; 2 - Nut; 3 - Camshaft; 4 -...
Valve seat machining
1. Insert the valve and press it firmly against the seat. 2. Measure the distance between the end of the valve stem and the top edge of the cylinder head (Fig. 6.29). 3. Calculate...
1. Insert the valve and press it firmly against the seat. 2. Measure the distance between the end of the valve stem and the top edge of the cylinder head (Fig. 6.29). 3. Calculate...
Checking the valve guide bushing
1. Insert the new valve into the sleeve so that the end of its stem is flush with the edge of the valve sleeve. 2. Determine the gap between the sleeve and the valve (Fig. 6.33)....
1. Insert the new valve into the sleeve so that the end of its stem is flush with the edge of the valve sleeve. 2. Determine the gap between the sleeve and the valve (Fig. 6.33)....
Checking hydraulic compensators
Attention! A faulty hydraulic compensator must be replaced as a whole. It cannot be repaired. Irregular knocking of the valves when starting the engine is normal. 1. Start the...
Attention! A faulty hydraulic compensator must be replaced as a whole. It cannot be repaired. Irregular knocking of the valves when starting the engine is normal. 1. Start the...
Swirl chamber replacement (1Y engines only)
Measure the swirl chamber protrusion (Fig. 6.35). Specification: 0.07 mm. If the required value is not achieved, replace the cylinder head.
Measure the swirl chamber protrusion (Fig. 6.35). Specification: 0.07 mm. If the required value is not achieved, replace the cylinder head.
Lubrication system
The elements of the lubrication system are shown in Fig. 6.36. Fig. 6.36. Elements of the lubrication system: 1 - Cover: 2, 12, 23 - Gaskets; 3 - Oil level indicator; 4 - Guide...
The elements of the lubrication system are shown in Fig. 6.36. Fig. 6.36. Elements of the lubrication system: 1 - Cover: 2, 12, 23 - Gaskets; 3 - Oil level indicator; 4 - Guide...
Checking oil pressure and pressure sensor
1. Unscrew the pressure sensor (0.25 bar, blue) and screw it into the tester (Fig. 6.39). 2. Screw the tester adapter into the hole for the pressure sensor in the cylinder head....
1. Unscrew the pressure sensor (0.25 bar, blue) and screw it into the tester (Fig. 6.39). 2. Screw the tester adapter into the hole for the pressure sensor in the cylinder head....
Cooling system
The cooling system elements are shown in Fig. 6.40, 6.41. The cooling system pump is shown in Fig. 6.42. Fig. 6.40. Elements of the cooling system: 1 - Clamp; 2 - Bolts with nuts;...
The cooling system elements are shown in Fig. 6.40, 6.41. The cooling system pump is shown in Fig. 6.42. Fig. 6.40. Elements of the cooling system: 1 - Clamp; 2 - Bolts with nuts;...
Power supply system
The elements of the fuel system of Polo Classic, Polo Estate are shown in Fig. 6.43, the elements of the fuel system of Caddy - in Fig. 6.44. Fig. 6.43. Elements of the Polo...
The elements of the fuel system of Polo Classic, Polo Estate are shown in Fig. 6.43, the elements of the fuel system of Caddy - in Fig. 6.44. Fig. 6.43. Elements of the Polo...
Fuel filter
The fuel filter is shown in Fig. 6.47. Fig. 6.47. Fuel filter: 1 - Fuel drain line from the high-pressure fuel pump; 2 - Fuel intake line to the high-pressure fuel pump; 3 -...
The fuel filter is shown in Fig. 6.47. Fig. 6.47. Fuel filter: 1 - Fuel drain line from the high-pressure fuel pump; 2 - Fuel intake line to the high-pressure fuel pump; 3 -...
Accelerator pedal
The accelerator pedal of cars with 1Y engine is shown in Fig. 6.48 a, cars with AEY, AHB, AHU, AKW, ALE engines - in Fig. 6.48 b, cars with AFN engine - in Fig. 6.48 c. Fig. 6.48...
The accelerator pedal of cars with 1Y engine is shown in Fig. 6.48 a, cars with AEY, AHB, AHU, AKW, ALE engines - in Fig. 6.48 b, cars with AFN engine - in Fig. 6.48 c. Fig. 6.48...
Checking the accelerator pedal position sensor (engines AEY, AFN, AHB, AHU, AKW, ALE)
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial "01" "Engine Electronics". The engine should idle. The display should show the following information: 2. Press "08"...
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial "01" "Engine Electronics". The engine should idle. The display should show the following information: 2. Press "08"...
Adjusting the accelerator pedal position sensor (engines AEY, AFN, AHB, AHU, AKW, ALE)
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial "01" "Engine Electronics". The engine should idle. The display should show the following information: 2. Press "08"...
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial "01" "Engine Electronics". The engine should idle. The display should show the following information: 2. Press "08"...
Turbocharging a diesel engine
The turbocharger with attached elements of the AHU, ALE engines is shown in Fig. 6.58 a, and of the AFN engine - in Fig. 6.58 b. Fig. 6.58 a. Turbocharger with attached elements...
The turbocharger with attached elements of the AHU, ALE engines is shown in Fig. 6.58 a, and of the AFN engine - in Fig. 6.58 b. Fig. 6.58 a. Turbocharger with attached elements...
Intercooler (intermediate cooling of the supercharged air)
Intercooler Elements (intermediate air cooling) are shown in Fig. 6.59. Fig. 6.59. Intercooler elements (intermediate air cooling): 1 - Exhaust manifold; 2 - Connecting tube...
Intercooler Elements (intermediate air cooling) are shown in Fig. 6.59. Fig. 6.59. Intercooler elements (intermediate air cooling): 1 - Exhaust manifold; 2 - Connecting tube...
Exhaust gas recirculation system
The arrangement of the exhaust gas recirculation system tubes of the AHU and ALE engines is shown in Fig. 6.60 a, and of the AFN engine - in Fig. 6.60 b. The arrangement of the...
The arrangement of the exhaust gas recirculation system tubes of the AHU and ALE engines is shown in Fig. 6.60 a, and of the AFN engine - in Fig. 6.60 b. The arrangement of the...
Checking the components of the exhaust gas recirculation system
On engine 1Y 1. Start the engine and let it idle. 2. The EGR valve diaphragm should move towards the tube fitting (can be determined by touch below the arrow) (Fig. 6.62). The...
On engine 1Y 1. Start the engine and let it idle. 2. The EGR valve diaphragm should move towards the tube fitting (can be determined by touch below the arrow) (Fig. 6.62). The...
Checking the mechanical EGR valve
AHU Engine 1. Disconnect the vacuum pipe from the EGR valve. 2. Attach the VAG 1390 hand pump to the valve. 3. Operate the pump (Fig. 6.66). The membrane rod should move to the...
AHU Engine 1. Disconnect the vacuum pipe from the EGR valve. 2. Attach the VAG 1390 hand pump to the valve. 3. Operate the pump (Fig. 6.66). The membrane rod should move to the...
Diesel fuel injection control system
The arrangement of the diesel fuel injection system elements in the engine compartment of vehicles with AEY, ANV, AKW engines is shown in Fig. 6.68 a, and of vehicles with AFN,...
The arrangement of the diesel fuel injection system elements in the engine compartment of vehicles with AEY, ANV, AKW engines is shown in Fig. 6.68 a, and of vehicles with AFN,...
Self-diagnosis of the injection system
The fuel injection system control unit is equipped with a fault memory, which records faults in sensors or systems, indicating the type of fault. Sometimes faults occur that are...
The fuel injection system control unit is equipped with a fault memory, which records faults in sensors or systems, indicating the type of fault. Sometimes faults occur that are...
Connecting the VAG 1551 fault code reader
1. Open the glove compartment lid on the driver's side and connect the VAG 1551 fault code reader using the VAG 1551/3 cable (Fig. 6.70). 2. After connecting the fault code...
1. Open the glove compartment lid on the driver's side and connect the VAG 1551 fault code reader using the VAG 1551/3 cable (Fig. 6.70). 2. After connecting the fault code...
Querying fault memory
To interrogate the fault memory, you need the VAG 1551 fault code reader and the VAG 1551/3 cable. 1. Connect the VAG 1551 fault code reader (V.A.G 1552) and, by typing "01"...
To interrogate the fault memory, you need the VAG 1551 fault code reader and the VAG 1551/3 cable. 1. Connect the VAG 1551 fault code reader (V.A.G 1552) and, by typing "01"...
Clearing fault memory
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and, by typing "01" "Engine Electronics", select the engine control unit. The engine should be idling. The display should...
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and, by typing "01" "Engine Electronics", select the engine control unit. The engine should be idling. The display should...
Reading a block of measured values
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial "01" "Engine Electronics" The engine should idle. The display should show the following information: 2. Press "08"...
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial "01" "Engine Electronics" The engine should idle. The display should show the following information: 2. Press "08"...
Removal and installation of fuel injection pump
Removal 1. Remove the air filter. 2. Remove the upper part of the timing belt cover. 3. Remove the cylinder head cover. 4. Align the TDC marks of the piston of cylinder No.1 on...
Removal 1. Remove the air filter. 2. Remove the upper part of the timing belt cover. 3. Remove the cylinder head cover. 4. Align the TDC marks of the piston of cylinder No.1 on...
Checking the valve timing
1. Remove the upper part of the timing belt cover. 2. Remove the cylinder head cover. 3. Align the TDC marks of the piston of cylinder No.1 on the crankshaft: A - Engines AEY,...
1. Remove the upper part of the timing belt cover. 2. Remove the cylinder head cover. 3. Align the TDC marks of the piston of cylinder No.1 on the crankshaft: A - Engines AEY,...
Checking the injectors
The injectors are tested on a stand (Fig. 6.75). At the moment of fuel spraying, check the opening pressure. Engines AEY, AFN, ANV, AHU, AKW Specification value: new injector -...
The injectors are tested on a stand (Fig. 6.75). At the moment of fuel spraying, check the opening pressure. Engines AEY, AFN, ANV, AHU, AKW Specification value: new injector -...
Checking the crankshaft speed sensor
1. Turn off the ignition. 2. Disconnect the wiring connector from the crankshaft speed sensor. 3. Measure the resistance between contacts 1 and 2 of the connector (Fig. 6.76)....
1. Turn off the ignition. 2. Disconnect the wiring connector from the crankshaft speed sensor. 3. Measure the resistance between contacts 1 and 2 of the connector (Fig. 6.76)....
Checking the coolant temperature sensor
1. Connect the VAG 1551 tester and dial "01" to select the "Address word" function of the engine control unit. The engine should be idling. The display should show the following...
1. Connect the VAG 1551 tester and dial "01" to select the "Address word" function of the engine control unit. The engine should be idling. The display should show the following...
Checking the temperature sensor in the intake manifold (on AFN, AHU, ALE engines)
1. Connect the VAG 1551 tester and dial "01" to select the "Address word" function of the engine control unit. The engine should be idling. The display should show the following...
1. Connect the VAG 1551 tester and dial "01" to select the "Address word" function of the engine control unit. The engine should be idling. The display should show the following...
Checking the inlet air temperature sensor (on AEY, ANV, AKW engines)
Connect the VAG 1551 tester and dial "01" to select the "Address word" function of the engine control unit. The engine should be idling. The display should show the following...
Connect the VAG 1551 tester and dial "01" to select the "Address word" function of the engine control unit. The engine should be idling. The display should show the following...
Checking the fuel temperature sensor
1. Connect the VAG 1551 tester and, by entering "01" "Engine Electronics", select the engine control unit. The engine should be idling. The display should show the following...
1. Connect the VAG 1551 tester and, by entering "01" "Engine Electronics", select the engine control unit. The engine should be idling. The display should show the following...
Checking the injector needle displacement sensor
1. Turn off the ignition. 2. Disconnect the wiring connector from the injector needle position sensor. 3. Measure the resistance between the connector contacts (Fig. 6.92)....
1. Turn off the ignition. 2. Disconnect the wiring connector from the injector needle position sensor. 3. Measure the resistance between the connector contacts (Fig. 6.92)....
Error codes
Fault code Faulty unit 00282 Throttle position sensor 00513 Crankshaft speed sensor 00519 Intake Manifold Pressure Sensor 00522 Coolant temperature sensor 00523 Inlet air...
Fault code Faulty unit 00282 Throttle position sensor 00513 Crankshaft speed sensor 00519 Intake Manifold Pressure Sensor 00522 Coolant temperature sensor 00523 Inlet air...
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Polo 4
Polo 3
- General information
- User manual
- Maintenance
- Power unit
- Engine repair
- Cooling and lubrication system
- Control system
- Injection system (diesel)
- Supply system
- Exhaust system
- Chassis
- Front suspension
- Rear suspension
- Steering
- Wheels and tires
- Brake system
- Body
- Interior
- Exterior
- Electrical equipment
- Equipment and devices
- Wiper system
- Lighting system
- Electrical circuits
- General information
- User manual
- Maintenance
- Power unit
- Petrol engines 1.4 and 1.6
- Petrol engines 1.4 (V16)
- Petrol engines 1.6 and 1.8
- Diesel engines 1.7 and 1.9
- Diesel engines 1.9 D and TD
- Transmission
- Mechanical gearbox 085
- Mechanical gearbox 020/02K
- Chassis
- Front suspension
- Rear suspension
- Steering
- Brake system
- Body
- Exterior
- Interior
- Electrical equipment
- Equipment and instruments (until 2000)
- Equipment and instruments (after 2000)
- Electrical circuits
- Wiring diagrams (petrol)
- Wiring diagrams (diesel)