Diesel engines 1.9L car Volkswagen Polo 3
Technical characteristics of AGP, AQM, AYQ 1.9 D and AGR, ALH 1.9 TD engines
Table 7.1. Engine specifications Engine code The engine code is located between the gearbox and the engine (Fig. 7.1). Additionally, the engine code is affixed to the timing belt...
Table 7.1. Engine specifications Engine code The engine code is located between the gearbox and the engine (Fig. 7.1). Additionally, the engine code is affixed to the timing belt...
Disassembling the engine
The engine elements are shown in Fig. 7.2 a, b. Fig. 7.2 a. Engine components: 1 - Ribbed belt: 2, 4, 8, 9 - Bolts; 3 - Crankshaft pulley/damper; 5 - Ribbed belt tensioner (only...
The engine elements are shown in Fig. 7.2 a, b. Fig. 7.2 a. Engine components: 1 - Ribbed belt: 2, 4, 8, 9 - Bolts; 3 - Crankshaft pulley/damper; 5 - Ribbed belt tensioner (only...
Ribbed belt
To remove the ribbed belt: remove the right soundproofing casing; mark the direction of belt movement; using the key, move the tension roller in the direction of the arrow (fig....
To remove the ribbed belt: remove the right soundproofing casing; mark the direction of belt movement; using the key, move the tension roller in the direction of the arrow (fig....
Sealing flange and flywheel
The sealing flange and flywheel are shown in Fig. 7.4. Fig. 7.4. Sealing flange and flywheel: 1 - Cylinder block; 2 - Pressure plate/drive plate (only on AGP, AQM, AYQ engines); 3...
The sealing flange and flywheel are shown in Fig. 7.4. Fig. 7.4. Sealing flange and flywheel: 1 - Cylinder block; 2 - Pressure plate/drive plate (only on AGP, AQM, AYQ engines); 3...
Connecting rod and piston group
The design features and dimensions of the connecting rod and piston group of the engines considered in this chapter are similar to the design features and dimensions of the...
The design features and dimensions of the connecting rod and piston group of the engines considered in this chapter are similar to the design features and dimensions of the...
Checking the piston protrusion at TDC
The piston protrusion at TDC is made when installing a new piston (Fig. 7.5). Depending on the piston protrusion, the cylinder head gasket is installed (table 7.3). Cylinder Head...
The piston protrusion at TDC is made when installing a new piston (Fig. 7.5). Depending on the piston protrusion, the cylinder head gasket is installed (table 7.3). Cylinder Head...
Cylinder head
The cylinder head is shown in Fig. 7.7. Fig. 7.7. Cylinder head: 1 - Upper part of the timing belt protective cover; 2 - Timing belt; 3 - Bolt with nut; 4, 5, 10, 12, 21, 28 -...
The cylinder head is shown in Fig. 7.7. Fig. 7.7. Cylinder head: 1 - Upper part of the timing belt protective cover; 2 - Timing belt; 3 - Bolt with nut; 4, 5, 10, 12, 21, 28 -...
Intake manifold
The intake manifold of the AGP, AQM engines is shown in Fig. 7.9 a, the AYQ engine - in Fig. 7.9 b, the AGR, ALH, ASV engines - in Fig. 7.9 c. Fig. 7.9 a. Intake manifold of AGP,...
The intake manifold of the AGP, AQM engines is shown in Fig. 7.9 a, the AYQ engine - in Fig. 7.9 b, the AGR, ALH, ASV engines - in Fig. 7.9 c. Fig. 7.9 a. Intake manifold of AGP,...
Removal and installation the timing belt
Removal On AGR, ALH, ASV engines 1. Disconnect the pipe between the compressed air radiator (intercooler) and the intake manifold. For all engines 2. Remove the upper part of the...
Removal On AGR, ALH, ASV engines 1. Disconnect the pipe between the compressed air radiator (intercooler) and the intake manifold. For all engines 2. Remove the upper part of the...
Compression check
On engines AGP, AQM, AYQ 1. Remove the upper part of the intake manifold. For all engines 2. Connect the measuring device to the high-pressure fuel pump (arrow) (Fig. 7.19). 3....
On engines AGP, AQM, AYQ 1. Remove the upper part of the intake manifold. For all engines 2. Connect the measuring device to the high-pressure fuel pump (arrow) (Fig. 7.19). 3....
Gas distribution mechanism
The elements of the gas distribution mechanism are shown in Fig. 7.21. Fig. 7.21. 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. 7.21. Fig. 7.21. 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 "a" between the end of the valve stem and the top edge of the cylinder head (Fig. 7.25). 3....
1. Insert the valve and press it firmly against the seat. 2. Measure the distance "a" between the end of the valve stem and the top edge of the cylinder head (Fig. 7.25). 3....
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. 7.28)....
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. 7.28)....
Checking hydraulic compensators
Attention! A faulty hydraulic compensator must be replaced as a whole. It cannot be repaired. Irregular valve knocking when starting the engine is normal. 1. Start the engine and...
Attention! A faulty hydraulic compensator must be replaced as a whole. It cannot be repaired. Irregular valve knocking when starting the engine is normal. 1. Start the engine and...
Lubrication system
Volume of the lubrication system with oil filter: 4.5 l. Elements of the lubrication system are shown in Fig. 7.30 a, b. Fig. 7.30 a. Elements of the lubrication system: 1 - Oil...
Volume of the lubrication system with oil filter: 4.5 l. Elements of the lubrication system are shown in Fig. 7.30 a, b. Fig. 7.30 a. Elements of the lubrication system: 1 - Oil...
Checking oil pressure and pressure sensor
1. Unscrew the pressure sensor and screw it into the tester (Fig. 7.31). 2. Screw the tester adapter into the hole for the pressure sensor in the cylinder head. 3. Connect the...
1. Unscrew the pressure sensor and screw it into the tester (Fig. 7.31). 2. Screw the tester adapter into the hole for the pressure sensor in the cylinder head. 3. Connect the...
Cooling system
The elements of the cooling system are shown in Fig. 7.32 a, b. Fig. 7.32 a. Elements of the cooling system: 1 - Clamp; 2 - Bolts with nuts; 3 - Radiator; 4 - Locking support; 5 -...
The elements of the cooling system are shown in Fig. 7.32 a, b. Fig. 7.32 a. Elements of the cooling system: 1 - Clamp; 2 - Bolts with nuts; 3 - Radiator; 4 - Locking support; 5 -...
Fuel filter
The fuel filter is shown in Fig. 7.33. Fig. 7.33. Fuel filter: 1 - Fuel drain line (into the fuel tank); 2 - Fuel intake line (from the fuel tank); 3 - Control valve (when...
The fuel filter is shown in Fig. 7.33. Fig. 7.33. Fuel filter: 1 - Fuel drain line (into the fuel tank); 2 - Fuel intake line (from the fuel tank); 3 - Control valve (when...
Accelerator pedal
The accelerator pedal is shown in Fig. 7.34. Fig. 7.34. Accelerator pedal: 1 - Bracket; 2 - Accelerator pedal position sensor; 3 - Bolt with nut; 4 - Accelerator cable cam; 5 -...
The accelerator pedal is shown in Fig. 7.34. Fig. 7.34. Accelerator pedal: 1 - Bracket; 2 - Accelerator pedal position sensor; 3 - Bolt with nut; 4 - Accelerator cable cam; 5 -...
Checking the accelerator pedal position sensor
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
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 AGR engine is shown in Fig. 7.41 a, and of the ALH and ASV engines - in Fig. 7.41 b. Fig. 7.41 a. Turbocharger with attached AGR...
The turbocharger with attached elements of the AGR engine is shown in Fig. 7.41 a, and of the ALH and ASV engines - in Fig. 7.41 b. Fig. 7.41 a. Turbocharger with attached AGR...
Intercooler (intermediate cooling of the supercharged air)
Intercooler Elements (intermediate air cooling) are shown in Fig. 7.42. Fig. 7.42. Intercooler elements (intermediate air cooling): 1, 10, 12 - Connecting tubes; 2 - Sealing ring;...
Intercooler Elements (intermediate air cooling) are shown in Fig. 7.42. Fig. 7.42. Intercooler elements (intermediate air cooling): 1, 10, 12 - Connecting tubes; 2 - Sealing ring;...
Diesel fuel injection control system
The arrangement of the diesel fuel injection system elements in the engine compartment of vehicles with AGP, AQM, AYQ engines is shown in Fig. 7.43 a, and of vehicles with AGR,...
The arrangement of the diesel fuel injection system elements in the engine compartment of vehicles with AGP, AQM, AYQ engines is shown in Fig. 7.43 a, and of vehicles with AGR,...
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. Remove ashtray 1 and connect the VAG 1551 fault code reader using the VAG 1551/3 cable (Fig. 7.45). 2. After connecting the fault code reader, depending on the selected...
1. Remove ashtray 1 and connect the VAG 1551 fault code reader using the VAG 1551/3 cable (Fig. 7.45). 2. After connecting the fault code reader, depending on the selected...
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. Disconnect the fuel lines from the high-pressure fuel...
Removal 1. Remove the air filter. 2. Remove the upper part of the timing belt cover. 3. Remove the cylinder head cover. 4. Disconnect the fuel lines from the high-pressure fuel...
Checking the injectors
The injectors are tested on a stand (Fig. 7.48). At the moment of fuel spraying, check the opening pressure. AGP, AGR, AQM, AYQ engines Specification value: new nozzle - 190-200...
The injectors are tested on a stand (Fig. 7.48). At the moment of fuel spraying, check the opening pressure. AGP, AGR, AQM, AYQ engines Specification value: new nozzle - 190-200...
Checking the crankshaft speed sensor
1. Turn off the ignition. 2. Disconnect the wiring connector from the crankshaft speed sensor (Fig. 7.49). 3. Measure the resistance between contacts 1 and 2 of the connector...
1. Turn off the ignition. 2. Disconnect the wiring connector from the crankshaft speed sensor (Fig. 7.49). 3. Measure the resistance between contacts 1 and 2 of the connector...
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 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 movement sensor (arrow) (Fig. 7.59). 3. Measure the resistance between the connector contacts...
1. Turn off the ignition. 2. Disconnect the wiring connector from the injector needle movement sensor (arrow) (Fig. 7.59). 3. Measure the resistance between the connector contacts...
Checking the air flow meter
The flow meter is used by the control unit to determine the amount of fuel injected and to control the exhaust gas recirculation. The smaller the signal from the flow meter, the...
The flow meter is used by the control unit to determine the amount of fuel injected and to control the exhaust gas recirculation. The smaller the signal from the flow meter, the...
Checking the intake manifold switching valve
1. AGP, AQM engines 1. Disconnect the wiring connector (arrow) from the intake manifold switching valve (Fig. 7.65). 2. Measure the resistance between the valve contacts (Fig....
1. AGP, AQM engines 1. Disconnect the wiring connector (arrow) from the intake manifold switching valve (Fig. 7.65). 2. Measure the resistance between the valve contacts (Fig....
Error codes
For example, the VAG 1551 code reader detects fault code 16502 P0118 035. The faulty unit is the coolant temperature sensor. 16502 - Fault code. P0118 - Additional fault code. 035...
For example, the VAG 1551 code reader detects fault code 16502 P0118 035. The faulty unit is the coolant temperature sensor. 16502 - Fault code. P0118 - Additional fault code. 035...
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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)