Gasoline engines 1.4 and 1.6 l car Volkswagen Polo 3
Technical characteristics of engines AEX, APQ, AKV, ANX 1.4 l and AEE, ALM 1.6 l
Table 3.1. Technical characteristics of engines Engine code The engine code ("Letter code" and "Serial number") is located on the front of the cylinder block on the gearbox side...
Table 3.1. Technical characteristics of engines Engine code The engine code ("Letter code" and "Serial number") is located on the front of the cylinder block on the gearbox side...
Removal and installation the ribbed belt
The engine elements are shown in Fig. 3.2 a-c. Fig. 3.2 a. Engine components: 1 - Upper part of the timing belt cover: 2 - Timing belt; 3, 5, 7, 10, 15, 17 - Bolts: 4 - Camshaft...
The engine elements are shown in Fig. 3.2 a-c. Fig. 3.2 a. Engine components: 1 - Upper part of the timing belt cover: 2 - Timing belt; 3, 5, 7, 10, 15, 17 - Bolts: 4 - Camshaft...
Checking the self-adjusting tension roller
1. Rotate the crankshaft two full turns in the direction of rotation and set the piston of the first cylinder to TDC. 2. Tighten the timing belt on the side opposite the tension...
1. Rotate the crankshaft two full turns in the direction of rotation and set the piston of the first cylinder to TDC. 2. Tighten the timing belt on the side opposite the tension...
Installing the timing belt
1. Install the camshaft pulley, aligning the marks (arrow A) (fig. 3.5 a). Set the crankshaft to the TDC position of the piston of the first cylinder. The missing tooth on the...
1. Install the camshaft pulley, aligning the marks (arrow A) (fig. 3.5 a). Set the crankshaft to the TDC position of the piston of the first cylinder. The missing tooth on the...
Cylinder block, camshaft and flywheel
The cylinder block, camshaft and flywheel are shown in Fig. 3.6. Fig. 3.6. Cylinder block, camshaft and flywheel: 1 - Inserts 1, 2, 4 and 5; 2, 7, 8 - Bolts; 3 - Main caps; 4 -...
The cylinder block, camshaft and flywheel are shown in Fig. 3.6. Fig. 3.6. Cylinder block, camshaft and flywheel: 1 - Inserts 1, 2, 4 and 5; 2, 7, 8 - Bolts; 3 - Main caps; 4 -...
Connecting rod and piston group
The piston and connecting rod are shown in Fig. 3.7. Fig. 3.7. 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. 3.7. Fig. 3.7. Piston and connecting rod: 1 - Piston rings; 2 - Piston; 3 - Piston pin; 4 - Retaining ring; 5 - Connecting rod; 6 -...
Cylinder head
The cylinder head is shown in Fig. 3.10. Fig. 3.10. Cylinder head: 1 - Upper part of the timing belt cover; 2 - Timing belt; 3, 5, 7, 12, 16, 18 - Bolts; 4 - Camshaft pulley; 6 -...
The cylinder head is shown in Fig. 3.10. Fig. 3.10. Cylinder head: 1 - Upper part of the timing belt cover; 2 - Timing belt; 3, 5, 7, 12, 16, 18 - Bolts; 4 - Camshaft pulley; 6 -...
Compression check
1. Remove the air filter. 2. Remove the spark plugs. 3. Disconnect the Hall sensor wiring connector. 4. With the help of a second mechanic, press the accelerator pedal all the way...
1. Remove the air filter. 2. Remove the spark plugs. 3. Disconnect the Hall sensor wiring connector. 4. With the help of a second mechanic, press the accelerator pedal all the way...
Gas distribution mechanism
The elements of the gas distribution mechanism are shown in Fig. 3.13 a. Fig. 3.13 a. Elements of the gas distribution mechanism: 1, 15 - Bolts; 2 - Nut; 3 - Camshaft main caps; 4...
The elements of the gas distribution mechanism are shown in Fig. 3.13 a. Fig. 3.13 a. Elements of the gas distribution mechanism: 1, 15 - Bolts; 2 - Nut; 3 - Camshaft main caps; 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. 3.14 a). 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. 3.14 a). 3....
Removal and installation the camshaft
Removal 1. Remove the ribbed belt. 2. Remove the vibration damper and the upper and lower parts of the timing belt cover. 3. Loosen the camshaft pulley mounting bolt. 4. Loosen...
Removal 1. Remove the ribbed belt. 2. Remove the vibration damper and the upper and lower parts of the timing belt cover. 3. Loosen the camshaft pulley mounting bolt. 4. Loosen...
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...
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. 3.17)....
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. 3.17)....
Lubrication system
The elements of the lubrication system are shown in Fig. 3.18, the elements of the lubrication system with a two-axle oil pump are shown in Fig. 3.19. Fig. 3.18. Elements of the...
The elements of the lubrication system are shown in Fig. 3.18, the elements of the lubrication system with a two-axle oil pump are shown in Fig. 3.19. Fig. 3.18. Elements of the...
Checking oil pressure and oil pressure sensor
1. Unscrew the pressure sensor and screw it into the tester (Fig. 3.21). 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. 3.21). 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. 3.22 a-c. Fig. 3.22 a. Elements of the cooling system: 1,3 - Bolts; 2 - Front air ducts; 4 - Retainer; 5 - Locking support; 6...
The elements of the cooling system are shown in Fig. 3.22 a-c. Fig. 3.22 a. Elements of the cooling system: 1,3 - Bolts; 2 - Front air ducts; 4 - Retainer; 5 - Locking support; 6...
Power supply system
The elements of the fuel system of Polo Classic, Polo Estate are shown in Fig. 3.23 a, the elements of the fuel system of Caddy - in Fig. 3.23 b. Fig. 3.23 a. Elements of the Polo...
The elements of the fuel system of Polo Classic, Polo Estate are shown in Fig. 3.23 a, the elements of the fuel system of Caddy - in Fig. 3.23 b. Fig. 3.23 a. Elements of the Polo...
Adjusting the accelerator cable
Adjustment is made by moving the lock on the support bracket until full opening of the throttle valve is achieved when the accelerator pedal is fully depressed (Fig. 3.24).
Adjustment is made by moving the lock on the support bracket until full opening of the throttle valve is achieved when the accelerator pedal is fully depressed (Fig. 3.24).
Checking the fuel pump
1. Disconnect the negative cable from the battery during the test. 2. Turn the crankshaft briefly with the starter. The fuel pump should turn on for about 1 second. 3. If the fuel...
1. Disconnect the negative cable from the battery during the test. 2. Turn the crankshaft briefly with the starter. The fuel pump should turn on for about 1 second. 3. If the fuel...
Gasoline vapor recovery system with carbon filter
The gasoline vapor recovery system with a carbon filter is shown in Fig. 3.26. Fig. 3.26. Gasoline vapor recovery system with carbon filter: 1 - Retaining ring; 2 - Bracket; 3 -...
The gasoline vapor recovery system with a carbon filter is shown in Fig. 3.26. Fig. 3.26. Gasoline vapor recovery system with carbon filter: 1 - Retaining ring; 2 - Bracket; 3 -...
Exhaust gas system
The exhaust system elements are shown in Fig. 3.27 a, the muffler with supports of the Classic, Polo Estate cars - in Fig. 3.27 b, the muffler with supports of the Caddy car - in...
The exhaust system elements are shown in Fig. 3.27 a, the muffler with supports of the Classic, Polo Estate cars - in Fig. 3.27 b, the muffler with supports of the Caddy car - in...
Fuel injection and ignition control system
The arrangement of the fuel injection and ignition system components is shown in Fig. 3.28 a-e. The ignition system adjustment data and spark plug markings are given in Table 3.2....
The arrangement of the fuel injection and ignition system components is shown in Fig. 3.28 a-e. The ignition system adjustment data and spark plug markings are given in Table 3.2....
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. 3.29). 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. 3.29). 2. After connecting the fault code...
Checking and clearing fault memory
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)...
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)...
Reading the measured value block and basic settings
The measured values in the functions for reading the measured value block and the basic settings are described during the individual test. Changing display groups is performed in...
The measured values in the functions for reading the measured value block and the basic settings are described during the individual test. Changing display groups is performed in...
Checking the fuel pressure regulator and holding pressure
Warning! The fuel system is under high pressure. Before disconnecting any of the fuel system components, it is recommended to place rags around the connection. Then relieve the...
Warning! The fuel system is under high pressure. Before disconnecting any of the fuel system components, it is recommended to place rags around the connection. Then relieve the...
Checking the engine operating modes
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial "01" "Electric Motor". The engine should be idling. The display should show the following formation: 2. Press "08"...
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial "01" "Electric Motor". The engine should be idling. The display should show the following formation: 2. Press "08"...
Checking the intake manifold pressure sensor
During self-diagnosis, the fault code "00519 Intake manifold pressure sensor" was determined. 1. Disconnect wiring connector 1 from the intake manifold pressure sensor with intake...
During self-diagnosis, the fault code "00519 Intake manifold pressure sensor" was determined. 1. Disconnect wiring connector 1 from the intake manifold pressure sensor with intake...
Checking the coolant temperature sensor
During self-diagnosis, the fault code "00522 Coolant temperature sensor" was detected. 1. Disconnect the 4-pin wiring connector 1 from the coolant temperature sensor 2 (Fig....
During self-diagnosis, the fault code "00522 Coolant temperature sensor" was detected. 1. Disconnect the 4-pin wiring connector 1 from the coolant temperature sensor 2 (Fig....
Checking the inlet air temperature sensor
If the intake air temperature sensor is faulty or the wiring is damaged, the control unit operates with a substituted temperature of 20°C. 1. Connect the VAG 1551 tester and dial...
If the intake air temperature sensor is faulty or the wiring is damaged, the control unit operates with a substituted temperature of 20°C. 1. Connect the VAG 1551 tester and dial...
Checking the oxygen sensor (lambda probe)
1, Connect the VAG 1551 tester (V.A.G 1552) and dial "01" to select the "Address Word" function of the engine control unit. The engine should be running at idle code. The display...
1, Connect the VAG 1551 tester (V.A.G 1552) and dial "01" to select the "Address Word" function of the engine control unit. The engine should be running at idle code. The display...
Checking the oxygen sensor heater
Checking the supply voltage 1. Connect the wiring connector to oxygen sensor 1 (Fig. 3.41). 2. Connect the multimeter using the adapter from the VAG 1594 tester to contacts 1 and...
Checking the supply voltage 1. Connect the wiring connector to oxygen sensor 1 (Fig. 3.41). 2. Connect the multimeter using the adapter from the VAG 1594 tester to contacts 1 and...
Checking the injector
1. Remove the air filter. 2. Disconnect the wiring connectors (arrows) from the injectors (fig. 3.42 a). 3. Connect the VAG 1527 diode tester to the contacts of the first cylinder...
1. Remove the air filter. 2. Disconnect the wiring connectors (arrows) from the injectors (fig. 3.42 a). 3. Connect the VAG 1527 diode tester to the contacts of the first cylinder...
Checking and adjusting the ignition timing angle
1. Connect the VAG 1767 tester or the VAG 1367 tester with the V AG 1367/8 clamps (Fig. 3.43). 2. Connect the VAG 15511 tester (V.A.G 1552) and dial "01" to select the "Address...
1. Connect the VAG 1767 tester or the VAG 1367 tester with the V AG 1367/8 clamps (Fig. 3.43). 2. Connect the VAG 15511 tester (V.A.G 1552) and dial "01" to select the "Address...
Checking the Hall sensor
1. Disconnect the wiring connector from the Hall sensor. 2. Connect the multimeter using the wires from VAG 1594 to the outer contacts of the wiring connectors (Fig. 3.44) 3. Turn...
1. Disconnect the wiring connector from the Hall sensor. 2. Connect the multimeter using the wires from VAG 1594 to the outer contacts of the wiring connectors (Fig. 3.44) 3. Turn...
Checking the ignition coil
1. Disconnect the connector and high-voltage wire from the ignition coil. 2. Check the resistance between terminals 1 and 15 of the primary winding (fig. 3.45 a). Specification...
1. Disconnect the connector and high-voltage wire from the ignition coil. 2. Check the resistance between terminals 1 and 15 of the primary winding (fig. 3.45 a). Specification...
Checking the knock sensor
1. Connect the VAG 1598/18 tester to the engine control unit wiring harness ( fig. 3.34 ). 2. Check the wires and the knock sensor for short circuit: sockets 19 and 39, 39 and 45,...
1. Connect the VAG 1598/18 tester to the engine control unit wiring harness ( fig. 3.34 ). 2. Check the wires and the knock sensor for short circuit: sockets 19 and 39, 39 and 45,...
Error codes
Fault code Faulty unit 00282 Throttle position sensor 00516 Idle switch 00518 Throttle position sensor 00519 Intake Manifold Pressure Sensor 00522 Coolant temperature sensor 00523...
Fault code Faulty unit 00282 Throttle position sensor 00516 Idle switch 00518 Throttle position sensor 00519 Intake Manifold Pressure Sensor 00522 Coolant temperature sensor 00523...
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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)