3-Cyl. Injection Engine (1.0l Engine, 4 V, EA 211) CHYA CHYB CHYC CHYD PDF

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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
24 - Mixture preparation - injection
26 - Exhaust system
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28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B8040D52F

Ameo 2017 ➤wa,gPoloen AG.2014
Volksw➤age, nPolo
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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
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1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
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1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.6 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.7 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 50
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.2 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Contents i
Ameo 2017 ➤ , Polo 2014 ➤ , Polo 2018 ➤ , Polo KH IN 2015 ➤
3-cylinder injection engine (1.0 l engine, 4 V, EA 211) - Edition 05.2019
4.4 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.5 Setting piston to TDC position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.3 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.1 Assembly overview - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.2 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.5 Preassembling and installing valve timing tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.7 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.8 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.4 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.5 Removing and installing toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.6 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
17 - Lubrication . . . . . . . . . . . . V.ol.ks.w.ag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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1 Sump, oil pump . a. g. . . . . . . . . . . . . . .d.o.es. n.o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Assemblyseoverview
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1.2 Engine ut oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Removing
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1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 170
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2 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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2.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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2.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

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3.1 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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2.1 Assembly overview - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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2.2 Assembly overview - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

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2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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2.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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2.5 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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2.6 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . .
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2.7 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 215

3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.2 Removing and installing coolant pipes ag. e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . 218
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4 Radiator, radiator fan . . . . . . d. b.y.V.o . . . . . . . . . . . . . . . . . . . . . . . t .gu. a.r . . . . . . . . . . . . . . . . . . 220
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4.1 Assembly overview - radiator/radiator
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ris fan . . . . . . . . . . . . . . . . . . . . . n.te.e . . . . . . . . . . . . . . . 220
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4.2 Assembly overview - radiator
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4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
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4.4 Removing and installing radiator cowl with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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1.2 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
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2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
2.2 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
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2.3 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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2.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
inform
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
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3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
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3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
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4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
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4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
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4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

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4.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
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4.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
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5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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5.1 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
6.1 Assembly overview - engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
6.2 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 269
6.3 Removing and installing engine (motor) control unit J623 with protective housing . . . . . . 271
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
7.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.3 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
1.6 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Contents iii
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
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iv Contents
00 – Technical data
1 Safety information
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⇒ “1.1 Safety regulations for working on fuel supply”,
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1.1 Safety regulations for working on fuel
supply
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Note the following when working on the fuel supply system:
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Risk of injury from highly pressurised fuel.
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The fuel system is pressurised. Injury from fuel spray possible.
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– Wear protective goggles.
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– To release pressure, wrap a clean cloth around the connection

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Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1. Safety information 1
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and
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1.4 Safety precautions when working on the cooling system
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Danger of scalding by hot coolant
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– Reduce excess pressure by covering cap of coolant expan‐
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1.5 Safety precautions when working on ignition system
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Risk of injury due to electric shock

The ignition system is under high voltage when the engine is run‐
ning. Touching the ignition system may result in an electric shock.
– Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
Risk of damage to components

Connecting or disconnecting electric cables or washing the en‐
gine while it is running may damage components.
– Switch off the ignition before connecting or disconnecting elec‐
tric cables.
– Switch off the ignition before washing the engine.
2 Rep. gr.00 - Technical data

2 Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1 Engine number/engine data

The engine code and the engine number can be found on the wage
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The engine code is also on the vehicle data sticker and ton
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The engine number consists of up to 9 characters (alphanumeric).
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The first part (maximum 3 characters) makes up the “engine
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“C”. The first 3 places show the mechanical design of engine and
are stamped on the engine as previously. The fourth digit denotes
the performance and torque rating of the engine and depends on
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the engine control unit - J623- . The four-digit engine code can be
found on the identification plate, the vehicle data sticker and the
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engine control unit.
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Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;

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Engine code CHYA CHYB CHYC CHYD
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Manufactured 04.14 ► 04.14 ► 08.17 ► 08.18 ►
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Exhaust emission standard EU6 EU6 EU6 EU4
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Displacement cm3 999 999 999 999
Power kW at rpm 44/5500 55/6200 48/5000 … 6000 56/6200
Torque Nm at rpm 95/4000 95/3000 … 4300 95/3000 … 4300 95/3000 … 4300
Bore Diameter, m 74.5 74.5 74.5 74.5
m
Stroke mm 76.4 76.4 76.4 76.4
Compression ratio 10.5 10.5 10.5 10.5
Valves per cylinder 4 4 4 4
RON min. 95 unleaded (in 95 unleaded (in 95 unleaded (in 95 unleaded (in
exceptional cir‐ exceptional cir‐ exceptional cir‐ exceptional cir‐
cumstances cumstances cumstances cumstances
min. 91 RON, min. 91 RON, min. 91 RON, min. 91 RON,
however with re‐ however with re‐ however with re‐ however with re‐
duced perform‐ duced perform‐ duced perform‐ duced perform‐
ance) ance) ance) ance)
Injection, ignition system Motronic ME 17 Motronic ME 17 Motronic ME 17 Motronic ME 17
Firing order 1-2-3 1-2-3 1-2-3 1-2-3
2. Identification 3
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 4
⇒ “3.2 General information”, page 4
⇒ “3.3 General repair instructions”, page 4
⇒ “3.4 Foreign objects in engine”, page 5
⇒ “3.5 Contact corrosion”, page 5
⇒ “3.6 Routing and attachment of lines”, page 5
⇒ “3.7 Fitting radiator and condensers”, page 5
⇒ “3.8 Checking vacuum system”, page 5
3.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
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♦ Carefully cover
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♦ Install only clean parts; do not remove new parts from pack‐
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♦ If system is open, do not work with compressed air. Do not

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3.2 General information

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♦ The engine control unit has a self-diagnosis capability. Before

carrying out repairs and for fault finding, first read event mem‐
rrectness of i
ory. Also the vacuum hoses and connections must be checked

(unmetered air).
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♦ For trouble-free operation of electrical components, a voltage

of at least 11.5 volts is necessary.
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♦ Do not use sealants containing silicone. Particles of silicone

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drawn into the engine will not be burnt in the engine and dam‐
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♦ Vehicles are fitted with a crash fuel shut-off circuit. It serves

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⇒ “1.1 Safety regulations for working on fuel supply”, page 1 .
3.3 General repair instructions

♦ Clean tools and workbench etc. before working on injection
system.
♦ If high-pressure lines are not renewed, they must be labelled
on removal. High-pressure fuel lines may only be re-installed
on the same cylinder.

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♦ Align high-pressure lines ho r so that they are not subjected to eo
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♦ Never attempt to reshape high-pressure fuel lines.
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♦ All cable ties which were opened or cut during removal must
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be renewed and installed in the same position during installa‐
tion.
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♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of crimp-type or screw-type clips is
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3.4 Foreign objects in engine
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To prevent the ingress of foreign bodies during work on the en‐
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3.5 Contact corrosion

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For this reason, only connecting elements with a special surface copy Vo
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In addition, rubber, plastic and adhesives are made of non-con‐

ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic Parts Catalogue .
3.6 Routing and attachment of lines

♦ In order to ensure that lines are all installed in their original
position, the lines for the fuel, hydraulic and vacuum systems
and for the activated charcoal filter system as well as electrical
wires must be marked appropriately before they are removed.
Where necessary, make sketches or take photographs.
♦ Because of the lack of space in the engine compartment, make
sure that there is sufficient clearance between lines and all
moving or hot components. This is to avoid damage to lines.
♦ Any clips, cable ties or other fastening devices that have been
cut through or damaged when loosening must be renewed.
♦ Insulation mats and other insulating devices must always be
re-fitted in their original positions.
3.7 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does not
mean that these components have been damaged. It is not per‐
missible to renew radiators, condensers or charge air coolers only
because of such minor dents.
3.8 Checking vacuum system

Special tools and workshop equipment required
3. Repair instructions 5
♦ Hand operated vacuum pump - VAS 6213-
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– Check all vacuum lines throughout entire vacuum system for:
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– Check vacuum line to solenoid valve and from solenoid valve
to relevant component.
– If an entry is stored in the event memory, check all vacuum
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lines leading to the corresponding component and also check
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the remaining vacuum lines leading to other components.

– If pressure cannot be built-up using hand vacuum pump - VAS nform
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6213- or pressure immediately drops again, check hand vac‐

uum pump and connecting hoses for leaks.
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10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 7
⇒ “1.2 Separating engine and gearbox”, page 24
⇒ “1.3 Securing engine on engine and gearbox support”,
page 25
⇒ “1.4 Installing engine”, page 27
1.1 Removing engine

⇒ “1.1.1 Removing engine, Polo 2014, Ameo”, page 7
⇒ “1.1.2 Removing engine, Polo 2018”, page 14
1.1.1 Removing engine, Polo 2014, Ameo
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1. Removing and installing engine 7

Special tools and workshop agen

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♦ Engine support - T10483-

♦ Drip tray for workshop hoist - VAS 6208-
♦ Engine and gearbox support - VAS 6095-
♦ Torque wrench - V.A.G 1331-
♦ Hose clamp pliers - VAS 6340-
♦ Adapter - T10480-
8 Rep. gr.10 - Removing and installing engine

♦ Engine and gearbox jack - V.A.G 1383 A- or -VAS 6931- (not

shown in illustration)
♦ Commercially available stepladder (not illustrated)
Note
♦ The engine is removed downwards with gearbox.

♦ Reinstall all cable ties in the same locations when installing.
– Check whether a coded radio is fitted. Obtain anti-theft coding

beforehand if necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery
– Remove air filter housing
⇒ “3.2 Removing and installing
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– Open and closeedcoolant
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expansion tank cap to releaseara pres‐
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– To release pressure, wrap a clean cloth around the connec‐

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tion and carefully loosen the connection.

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– Release and pull off fuel supply line -1- and breather line
rrectness of i
-2-.⇒ Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-in

connectors .
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– Line guide -3- does not need to be opened. The hoses can
remain in the guide.
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– Seal lines so that fuel system is not contaminated by dirt.

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– Remove noise insulation. ⇒ General body repairs, exterior;

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Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐

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– Drain coolant
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t.
⇒ “1.3 Draining and adding coolant”, page 183 . Cop
yi Co
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t. rig
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– Disconnect all coolant hoses -1- from coolant pump. p by
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Prote AG.

olkswagen AG
en AG. V
– Open coolant hose clamps on engine -arrows-, andolay
kswcoolant
ag does
not
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hoses to one side. ed
by gu
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– Release connectors -2- and pull off. aut
ho eo
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pt
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew securing bolts -3-.
rrectness of i
– Place coolant expansion tank -1- on engine.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
– Disconnect connectors of lambda probe 1 after catalytic con‐
gh ht
pyri by
verter - GX7- and lambda probe 1 before catalytic converter -
o Vo
by c lksw
cted agen
GX10- -arrows-. Prote AG.
– Remove vacuum line -1- from intake manifold -2-.

– Lay vacuum line to one side.
– Detach or cut open cable tie.
– Remove engine control unit - J623- from holder
⇒ “6.2 Removing and installing engine (motor) control unit
J623 ”, page 269 .

– Release and pull off lower connector -1- on engine control unit
- J623- . Separate connection -4-.
– Unscrew bolts -2- and -3- on fuse box, and pull off lines.
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Remove clutch slave cylinder: ⇒ Rep. gr.
s au 30 ; Clutch slave ra
c
cylinder; Removing and installing clutch slave cylinder s
ce
e
nl
pt
du
– Release and disconnect connectors -1-, -2- and -3-.
an
itte
y li
erm
ab
– Unclip the wiring harness from the fastening points and attach
ility
ot p
it to the engine.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unbolt earth wire from stud -1-, and unscrew stud by approx.
2 turns.
nf
ercia
– Unscrew bolts -arrows- on engine mounting approx. 2 turns.
orm
m
atio
om
n in
or c
thi
te
sd
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f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew securing bolts -arrows- on gearbox mounting by ap‐

prox. 2 turns.
Vehicles with air conditioning system
. Volkswagen AG
gen AG does
swa
Note byV
olk not
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or
♦ The air conditioning
aut
h system lines must not be opened. e or a
ss c
♦ Prevent damage to condenser and refrigerant lines and hoses.
ce
e
nl
pt
du
an
♦ Do NOT stretch, kink or bend lines and hoses.
itte
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erm
ab
ility
ot p
– Remove poly V-belt
wit
, is n
⇒ “1.3 Removing and installing poly-V belt”, page 57 .
h re
hole
spec
– Remove air conditioner compressor: ⇒ Heating, air condition‐
es, in part or in w
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
t to the co
installing air conditioner compressor .
– Secure air conditioner compressor to lock carrier.
rrectness of i
Make sure lines are not kinked.
l purpos
Continued for all vehicles

nform
mercia
at
– Unscrew fastening bolt from catalytic converter and remove
om
ion
bracket -2-.
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove securing nuts -arrows- and pull catalytic converter off

stud bolts.
– Remove pendulum support
⇒ “2.4 Removing and installing pendulum support”,
page 43 .
– Remove right and left drive shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Drain engine oil ⇒ page 163 .
– Remove oil level and oil temperature sender - G266-
⇒ “1.5 Removing and installing oil level and oil temperature
sender G266 ”, page 170 .

Engine support - T10483- with adapters -/1-, -/2- and -/3- is re‐
quired to lower engine and gearbox.
– Push engine support - T10483- into crankcase holes
-arrows- to stop.
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
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au ra
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ce
le
un
pt
an
d
itte
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– Tighten bolts -1- by hand first.
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– At first, tighten bolt -arrow- hand-tight.
atio
om
n
c
– Tighten bolts -arrows- to 20 Nm.

i
or
n thi
te
sd
a
– Also tighten all remaining bolts to 20 Nm.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Position engine and gearbox jack - V.A.G 1383 A- on engine

support - T10416- .
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
Note
To remove securing bolts use a stepladder - VAS 5085- .

– Unscrew bolts and studs -arrows- from engine mounting.
AG. Volkswagen AG d
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ara
ed
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aut ra
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pt
du
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itte
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erm
ab
ility
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wit
, is n
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– Unscrew securing bolts -arrows- from gearbox mounting.
hole
spec
es, in part or in w
t to the co
Note
When lifted out, the engine/gearbox assembly must be carefully
rrectness of i
guided to prevent damage to the bodywork.
l purpos
– Carefully lower engine and gearbox.
nf
ercia
o
Secure engine to engine and gearbox support - VAS 6095- to
rm
m
carry out repairs.
atio
om
n in
or c
thi
te
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a
1.1.2 Removing engine, Polo 2018

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Prote AG.

Special tools and workshop

equipment required
AG. Volkswagen AG d
agen oes
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or eo
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nl
pt
du
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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te
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Cop py
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pyri by
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by c lksw
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Prote AG.

♦ Release lever - 80-200-

♦ Engine bung set - VAS 6122-
♦ Spring-type clip pliers - VAS 6362-
♦ Engine and gearbox jack - VAS 6931- or -V.A.G 1383 A-
♦ Engine support - T10483-
♦ Transport lock - T10403-
♦ Tensioning strap - T10038-
♦ Protective mat - VAS 531003- (not illustrated) n AG. Volkswagen A
ge G do
swa es n
♦ Commercially available stepladder by Volk ot g
ua
ed ran
♦ Wing protector - VAS 6805- oris tee
th or
au ac
♦ Front cover - VAS 6808- ss
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pt
du
♦ Safety glasses
an
itte
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ab
♦ Safety gloves
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Procedure
wit
, is n
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hole
spec
es, in part or in w
Note
t to the co
♦ The engine is removed downwards together with the gearbox.
rrectness of i
♦ Attach cable ties in all the same places when installing.
l purpos
♦ Fit all heat shield sleeves in the same place when installing.
nform
ercia
CAUTION
m
at
om
ion

c
in t
or
his
e
Skin and other parts of the body may be scalded.

at
do
priv

cum
for
en
g

n
t.
yi Co
op py
– Reduce excess pressure by covering cap of coolant expan‐ t. C rig
gh ht
sion tank with a cloth and opening it carefully. yri
p by
co Vo
by lksw
cted agen
Prote AG.
– Carefully open filler cap -arrow- of coolant expansion tank.
⇒ “3.2 Removing and installing air filter housing”, page 258 .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 183 .

– Disconnect connector -arrow- from vacuum sender - G608- .

– Pull off vacuum line -1- from brake servo.
lkswage es n
o ot g
byV ua
d ran
ir se
– Disconnect connectors -1- andth -2-, and unclip wiring harness
o tee
or
from retainer. ss
au ac
ce
e
– Unclip line guides for lambda probes from vehicle.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Open catch -arrow-, pull off vacuum line.
l purpos
CAUTION
nform
ercia

m
at
om

ion
c
in t
r

o
his
ate

do
priv
cum
or

f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Open catch -3- and lay lines -2- of fuel supply system and ac‐
AG.
tivated charcoal filter aside, quick-release couplings ⇒ Rep.

gr. 20 ; Quick-release couplings: removing .
– Disconnect electrical connector -1-.
– Seal open lines and connections with suitable plugs from en‐
gine bung set - VAS 6122- .
– Release catches in direction of -arrow- with a screwdriver and
place coolant expansion tank on engine.

– Lift retaining clips -arrows- and disconnect coolant hoses from

heat exchanger for heater.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
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le
un
pt
an
d
itte
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erm
ab
– Open spring-type clips -arrows-.
ility
ot p
– Pull off coolant hoses -1- and -2- from top left of radiator.
wit
is n
h re
ole,
– Secure coolant hoses above engine.
spec
– Remove radiator cowl
t to the co
⇒ “4.4 Removing and installing radiator cowl with radiator fan”,
page 233
rrectness o
cial p
f inform
mer
atio
– Cover radiator using protective mat - VAS 531003- .
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove securing clip -1- for gear selector cable from gearbox
selector lever -B-.
Note
Item -2- can be disregarded.

– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece.
Note
Item -2- can be disregarded.
– Unscrew bolts -arrows-, raise and tie cable support bracket

with cables.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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– Unscrew bolts -arrows-, remove s auclutch slave cylinder -1-, and ra
c
lay it aside. Do not open the pipe/hose
s system.
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
Do not operate clutch pedal when clutch slave cylinder is re‐

, is n
h re
moved.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

stud bolts.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Release and pull off electrical connector -2- on engine control

unit - J623- .
– Disconnect connectors -1- and -3-:
– Detach wiring harness from attachment -arrow-.
– Secure cables to engine using a cable tie.
– Detach connectors -2-, -3- and -4-.

– Unscrew nut -arrow- for earth line -1-.
– Secure electrical wires on left longitudinal member using a
cable tie.
. Volkswag
– Unscrew bolts -arrows- for engine mounting
ksw
agapprox.
en AG 2 turns.
en AG
does
ol not
yV gu
edb ara
ris nte
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ss c
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e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolts -arrows- on gearbox mounting approx. 2 turns.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Vehicles with air conditioner compressor

– Remove poly V-belt
CAUTION
Risk of freezing injury caused by refrigerant.
. Volkswagen AG
– Do not open refrigerant gen AG of air conditioning
acircuit does system.
lksw o n ot g
yV ua
edb ran
is
– Separate electrical
ut
hor
connector -1- from fuel pressure regulating
tee
or
valve - N280-
ss
a . ac
ce
le
– Unclip refrigerant lines from right longitudinal member.

un
pt
an
d
itte
y li
– Unscrew bolts -arrows- for air conditioning compressor.
rm
ab
pe
ility
ot
NOTICE
wit
, is n
h re
Risk of damage to refrigerant lines from rupture of inner foil.
hole
spec
– Never bend refrigerant lines to a radius tighter than
es, in part or in w
t to the co
r = 100 mm.
rrectness of i
– Remove air conditioner compressor with refrigerant lines at‐
tached and secure to right-hand side of lock carrier with ten‐
l purpos
sioning strap - T10038- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
– If fitted, remove underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐
view - underbody cladding .
– If present: unscrew bolts -arrows- and remove heat shield for

right drive shaft.
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .

– Loosen clamp -1- and push towards rear.
– Unscrew bolt -1-.

– Unscrew securing bolts -3- from catalytic converter and re‐
move bracket -2-.
Note
♦ Do not allow the flexible joint to kink by more than 10°. It could
become damaged.
♦ Install flexible joint so that it is not under tension.
♦ Do not damage wire mesh on decoupling element.
♦ Do not remove protective packaging from replacement part agen
AG. Volkswagen AG d
oes
until decoupling element is about to be installed olksw not
byV gu
ara
ed
ris nte
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– Place transit lock - T10403- on decoupling element. aut
h
ra
ss c
ce
le
– Unscrew bolts -arrows-.

un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
When removing the catalytic converter from its fitting location,
hole
spec
ensure that the Lambda probes and their connections are not
es, in part or in w
damaged.
t to the co
– Remove catalytic converter with front exhaust pipe and pull
rrectness of i
out between tunnel of underbody and subframe.
l purpos
– Unscrew bolts -arrows- and remove pendulum support -1-.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Engine support - T10483- with adapters - T10483-/1, -/2 and -/3-

are required to lower engine and G. Volkswagen AG d
gen Agearbox.
swa oes
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Push engine support - T10483- to stop into holes -arrows- in
cylinder block.
rrectness of i
– Tighten bolts -1- by hand first.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
– At first, tighten bolt -arrow- hand-tight. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Tighten bolts -arrows- to 20 Nm.

– Tighten all bolts of engine support - T10483- on cylinder block
to 20 Nm.
– Fit engine and gearbox jack - VAS 6931- to engine support -
T10483- , and raise engine/gearbox assembly slightly.
Note
Use a stepladder to unscrew the bolts for engine/gearbox mount‐

ing.

– Completely unscrew bolts -arrows- for gearbox mounting sup‐

port arm.
– Completely unscrew bolts -arrows- for gearbox mounting.
Note
♦ Risk of damage to the vacuum lines or electrical wiring as well

as damage to the engine compartment.
♦ Check that all vacuum lines and electrical wiring between en‐
gine, gearbox, subframe and body have been detached.
♦ Carefully guide engine/gearbox assembly out of engine com‐
partment when lowering.
– Pull engine/gearbox assembly as far as possible towards the

front, and lower it gradually.
1.2 Separating engine and gearbox

♦ Hook - 10 - 222 A /12- AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
ss c
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e
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pt
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an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Workshop hoist - VAS 6100-

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10483- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 n; AStarter;
G. Volkswagen AG d
Removing and installing starter . olks
wage oes
no
V t gu
by ara
– Install shackle - 10-222A/12- to gearbox.
ris
ed nte
tho eo
– Attach workshop hoist - VAS 6100-
ss
au to shackle - 10-222A/12- . ra
c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
– Unscrew bolts -1, 2, 3- and -6 … 9- from threaded connection
thi
te
on engine.
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
Disregards items -4, 5- and -A-.
p by
co Vo
by lksw
cted agen
Prote AG.
– Pull gearbox off engine.
1.3 Securing engine on engine and gearbox

support
♦ Lifting tackle - 2024 A-

♦ Workshop hoist - VAS 6100-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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ility
ot
Procedure
wit
, is n
h re
• Engine removed ⇒ “1.1 Removing engine”, page 7
hole
spec
es, in part or in w
• Gearbox detached from engine
t to the co
⇒ “1.2 Separating engine and gearbox”, page 24 .
– Secure lifting tackle - 2024 A- on engine, and attach it to work‐
rrectness of i
shop hoist - VAS 6100- as shown in illustration.
l purpos
Note
nform
ercia
In order to match the lifting tackle to the centre of gravity of the

m
a
engine, the holes in the hook rail must be allocated as shown in
com
tio
the illustration.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
Note
en
ng
t.
yi Co
Cop py
♦ Risk of accident due to loose components of lifting tackle.
t. rig
gh ht
pyri by
Vo
o
♦ In order to match the lifting tackle to the centre of gravity of the
by c lksw
cted agen
engine, the holes in the hook rail must be allocated as shown
Prote AG.
in the illustration.
♦ The support hooks and pins on the lifting tackle must be se‐
cured with locking pins -arrows-.
– Lift engine off T10483 using workshop hoist - VAS 6100- .

– Secure engine to engine and gearbox bracket - VAS 6095-

using pins -arrows- as shown in illustration.
– Insert spacers -arrow-.
• Dimension -a- = 10 mm.
1.4 Installing engine

⇒ “1.4.1 Installing engine, Polo 2014, Ameo”, page 27
⇒ “1.4.2 Installing engine, Polo 2018”, page 28
1.4.1 Installing engine, Polo 2014, Ameo

Installation is carried out in reverse order of removal. When in‐
stalling, note the following:
. Volkswagen AG
gen AG does
– Check clutch release bearing for wear and renew if necessary.
Vol
ksw
a
not
y gu
db ara
– Lightly grease clutch release bearing, release bearing
or
ise guide nte
eo
sleeve and splines on input shaft with G 000 100.
au
th
ra
ss c
– Check whether dowel sleeves for aligning engine and gearbox
ce
e
nl
pt
are fitted in cylinder block and install if necessary.
du
an
itte
y li
erm
– Rock engine to align engine mountings stress-free.
ab
ility
ot p
– Install gearbox. ⇒ Rep. gr. 34 ; Removing and installing gear‐
wit
, is n
box; Installing gearbox
h re
hole
spec
es, in part or in w
t to the co
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
rrectness of i
– Install poly V-belt
l purpos

nf
ercia
or
– Install right and left drive shafts ⇒ Running gear, axles, steer‐
m
m
atio
ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive

om
n in
shaft .
or c
thi
te
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;

sd
iva
o
r
Removing and installing clutch slave cylinder .

rp
cu
o
m
f
en
ng
Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Removing

t.
yi Co
op
and installing starter . C py
ht. rig
rig ht
by
– Install selector mechanism to gearbox ⇒ Rep. gr. 34 ; Selector copy Vo
by lksw
mechanism; Overview - selector mechanism . cted agen
Prote AG.
– Add coolant ⇒ “1.3 Draining and adding coolant”, page 183 .

– Install noise insulation. ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview - noise insulation
– Install air filter housing
– Connect the vehicle diagnostic tester .

– Erase learnt values and adapt engine control unit - J623- to

throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
tions”.
– Perform vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
ded fault finding”.
– Finish the vehicle system test so that any event entries stored
during assembly can be cleared automatically.
Note safety precautions applicable to a road test.
– Carry out road test.
– Then carry out vehicle system test again and rectify any faults
which may have occurred.
Specified torques
♦ Securing bolts for gearbox ⇒ Rep. gr. 34 ; Removing and
installing gearbox; Specified torques for gearbox
♦ Specified torques for assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 32
♦ Specified torques for catalytic converter
⇒ “2.1 Assembly overview - emission control”, page 294
♦ Securing bolts for coolant expansion tank: 1.8 Nm
AG. Volkswagen AG d
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1.4.2 Installing engine, Polo 2018 d by
Volksw not
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Procedure ut
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Note
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♦ Renew bolts that are tightened with turning further angle.
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♦ Renew self-locking nuts and bolts, and seals, O-rings and
h re
gaskets.
hole
spec
es, in part or in w
♦ Secure all hose connections with the hose clips corresponding
t to the co
to the original equipment ⇒ Electronic Parts Catalogue (ET‐
KA)
rrectness of i
♦ Fit all heat shield sleeves in the same place when installing.
l purpos
– Install intermediate plate. ⇒ page 71

– If there are no dowel sleeves -A- in the cylinder block for cen‐ nform
ercia
tring the engine and gearbox, insert new dowel sleeves.

m
at
om
– Clean input shaft splines, and apply thin coat of grease for
ion
c
clutch plate splines .

in t
or
his
ate
– Check centring of clutch plate.

do
priv
cum
or
– Securely bolt gearbox to engine ⇒ Rep. gr. 34 ; Removing

f
en
ng
t.
yi
and installing gearbox; Installing gearbox .
Co
Cop py
t. rig
– Take up engine/gearbox assembly with engine support
gh ht
pyri by
T10483 .
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by c lksw
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Prote AG.
– Guide engine/gearbox assembly into body.

– First screw bolts -arrows- for engine mountings into stop by

hand.
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Cop py
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29
Prote AG.
1. Removing and installing engine
– First screw bolts -arrows- for gearbox mountings into stop by

hand.
Note
The bolts are tightened to final torque only after adjusting the as‐
sembly mountings
⇒ “2.6 Adjusting assembly mountings”, page 49 .
– Remove engine bracket - T10483- from engine.

Vehicles with air conditioner compressor
– Install air conditioner compressor: ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Install catalytic converter
⇒ “2.2 Removing and installing catalytic converter”,
page 297 .
– Install drive shafts ⇒ Running gear, w axles,
agen steering; Rep.
AG. Volkswagen AG dgr.
oes
40 ; Drive shaft; Removing and yinstalling
Volks
drive shafts . not
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– Install pendulum support thoris nte
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au pendulum support”, or
ac
page 43 . ss
ce
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pt
– Mount front wheels ⇒ Running gear, axles, steering; Rep. gr.

an
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44 ; Wheels, tyres; Wheel alignment; Wheel change .

erm
ab
ility
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– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐

wit
is n
sembly overview - starter .

h re
ole,
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;

spec
Removing and installing clutch slave cylinder .

t to the co
– Install selector mechanism ⇒ Rep. gr. 34 ; Selector mecha‐

nism; Assembly overview - cables .
rrectne
– Adjusting assembly mountings

⇒ “2.6 Adjusting assembly mountings”, page 49 .
ss o
– Install radiator cowl

cial p
f i

nform
page 233 .
mer
atio
m
– Fit coolant hoses; observe markings on hoses for installation

o
n
c
position and attachment of spring-type clip.

or
n thi
te
sd
va
– Electrical connections and routing ⇒ Electrical system; Rep.

i
o
pr
cum
gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Over‐

r
fo
en
ng
view of fitting locations - relay carriers, fuse carriers, electron‐

t.
yi Co
ics boxes ⇒ Current flow diagrams, Electrical fault finding and Cop py
t. rig
Fitting locations. opyri
gh by
Vo
ht
c lksw
– Install engine control unit - J623-
by
cted agen
Prote
⇒ “6 Engine control unit”, page 268 .
AG.
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery tray .
– Observe measures required after connecting battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
– Attach fuel hoses ⇒ Fuel supply system; Rep. gr. 20 ; Plug-
in connectors; Disconnecting plug-in connectors .


– Check oil level ⇒ Maintenance ; Booklet KJ1 .
Note
♦ Never use battery charging equipment for boost starting.

♦ Danger of destroying control units through excessive voltage.
Note
Do not reuse old coolant.
– Connect vehicle diagnostic tester ⇒ Maintenance ; Booklet

KJ1 ; General; Connecting vehicle diagnostic tester .
♦ Delete entries in event memory Guided Functions , Read
event memory .
After renewing engine, also perform the following:

♦ Adapt learnt values of injectors: Guided Functions , Adapt
learnt values of injectors .
AG. Volkswagen AG d
Specified torques lksw
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♦ The specified torques are only valid for nuts and bolts which
un
pt
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d
have been slightly greased, oiled, phosphate-treated or black-

itte
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oxided.
erm
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ility
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♦ Additional lubricant such as engine oil or gear oil may be used,

wit
is n
but do not use lubricant containing graphite.

h re
ole,
spec
♦ Do not use degreased parts.

t to the co
♦ Tolerances for specified torques ± 15%.

rrectne
Component Nm
Bolts and nuts M6 9
ss
M7 15
o
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f in
M8 20
form
mer
M10 40
atio
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M12 65
c
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or
n thi
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♦ Assembly mountings
iv
o
pr

um
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fo
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t.
♦ Securing gearbox to engine ⇒ Rep. gr. 34 ; Removing and
yi Co
op py
installing gearbox; Specified torques for gearbox . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Assembly mountings
⇒ “2.2 Removing and installing engine mounting”, page 36
⇒ “2.3 Removing and installing gearbox mounting”, page 39
⇒ “2.4 Removing and installing pendulum support”, page 43
⇒ “2.5 Supporting engine in installation position”, page 45
⇒ “2.6 Adjusting assembly mountings”,
wage page 49
es ks not
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⇒ “2.7 Checking adjustment d bof assembly mountings (engine and
y ua
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gearbox mountings)”, page
thori 50 tee
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2.1 Assembly overview - assembly mount‐
s c
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un
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ings
an
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itte
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⇒ “2.1.1 Assembly overview - assembly mountings, Polo 2014,
ility
ot p
Ameo”, page 32
wit
is n
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⇒ “2.1.2 Assembly overview - assembly mountings, Polo 2018”,
ole,
spec
page 34
t to the co
2.1.1 Assembly overview - assembly mountings, Polo 2014, Ameo
rrectne
1 - Engine support
❑ Removing and installing
ss
⇒ “1.5 Removing and in‐
o
cial p
stalling engine support”, f inform

page 65
mer
❑ Specified torque and

atio
m
tightening sequence
o
n
c
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or
⇒ page 34
thi
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2 - Bolt
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❑ Renew after removal

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❑ Specified torque and Cop py
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tightening sequence yri
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⇒ page 34
op Vo
by c lksw
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3 - Engine mounting
AG.

stalling engine mount‐
ing”, page 36
❑ Aligning engine mount‐
ing ⇒ page 33
4 - Bolt
❑ 20 Nm +90°
❑ Qty. 4
5 - Nut
Note
The securing nut must not be loos‐

ened.
6 - Centre hex stud

❑ With mounting for earth

wire; specified torque

⇒ page 33 agen
AG. Volkswagen AG d
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❑ 30 Nm +90°
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8 - Bolt
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❑ 40 Nm +90°
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❑ Tightening sequence ⇒ page 34
9 - Gearbox mounting
rrectness of i
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❑ Tightening sequence - gearbox mounting ⇒ page 34 .

10 - Bolt
nform
ercia

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❑ 50 Nm +90°
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11 - Bolt
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❑ 50 Nm +90° C py
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12 - Pendulum support
❑ Removing and installing ⇒ “2.4 Removing and installing pendulum support”, page 43
13 - Bolt
❑ 40 Nm +90°
14 - Bolt
❑ 30 Nm +90°
❑ Qty. 2
Earth strap on engine mounting

– Earth strap -1- is secured to stud with a nut -2-.
Nut Specified torque
-2- 20 Nm
Aligning engine mountings
2. Assembly mountings 33
– Fit engine mounting on longitudinal member.
Note
♦ There is a risk of damage to the threads if bolts are started at

an angle.
♦ Before tightening the bolts of the engine support, push the en‐
gine support upwards as far as possible to prevent the ingress
of water and dirt.
• The positioning holes -arrows- must be in line; check with ap‐

propriate drill if necessary.
Engine support - specified torque and tightening sequence
Note
There is a risk of damage to the threads if bolts are started at an

angle.
– Tighten bolts in stages in the sequence shown.

Stage Bolts Specified torque/turning further angle
1 -1 … 3- 7 Nm olks
wage es n
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2 -1 … 3- 40 Nm ed
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3 -1 … 3- Turn 90° further
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Tightening sequence - gearbox mounting

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Ite Procedure Specified torque

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B Start bolts before tightening hand-tight

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B Tighten bolts 50 Nm +90°

m
C Tighten bolt. 50 Nm +90°

a
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tion in
A Start bolts before tightening hand-tight

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2.1.2 Assembly overview - assembly mountings, Polo 2018 C py
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1 - Bolt
tightening sequence
⇒ page 34
2 - Engine support
stalling engine support”,
page 65
❑ Specified torque and agen
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⇒ page 34 rised ara
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❑ Due to restricted space, aut
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push engine support to ss c
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one side
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3 - Engine mountings
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stalling engine mount‐
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spec
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4 - Bolt
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❑ 40 Nm +90°
rrectness of i
5 - Bolt
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6 - Nut
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❑ 20 Nm +90°
n in
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7 - Bolt
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❑ 60 Nm +90°
n
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8 - Pendulum support
t. C rig
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❑ Removing and installing ⇒ “2.4 Removing and installing pendulum support”, page 43
op Vo
by c lksw
cted agen
Prote
9 - Bolt
AG.

❑ 130 Nm +90°
10 - Bolt
❑ 50 Nm +90°
11 - Bolt
❑ 50 Nm +90°
12 - Bolt
❑ 60 Nm +90°
13 - Bolt
lkswage es n
Vo ot g
Ameo 2017 ➤ , Polo 2014 ➤ , Polo 2018 ➤ed, Polo KH IN 2015 ➤
by ua
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3-cylinder injection engine (1.0 l engine, th4 V, EA 211) - Edition 05.2019
o tee
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❑ 50 Nm +90°
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un
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an
14 - Gearbox mounting
d
itte
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❑ Removing and installing ⇒ “2.3 Removing and installing gearbox mounting”, page 39
ility
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15 - Bolt
wit
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spec
❑ 40 Nm +90°
t to the co
16 - Gearbox bracket
rrectne
Engine support - specified torque and installation sequence
ss o
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f in
Note
form
mer
atio
Risk of damage to threads by starting bolts at an angle.
om
n
c
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– Tighten bolts in stages in the sequence shown:

t
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1 -1 … 3- 7 Nm t. Cop py
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2 -1 … 3- 40 Nm
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3 -1 … 3- Turn 90° further Prote
cted AG.
agen
Pendulum support - specified torque and tightening sequence
Note
Renew bolts that are tightened with turning further angle.
– Tighten bolts in stages in the sequence shown:

1 -2, 3- 50 Nm
2 -1- 130 Nm
3 -1 … 3- Turn 90° further
2.2 Removing and installing engine mount‐

ing
⇒ “2.2.1 Removing and installing engine mounting, Polo 2014,
Ameo”, page 36
⇒ “2.2.2 Removing and installing engine mounting, Polo 2018”,
page 37
2.2.1 Removing and installing engine mount‐

ing, Polo 2014, Ameo
Removing
– Loosen hose clips -1- and -2-.

AG. Volkswagen AG d
agen Ameo 2017 ➤ , Polo
oes 2014 ➤ , Polo 2018 ➤ , Polo KH IN 2015 ➤
olksw not
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3-cylinder injection engine (1.0gu l engine, 4 V, EA 211) - Edition 05.2019
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– Release aut
connectors -2- and pull off. ra
ss c
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itte
– Place coolant expansion tank -1- on engine.
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– Support engine in installation position
ot
wit
⇒ “2.5 Supporting engine in installation position”, page 45 .
, is n
h re
hole
– Take up weight of engine/gearbox assembly slightly with spin‐
spec
dle; do not lift.
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew nut -3-.

– Remove earth wire.
nform
mercia
a
com
ti
Note
on in
r
te o
thi
The securing nut -4- must not be loosened.
s
iva
do
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fo
en
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– Unscrew bolts -2- between engine mounting and engine.

n
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op py
– Unscrew bolts -arrows- and remove engine mounting.
t. C rig
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Installing by c lksw
cted agen
Prote AG.
Install in reverse order of removal. During this procedure, observe
the following:
– Place assembly mounting on longitudinal member.

• The positioning holes -arrows- must be in line; check with ap‐
propriate drill if necessary.
Note
♦ There is a risk of damage to the threads if bolts are started at

an angle.
♦ Do not remove support bracket - 10 - 222 A- until the bolts
securing the assembly mounting have been tightened to
specified torque.
– Remove support bracket - 10 - 222 A- from engine.

Specified torques
♦ Securing bolts for engine mounting to body
♦ Securing bolts for engine mounting to engine support
♦ Securing bolts for coolant expansion tank: 1.8 Nm
2.2.2 Removing and installing engine mount‐

ing, Polo 2018
♦ Engine bung set - VAS 6122-
AG. Volkswagen AG d
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aut ra
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Removing
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ab
ility
– Open catch -3- and lay lines -2- of fuel supply system and ac‐
ot p
tivated charcoal filter aside.

wit
is n
h re
ole,

spec
– Seal open lines and connections with suitable plugs from en‐
t to the co
gine bung set - VAS 6122- .

– Release catches in direction of -arrow- with a screwdriver and
rrectne
move coolant expansion tank to one side.

– Support engine in its installation position
ss

o
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f inform
mer
atio
om
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Cop py
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38
by c lksw
cted
Rep. gr.10 - Removing and installing engine
agen
Prote AG.
– Unscrew bolts -arrows- and remove engine mounting -1-.

Installing
Carry out assembly in the reverse sequence, noting the following:
Note

♦ Risk of damage to threads by starting bolts at an angle.
♦ Do not remove support bracket - 10 - 222 A- until the bolts
securing the assembly mounting have been tightened to
specified torque.
– First screw in bolts -arrows- for engine mounting -1- onto stop
by hand.
– Tighten bolts -arrows-
⇒ “2.1 Assembly overview - assembly mountings”, page 32 .
– Checking adjustment of assembly mountings
⇒ “2.7 Checking adjustment of assembly mountings (engine agen
AG. Volkswagen AG d
and gearbox mountings)”, page 50 . Volksw
oes
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– Remove support bracket - 10 - 222 A- from engine. oris tee
th or
au
Specified torques ss
ac
ce
e
nl
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32
pt
du
an
itte
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erm
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2.3 Removing and installing gearbox
ility
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mounting
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spec
⇒ “2.3.1 Removing and installing gearbox mounting, Polo 2014,
es, in part or in w
Ameo”, page 39
t to the co
⇒ “2.3.2 Removing and installing gearbox mounting, Polo 2018”,
page 40
rrectness of i
2.3.1 Removing and installing gearbox
l purpos
mounting, Polo 2014, Ameo
nf
ercia
orm
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rig ht
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by lksw
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Removing
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
– Carefully loosen wiring harness at its fastening points
-arrows-.
– Support engine in installation position
G. Volkswagen
– Take up weight of engine/gearbox assembly
lksw
agenslightly with spin‐
A AG do
es n
dle; do not lift. by
Vo ot g
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th or
au ac
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– Unscrew securing bolts -arrows- from gearbox mounting.
, is n
h re
hole
Installing
spec
es, in part or in w

t to the co
the following:
rrectness of i
Note
l purpos

angle.
nform
mercia

com
tion in
r
Specified torques
te o
thi
s
iva
do
♦ Tightening sequence for engine mounting

r
rp
cum

fo
en
ng
t.
yi Co
♦ Tightening sequence for gearbox mounting ⇒ page 34 . Cop py
t. rig
gh ht
yri
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview p by
co Vo
- battery
by lksw
cted agen
Prote AG.
2.3.2 Removing and installing gearbox

mounting, Polo 2018

♦ Torque wrench - V.A.G 1331- AG. Volkswagen AG d

agen oes
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, is n
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es, in part or in w
t to the co
rrectness of i
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tion in
r
te o
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t.
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Cop py
t. rig
gh ht
Removing yri
p by
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by c lksw
cted
– Disconnect earth wire from battery terminal ⇒ Electrical sys‐
agen
Prote AG.
tem; Rep. gr. 27 ; Battery, Disconnecting and connecting
battery .
– Remove engine control unit - J623-
– Unscrew nuts -arrows- and remove bracket -1-.
Note
Different types of brackets are fitted depending on version.
– Detach line guide -1- from its anchorage points -arrows-, push
upwards in direction of -arrow- and secure to one side.
dle; do not lift.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
– Unscrew bolts -arrows- and remove gearbox mounting -1-.
y li
erm
ab
ility
Installing
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
♦ Risk of damage to threads by starting bolts at an angle.
rrectness of i
♦ Renew bolts that are tightened with turning further angle after
l purpos
each removal.
nf
ercia
– Lift gearbox with spindle of support bracket until gearbox sup‐
or
port makes contact with support arm of gearbox mounting.
m
m
atio
om
– Checking adjustment of assembly mountings
n in
or c
⇒ “2.7 Checking adjustment of assembly mountings (engine
thi
te
and gearbox mountings)”, page 50 .
sd
iva
o
r
rp
cu
– Install engine control unit - J623-
o
m
f
en
ng

t.
yi Co
Cop py
.
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
ht rig
rig ht
by
Removing and installing battery tray . copy Vo
by lksw
cted agen
Prote
– Connect earth wire to battery terminal ⇒ Electrical system;
AG.
Rep. gr. 27 ; Battery, Disconnecting and connecting battery .

Specified torques
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery

2.4 Removing and installing pendulum sup‐

port
⇒ “2.4.1 Removing and installing pendulum support, Polo 2014,
Ameo”, page 43
⇒ “2.4.2 Removing and installing pendulum support, Polo 2018”,
page 44
2.4.1 Removing and installing pendulum sup‐

port, Polo 2014, Ameo
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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aut ra
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nl
pt
du
an
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erm
Removing
ab
ility
ot p
– Remove noise insulation. ⇒ General body repairs, exterior;

wit
, is n

h re
hole
sulation
spec
es, in part or in w
– Unscrew bolts -arrows- for pendulum support.

t to the co
Note
rrectness of i
l purpos
Bolt -1- must not be loosened.

nform
ercia
– Pull pendulum support out of subframe.

m
at
Installing
om
ion
c
in t

or
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e
the following:
at
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Cop py
ht. rig
rig ht
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co Vo
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Prote AG.
Note
♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes

for the pendulum support.
wage e
♦ Identification: shouldery along
Vol
ks beginning of thread -arrow-.
s no
t gu
b ara
ed nte
oris e
Specified torques auth or
ac
ss
♦ Securing bolts for pendulum support
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
2.4.2 Removing and installing pendulum sup‐
wit
is n
h re
port, Polo 2018
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.

3-cylinder injection engine (1.0
enlAengine,
G. Volksw4
agV,
en AEA
G 211) - Edition 05.2019
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Removing ed
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– Remove noise insulation ⇒ General body
au repairs, exterior;
t ra
c
Rep. gr. 66 ; Noise insulation; Assembly
ss overview - noise in‐
ce
le
sulation .
un
pt
an
d
itte
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– Unscrew bolts -2, 3 and 4- of pendulum support -1-.
rm
ab
pe
ility
– Pull out pendulum support -1- from subframe.
ot
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Renew bolts that are tightened with turning further angle after
l purpos
each removal.
nform
ercia
– Bolt pendulum support first to gearbox and then to subframe.

m
a
com
tion in
r
te o
Note
thi
s
iva
do
r
rp
c
♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes
um
fo
en
g
for the pendulum support.

n
t.
yi Co
op py
♦ Identification: shoulder on first thread -arrow-.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted
– Remove noise insulation ⇒ General body repairs, exterior;
agen
Prote AG.
sulation .
Specified torques
2.5 Supporting engine in installation posi‐

tion
⇒ “2.5.1 Supporting engine in installation position, Polo 2014,
Ameo”, page 45
⇒ “2.5.2 Supporting engine in installation position, Polo 2018”,
page 47
2.5.1 Supporting engine in installation posi‐

tion, Polo 2014, Ameo
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Tensioning strap - T10038-

lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
To prevent damage to edges of wings, cover lower areas of both
adapters - 10 - 222 A /8- with woven adhesive tape -arrow- ⇒
Electronic Parts Catalogue (ETKA) .
rrectness of i
Procedure
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
– Push adapter - 10 - 222 A- -4- and adapter - 10 - 222 A /18- y li

erm
-3- as shown onto support bracket - 10 - 222 A- -2-. ab

ility
ot p
wit
, is n
– Mount adapter - 10 - 222 A /8- -1- on support bracket - 10 - h re

222 A- -2-.
hole
spec
es, in part or in w
– Position engine support bracket - 10 - 222 A- -2- on left and

t to the co
right onto longitudinal members as shown in illustration.

rrectness of i
Note
l purpos
Do not position engine support bracket - 10 - 222 A- on edges of wings.

nf
ercia
– Push adapter - 10 - 222 A /8- -1- against panels of headlights

rm
m
-arrow-.
atio
om
n in
c
– Mount adapter - 10 - 222 A- -4- on mountings of engine as

or
thi
e
shown in illustration.
t
sd
iva
o
r
rp
cu

o
m
f
en
dle; do not lift.

ng
t.
yi Co
op py
2.5.2 Supporting engine in installation posi‐
t. C rig
gh ht
yri by
tion, Polo 2018
cop Vo
by lksw
cted agen
Prote AG.
♦ Support - 10 - 222 A-
♦ Shackle - 10-222A/12-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
♦ Adapter - 10-222A/22-
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Adapter - 10-222A/32-
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Procedure
– Remove air filter housing.
– Secure support bracket - 10 - 222 A- -1- with adapters -
10-222A/22- -2-, adapter - 10-222A/32- -3- and shackle -
10-222A/12- -4- on cylinder head -5- as shown.
– Take up weight of engine/gearbox assembly.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
le
2.6 Adjusting assembly mountings

un
pt
an
d
itte
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Procedure
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew engine mounting bolts -arrows- one after the other
and renew them (if not already renewed when installing en‐
rrectness of i
gine).
l purpos
– First screw bolts in loosely.

nform
mercia
– Unscrew bolts -arrows- for gearbox mounting -1- in succes‐

a
com
tio
sion and renew (if not already carried out on installing engine).
n in
r
te o
thi
– First screw bolts in loosely.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Using assembly lever, adjust engine/gearbox assembly so

that specifications listed below are attained:
• Distance -a- between engine support -2- and engine mounting
-1- must be 10 mm.
• Side surface of engine support -2- must be located parallel to
support arm of engine mounting -1-.
• Dimension -b- must be identical at front and rear.
Note AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
Distance -a- = 10 mm can also be checked with orisa metal rod of
e nte
eo
suitable size, or similar. aut
h
ra
ss c
ce
le
un
– Tighten bolts for engine mounting.
pt
an
d
itte
y li
rm
ab
– On the gearbox side, ensure that the edges of the support arm
pe
ility
-2- and gearbox support -1- are parallel.
ot
wit
, is n
h re
• Distance -x- = distance -x-.
hole
spec
– Tighten bolts for gearbox mounting.
es, in part or in w
t to the co
Specified torques
rrectness of i
l purpos
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview

- battery
nform
mercia
a
com
t
2.7 Checking adjustment of assembly
ion in
r
te o
mountings (engine and gearbox mount‐
thi
s
iva
do
ings)
r
rp
cum
fo
en
ng
Procedure
t.
yi Co
Cop py
t. rig
The following dimensions must be attained: opyri
gh by
Vo
ht
by c
• Distance -a- between engine support -2- and engine mounting
lksw
cted agen
Prote
-1- must be 10 mm.
AG.
• Side surface of engine support -2- must be located parallel to

support arm of engine mounting -1-.
• Dimension -b- must be identical at front and rear.
Note
Distance -a- = 10 mm can also be checked with a metal rod of

suitable size, or similar.
– If the dimension is too small or too high, adjust assembly

mountings ⇒ “2.6 Adjusting assembly mountings”, page 49 .

13 – Crankshaft groupolkswagen AG. Volkswagen AG does no

yV t gu
db ara
ise
1 Cylinder block (pulley end) r nte
tho eo
au ra
c
ss
⇒ “1.1 Assembly overview - poly V-belt drive”, page 51
ce
le
un
pt
an
d
⇒ “1.2 Assembly overview - cylinder block (pulley end)”,
itte
y li
page 55 erm
ab
ility
ot p
⇒ “1.3 Removing and installing poly-V belt”, page 57
wit
is n
h re
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
ole,
spec
page 62
t to the co
⇒ “1.5 Removing and installing engine support”, page 65
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 67
rrectne
1.1 Assembly overview - poly V-belt drive
ss o
cial p
f
⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles without
inform
air conditioner compressor”, page 51
mer
atio
⇒ “1.1.2 Assembly overview - poly V-belt drive, Polo 2014, Ameo,
om
n
vehicles with air conditioner compressor”, page 53
c
i
or
n thi
te
⇒ “1.1.3 Assembly overview - poly V-belt drive, Polo 2018, vehi‐
sd
iva
o
r
cles with air conditioner compressor”, page 54

p
cum
r
fo
en
ng
1.1.1 Assembly overview - poly V-belt drive, vehicles without air conditioner com‐
t.
yi Co
Cop py
pressor
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder block (pulley end) 51

1 - Bolt
❑ Use counter-hold tool -
T10475- to loosen and
tighten
❑ 150 Nm +180°
2 - Vibration damper
❑ For crankshaft
❑ Do not cant when instal‐
ling
❑ To remove and install,
use counterhold tool -
T10475- .
3 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen
❑ Determine length of poly
V-belt in accordance
with ⇒ Electronic parts
catalogue (ETKA) de‐
pending on type of de‐
coupling element.
❑ Do not kink
❑ Poly V-belt routing
⇒ page 62
stalling poly-V belt”,
page 57
❑ When installing, make n AG. Volkswagen A
sure it is properly oseated
lksw
age G do
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on pulleys. d by V ua
r e an
ris tee
4 - Bolt tho or
au ac
❑ Renew
s after removal
s
ce
e
nl
❑ 20 Nm +90°
pt
du
an
itte
y li
5 - Tensioning device for poly V-belt

erm
ab
ility
ot p
❑ Pivot with socket to slacken poly V-belt

wit
, is n
❑ Lock with counterhold - T10060 A- .

h re
hole
spec
❑ Removing and installing ⇒ “1.4 Removing and installing tensioner for poly V-belt”, page 62
es, in part or in w
t to the co
6 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
rrectness of i
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
l purpos
❑ With freewheel
❑ Different decoupler belt pulleys -A- or -B- may be fitted depending on type and version of alternator:
nf
ercia
correspondence ⇒ page 53 .
rm
m
atio
m
❑ Determine length of poly V-belt in accordance with ⇒ Electronic parts catalogue (ETKA) depending on
o
n in
c
type of decoupling element.

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
52
AG.
Rep. gr.13 - Crankshaft group
Allocation of decoupler belt pulley
lkswage es n
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byV ua
d ran
ir se tee
o
1.1.2 Assembly overview - poly V-belt drive, Polo 2014, Ameo, vehicles with air
th or
au ac
ss
conditioner compressor
ce
e
nl
pt
du
an
itte
y li
erm
ab
1 - Bolt
ility
ot p
wit
❑ Renew
, is n
h re
❑ 150 Nm +180° further
hole
spec
es, in part or in w
t to the co
❑ For crankshaft
ling rrectness of i
l purpos

T10475- .
nform
ercia
3 - Bolt
m
at
om
❑ Renew
ion
c
in t
or
his
ate
do
riv
4 - Cap
p
cum
for
5 - Bolt
en
ng
t.
yi Co
op
❑ 30 Nm C py
t. rig
gh ht
yri
6 - Tensioning element
p by
co Vo
by lksw
cted agen
7 - Bolt
Prote AG.
❑ 23 Nm
8 - Alternator
9 - Guide bush
10 - Air conditioner compres‐
sor
11 - Bolt
❑ 23 Nm
12 - Poly V-belt
❑ Mark direction of rota‐
tion before removing

poly V-belt ⇒ “1.3 Removing and installing poly-V belt”, page 57
1.1.3 Assembly overview - poly V-belt drive, Polo 2018, vehicles with air condi‐
tioner compressor
1 - Poly V-belt
❑ Check for wear
chalk or felt-tipped pen
❑ Determine length of poly
V-belt in accordance
with ⇒ Electronic parts
catalogue (ETKA) de‐
pending on type of de‐
coupling element.
❑ Do not kink
❑ Poly V-belt routing
⇒ page 60
stalling poly-V belt”,
page 57
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ Use counter-hold tool -
T10475- to loosen and AG. Volkswagen
tighten lksw
agen AG do
es n
Vo ot g
❑ 150 Nm +180° ed by ua
ran
is tee
or
au
th or
ac
ss
❑ For crankshaft
ce
le
un
pt

an
d
itte
y li
ling
erm
ab

ility
ot p

wit
is n
h re
T10475- .
ole,
spec
4 - Tensioning device for poly V-belt

t to the co
❑ Pivot with socket to slacken poly V-belt

❑ Lock with counterhold - T10060 A- .
rrectne
❑ Removing and installing ⇒ “1.4 Removing and installing tensioner for poly V-belt”, page 62
5 - Bolt
ss

o
cial p
f in
❑ 20 Nm +90°
form
mer
6 - Bolt
atio
om
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
c
i
or
n thi
te
sd
7 - Alternator
iva
o
pr
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
um
r
fo
en
ng
t.
❑ With freewheel
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
54
AG.
❑ Different decoupler belt pulleys -A- or -B- may be fitted depending on type and version of alternator:
correspondence ⇒ page 53 .
❑ Determine length of poly V-belt in accordance with ⇒ Electronic parts catalogue (ETKA) depending on
type of decoupling element.
8 - Dowel sleeve
❑ For air conditioner compressor.
9 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant lines
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing air conditioner compressor from and to bracket
10 - Bolt
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor .
Allocation of decoupler belt pulley
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.2 Assembly overview - cylinder block (pul‐

ley end)
nform
mercia
a
com
ti
Note
on in
r
te o
thi
♦ The crankshaft must not be removed.

s
iva
do
r
rp
cum
♦ Just loosening the main bearing caps will cause deformation

fo
en
g
of the cylinder block bearing pedestals.

n
t.
yi Co
Cop py
♦ This deformation will cause a reduction of the bearing clear‐
t. rig
gh ht
yri by
ance. Even if the bearing shells are not renewed, bearing cop Vo
by lksw
damage could occur due to a different bearing clearance. cted agen
Prote AG.
♦ If the bearing cap bolts are loosened, the cylinder block must
be renewed complete with the crankshaft.
♦ Measuring the main bearing clearance is not possible with
normal workshop equipment.

1 - Bolt
❑ 8 Nm
2 - Toothed belt guard
3 - Bolt
❑ Renew
4 - Crankshaft
❑ For exhaust camshaft
stalling toothed belt pul‐
ley”, page 149
5 - Seal
stalling camshaft oil
seal”, page 140
6 - Toothed belt
chalk or felt-tipped
marker pen.
❑ Check for wear ⇒ Main‐
tenance ; Booklet 3.1
stalling toothed belt”,
page 107
7 - Plug
❑ 20 Nm
8 - Seal
AG. Volkswagen AG d
❑ Renew if damaged agen oes
olksw not
y V gu
b ara
9 - Bolt rise
d
nte
ho eo
❑ Renew s aut ra
c
s
ce
e
nl
pt
du
an
10 - Camshaft adjuster
itte
y li
erm
ab
❑ For inlet camshaft

ility
ot p
❑ Removing and installing ⇒ “3.4 Removing and installing camshaft adjuster”, page 144
wit
, is n
h re
11 - Guide bush
hole
spec
es, in part or in w
12 - Seal
t to the co
❑ Removing and installing ⇒ “3.3 Removing and installing camshaft oil seal”, page 140
13 - Bolt
rrectness of i
❑ 25 Nm
l purpos
14 - Tensioning pulley
15 - Idler roller
nform
mercia
16 - Spacer sleeve
at
om
io
❑ Renew if idler roller “item 15” is damaged

n
c
in t
or
his
e
17 - Seal
at
do
priv
❑ Renew if idler roller “item 15” is damaged

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
56
cop Vo
by lksw
Rep. gr.13 - Crankshaft group Prote
cted AG.
agen
18 - Bolt
❑ 40 Nm
19 - Crankshaft
20 - Seal
❑ Removing and installing ⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”, page 67
❑ For crankshaft
❑ Do not cant when installing AG. Volkswagen
agen AG do
V ouse
lksw counterhold tool - T10475-
es n
ot g .
y ua
db ran
22 - Bolt ris
e
tee
tho or
❑ Renew ss
au ac
ce
le
un
pt
an
d
itte
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erm
ab
24 - Bolt
ility
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wit
is n
❑ 8 Nm
h re
ole,
25 - Bolt
spec
❑ Renew
t to the co
26 - Bolt
rrectne
❑ Renew
s
s o
cial p
f i
27 - Engine mounting bracket
nform
mer
❑ Before removal, support using support bracket - 10 - 222 A-

atio
m
❑ Removing and installing ⇒ “1.5 Removing and installing engine support”, page 65
o
n
c
i
or
n thi
te
sd
iva
o
pr
1.3 Removing and installing poly-V belt

um
r
fo
en
ng
t.
yi Co
op
⇒ “1.3.1 Removing and installing poly V-belt, Polo 2014, Ameo, C py
t. rig
gh ht
pyri by
Vo
co lksw
by
⇒ “1.3.2 Removing and installing poly V-belt, Polo 2018, vehicles Prote
cted AG.
agen
with air conditioner compressor”, page 59
⇒ “1.3.3 Removing and installing poly V-belt, Polo 2014, Ameo,
vehicles without air conditioner compressor”, page 60
⇒ “1.3.4 Removing and installing poly V-belt, Polo 2018, vehicles
without air conditioner compressor”, page 61
1.3.1 Removing and installing poly V-belt, Po‐

lo 2014, Ameo, vehicles with air condi‐
tioner compressor

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
Removing
wit
, is n
h re
hole
– Mark the direction of rotation of the poly V-belt with a marker.
spec
es, in part or in w
– Lever off belt tensioner cap -arrow- using a screwdriver.
t to the co
– Loosen securing bolt -1-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Turn belt tensioner -2- in -direction of arrow- past TDC using

en
ng
t.
yi Co
a socket. t. Cop py
rig
gh ht
– Remove poly V-belt. pyri by
Vo
co lksw
by
cted agen
Installing Prote AG.
Note
When installing the poly V-belt, ensure that the belt is properly
seated in the vibration damper and the pulleys.
– Fit poly V-belt over vibration damper pulley and pulleys of al‐
ternator and air conditioner compressor.
– Push belt onto belt tensioner.
– Turn belt tensioner -2- in -direction of arrow- past TDC using

a socket.
– Tighten securing bolt -1- to 30 Nm.
58 Rep. gr.13 - Crankshaft group

Poly V-belt routing

1 - Vibration damper/crankshaft
3 - Alternator pulley
4 - Poly V-belt
5 - Air conditioner compressor pulley
AG. Volkswagen AG d
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Special tools and workshop equipment required du
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♦ Locking pin - T10060 A-
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♦ The poly V-belt is fitted from above.
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belt using chalk or felt tip pen before removing.
co Vo
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Version 1
– To slacken poly V-belt turn tensioning device in direction of
-arrow-.

Version 2
– To slacken poly V-belt turn tensioning device in direction of
-arrow-.
– Use the counterhold - T10060 A- to lock the tensioner.
– Remove poly V-belt.
Installing
– Fit poly V-belt as shown in illustration.
1- Pulley
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
Version 1
– Turn tensioning device in -direction of arrow-, and pull out
locking pin - T10060 A- .
AG. Volkswagen AG d
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Version 2
hole
spec
es, in part or in w
– Turn tensioning device in -direction of arrow-, and pull out

t to the co
locking pin - T10060 A- .

rrectness of i
– Release tensioner.
l purpos
– Check that poly V-belt is properly seated.

– Start engine and check that poly V-belt runs properly.
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ditioner compressor Cop py
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rig ht
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♦ Poly V-belt repair kit with assembly tools ⇒ Electronic Parts
Catalogue (ETKA)

Procedure
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The poly V-belt repairskit
au with assembly tool contains the assem‐ ac
bly tool -T10367/2- and instructions. s
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nl
pt
du
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– Cut through poly V-belt.
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Proceed as described in the instructions provided with the repair
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, is n
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Poly V-belt routing
spec
es, in part or in w
1 - Vibration damper/crankshaft
t to the co
2 - Poly V-belt
rrectness of i
3 - Alternator pulley
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compressor
C py
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♦ Locking pin - T10060 A-
Removing
Note
♦ The poly V-belt is fitted from above.

♦ If poly V-belt is to be reinstalled, mark direction of rotation on
belt using chalk or felt tip pen before removing.

– To slacken poly V-belt, turn tensioner in anti-clockwise direc‐

tion -arrow-.
– Use the counterhold - T10060 A- to lock the tensioner.
– Remove poly V-belt.
Installing
olkswagen AG
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Carry out assembly in the reverseolsequence,
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– Fit poly V-belt as shown
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1- Pulley au ra
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2- Tensioning device for poly V-belt
pt
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3- Alternator
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– Turn tensioning device in direction of -arrow- and pull out
counterhold - T10060 A- .
– Release tensioner. rrectness of i
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– Check that poly V-belt is properly seated.

– Start engine and check that poly V-belt runs properly.
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1.4 Removing and installing tensioner for
Co
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poly V-belt
gh ht
pyri by
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cted agen
⇒ “1.4.1 Removing and installing tensioner for poly V-belt, vehi‐ Prote AG.
cles without air conditioner compressor”, page 62
⇒ “1.4.2 Removing and installing tensioner for poly V-belt, vehi‐
cles with air conditioner compressor”, page 64
1.4.1 Removing and installing tensioner for

poly V-belt, vehicles without air condi‐
tioner compressor

♦ Torque wrench - V.A.G 1331- lkswage es n
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♦ Ratchet 1/2" x 9-12" ref. (735/10) - VAG 1331/1-
rrectness o
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Cop py
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♦ Special wrench - 3410-
c by lksw
cted agen
Prote AG.
Removing
– Remove poly V-belt from tensioner
⇒ “1.3.4 Removing and installing poly V-belt, Polo 2018, ve‐
hicles without air conditioner compressor”, page 61 .
– Unscrew bolts -arrows- with special wrench - 3410- , detach
tensioning device -1- from poly V-belt.
Installing
hicles without air conditioner compressor”, page 61 .
Specified torques
♦ ⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles with‐
out air conditioner compressor”, page 51

1.4.2 Removing and installing tensioner for

poly V-belt, vehicles with air conditioner
compressor
♦ Ratchet 1/2" x 9-12" ref. (735/10) - VAG 1331/1-
lkswage es n
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♦ Special wrench - 3410-
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cum
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Cop py
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Prote AG.

Removing
– Remove poly V-belt from tensioner
hicles with air conditioner compressor”, page 59 .
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.
Installing
Volkswagen AG
– Install poly V-belt agen
AG. does
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⇒ “1.3.2 Removing and installing poly V-belt, Poloby
V2018, ve‐
ol not
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hicles with air conditioner compressor”, pageris59
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Specified torques ss au ra
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♦ ⇒ “1.1.3 Assembly overview - poly V-belt drive, Polo 2018, nl
pt
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1.5 Removing and installing engine support
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t.
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Cop py
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rig ht
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Prote AG.
Removing
– Removing engine mounting
⇒ “2.2 Removing and installing engine mounting”, page 36 .
– Detach hoses from retainer -3-.
– Release clips -arrows- and remove upper toothed belt guard
-1-.
– Remove tensioner for poly V-belt
⇒ “1.4 Removing and installing tensioner for poly V-belt”, page
62 .

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– Loosen bolt -1- but do not remove. ss
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– Swivel alternator -3- in direction of -arrow-.
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– Remove bolts -arrows- for toothed belt cover (bottom) -1-.
nform
mercia
at
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ion
c
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Cop py
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– If fitted, remove bracket -1-. To do so, remove bolts -arrows-.

– Remove bracket -1- from engine support -2-.
– Unscrew bolts -1- to -3-.

3-cylinder injectionAG
engine
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– Detach lower protector -2- in direction
ed
by V
of -arrow- in order to lay ua
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engine support -1- aside. hor is tee
ut or
a ac
– Detach engine support and
ss lay aside. Note -arrows A, B- when
doing this. Remove engine support upwards.
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Installing
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Note
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Before tightening the bolts of the engine support, push the engine
support upwards as far as possible to prevent the ingress of water
and dirt.
rrectness of i
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nform
mercia
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– If present, install bracket -1- on engine support -2-.
r
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– To do this, tighten bolts -arrows- ⇒ page 67 .
do
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Specified torques
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♦ Securing bolts for engine mounting and console for engine C py
t. rig
mounting
gh ht
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cop Vo
by lksw
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Prote AG.
♦ Securing bolts for tensioning roller
62
♦ Securing bolts for alternator
⇒ “1.1 Assembly overview - poly V-belt drive”, page 51
♦ Securing bolts for toothed belt guard
⇒ “1.2 Assembly overview - cylinder block (pulley end)”, page
55
♦ Securing bolt for air filter housing
⇒ “3.1 Assembly overview - air filter housing”, page 255
♦ Securing bolts for alternator ⇒ Electrical system; Rep. gr. 27 ;
Alternator; Assembly overview - alternator
♦ Securing bolts for noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
Component Specified torque
Bracket to engine mounting 20 Nm
Securing bolt for coolant expansion 1.8 Nm
tank
1.6 Renewing crankshaft oil seal - belt pulley end


equipment required
AG. Volkswagen AG d
agen oes
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♦ Assembly tool - T10485-

hole
spec
es, in part or in w

t to the co
♦ Extractor hook - T20143-

♦ Counter-hold - T10475-
rrectness of i
l purpos
Removing
nform
ercia
– Remove toothed belt

⇒ “2.4 Removing and installing toothed belt”, page 107 .
m
at
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ion
c
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or
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ate
do
priv
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for
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

– Remove seal -1- using extractor hook - T20143/1- .

Installing
– Put together assembly sleeves - T10485/2- and -T10485/3- in
-direction of arrow-.
– Fit new seal in -direction of arrow- onto assembly sleeve -

T10485/2- .
– Pull off assembly sleeve - T10485/3- in -direction of arrow-.

– Fit assembly sleeve - T10485/2- with seal -1- onto crankshaft
stub.
AG. Volkswagen AG d
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– Draw in thrust piece - T10485/1- to stop with securing bolt of

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vibration damper -2-.

is n
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– Install toothed belt

spec

t to the co
Note
rrectne
After completing work, it is essential to make sure that the locking

pin - T10340- has been removed.
ss o
cial p
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Further assembly is basically a reverse of the dismantling se‐

form
mer
quence.
atio
om
Specified torques:
c
i
or
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e
♦ Crankcase plug: 30 Nm
t
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2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 70
⇒ “2.2 Removing and installing flywheel”, page 71
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 72
2.1 Assembly overview - cylinder block, gearbox end
1 - Bolt
❑ 60 Nm +90°
2 - Flywheel agen
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❑ Removing and installing by Vo gu
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⇒ “2.2 Removing and in‐ rise
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page 71 ss c
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❑ Fitting possible in one

nl
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3 - Engine speed sender -
ility
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G28-
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stalling engine speed
t to the co
sender G28 ”,
page 309
❑ Assembly overview
rrectness of i
⇒ “1.1 Assembly over‐
view - ignition system”,
l purpos
page 303
4 - Bolt
nf
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❑ Specified torque
m
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⇒ Item 15 (page 304)

o
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5 - Dowel pin
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❑ Qty. 2
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6 - Adapter
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❑ Do not damage or bend C py
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when assembling.
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❑ Installing ⇒ page 71
by lksw
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7 - Bolt
❑ Prescribed torques and
tightening sequence .
8 - Sealing flange with sender wheel and oil seal
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 72

Sealing flange on gearbox side - specified torque and tightening

sequence
– Tighten bolts in stages as follows:
Stage Bolts Specified torque
1 -1 … 6- Screw in by hand as far as stop
2 -1 … 6- In diagonal sequence and in stages;
final torque 10 Nm.
Install intermediate plate.

– Attach intermediate plate -1- to sealing flange -2- -arrow B-.
– Slide intermediate plate onto dowel sleeves -arrows A-.
2.2 Removing and installing flywheel

♦ Counter-hold - 3067-
AG. Volkswagen AG d
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Removing
• Gearbox removed ⇒ 5-speed manual gearbox 0DF; Rep. gr.
34 ; Removing and installing gearbox
rrectness of i
• Clutch pressure plate removed ⇒ 5-speed manual gearbox

l purpos
0DF; Rep. gr. 30 ; Clutch; Removing and installing clutch

• Screw out bolts -B- not with an air wrench or power impact
nf
ercia
wrench but by hand.

rm
m
atio
m
• When removing the bolts, make sure that the bolt heads do
o
n in
c
not come into contact with the flywheel.

or
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• Rotate dual-mass flywheel -A- so that bolts -B- align centrally

iv
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with the holes -arrows-.

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– Turn flywheel -A- so that heads of bolts -B- are in centre of
yi Co
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holes -arrows-.
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Prote AG.
2. Cylinder block, gearbox end 71

– Insert counterhold - 3067- in opening of cylinder block

-item B-.
– Loosen and remove flywheel bolts.
Installing
Note n AG. Volkswagen AG do

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♦ Renew bolts that are tightened
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b ua
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Flywheel with sender wheel can only be fitted in one position.
h
♦ aut or
ac
ss
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nl
pt
– Insert counterhold - 3067- in hole in cylinder block -item A-.
du
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Specified torques
erm
ab
ility
ot p
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
wit
, is n
70
h re
hole
spec
es, in part or in w
2.3 Removing and installing sealing flange
t to the co
on gearbox side
rrectness of i
♦ Open ring spanner insert, 24 mm - V.A.G 1332/11-
l purpos
nf
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orm
m
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♦ Depth gauge - VAS 6082-

♦ Securing bolt - T10340-
♦ Bolt M6x35 (3x)

♦ Spark plug socket , e.g. -3122 B-
♦ Screwdriver with a shaft length of at least 250 mm
♦ Hexagon key
Procedure
AG. Volkswagen AG d
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olksw not
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Note ed by ara
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For reasons of clarity, illustration shows swork
s a procedure with en‐ c
gine removed.
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ab

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sulation .
wit
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– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing

hole
spec
gearbox .
es, in part or in w
t to the co
– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing

clutch .
rrectness of i
– Remove flywheel
⇒ “2.2 Removing and installing flywheel”, page 71 .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Cop py
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73
cted agen
Prote
2. Cylinder block, gearbox end
AG.
– Remove intermediate plate -1- from dowel sleeves

-arrows A-.
– Guide intermediate plate -1- upwards.
– While doing so, pull retaining lug -arrow B- of intermediate
plate -1- out of recess behind sealing flange.
– Set piston of cylinder no. 1 to “TDC” position
⇒ “4.5 Setting piston to TDC position”, page 86 .
– Remove sump
⇒ “1.3 Removing and installing sump”, page 165 .
– Remove engine speed sender - G28- -arrow-
⇒ “1.5 Removing and installing engine speed sender G28 ”,
page 309 . agen
AG. Volkswagen AG d
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– Unscrew bolts -arrows- for sealing ris flange -1-.
ed ran
tee
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es, in part or in w
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rrectness of i
– To press off, screw 3 bolts M6 x 35 into sealing flange -1-
-arrows-.
l purpos
nform
ercia
Note
m
at
om
io
The sealing flange -1- is pressed off crankshaft -3- together with
n
c
in t
the sender wheel -2-.

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ate
do
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– Screw bolts alternately into sealing flange no more than 1/2

um
for
en
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turn at a time.
n
t.
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– Remove sealing flange -1- together with sender wheel -2-.
t. rig
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Pressing in sealing flange with sender ring Prote AG.
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring -2-. This support ring serves as a fitting sleeve
and must not be removed prior to installation.
♦ Sealing flange and sender wheel -1- must not be separated
after removal from packaging.
♦ The sender wheel -3- is held in its installation position on the
locating pin of the assembly tool - T10134- ⇒ page 75 .
♦ Sealing flange and oil seal form one unit and may only be re‐
newed together with the sender wheel.
♦ The assembly tool - T10134- is held in its position relative to
the crankshaft by a guide pin inserted into a hole in the crank‐
shaft ⇒ page 75 .

Set-up of assembly tool - T10134- :

A - Clamping surface
B - Nut
C - Assembly housing
D-
Locating pin
E - Hexagon socket head bolt (qty. 2)
F-
Guide pin for diesel engines (red shaft)
G - Guide pin for diesel engines (black shaft)
H - Knurled screws (qty. 3)
I - Inside
Fitting sealing flange with sender wheel on assembly tool -

T10134- :
– Screw on nut -B- and stop just before it comes into contact
with clamping surface -A- of threaded spindle.
AG. Volkswagen AG d
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– Clamp assembly by Vdevice - T10134- at clamping surface
ol not
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threaded spindle
rised in a vice -1-. ara
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– Push assembly
s au housing -C- downwards until it rests against ra
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nut -B-.
s
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• Inner part of assembly tool and assembly housing must be at

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same height.
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– If fitted, remove securing clip -arrow- from new sealing flange.

rrectnes
Note
s o
cial p
f inform
Do not take the sender wheel and support ring out of the sealing
mer
flange.
atio
om
n
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Cop py
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– Place sealing flange -1- with front side facing downwards on

a clean level surface.
– Push sealing lip support ring -1- downwards in
-direction of arrow- until it rests against flat surface.
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.
– Place sealing flange -1- with front side facing downwards onto
assembly tool - T10134- so that locating pin -D- is seated in
hole -3- in sender wheel hole -2-.
Note
♦ The sealing flange can be supplied in different

ks
versions.
AG. Vol wagen AG d
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♦ On some versions, the »TDC
Vol position hole« -3- is not in the
es n o
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requisite TDC position s-D-.
ed
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– If the position -3-ssis not correct in relation to the locating pin ac
-D-, carefully rotate the sender wheel -2- with support ring.
ce
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• The sealing flange must rest flat against the assembly tool.
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ility
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– Screw knurled screws -H- into sealing flange -1-.

wit
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– Press sealing flange -1- and sealing lip support ring -2- against
hole
spec
surface of assembly tool - T10134- whilst tightening knurled

es, in part or in w
screws.
t to the co
– This prevents the locating pin from slipping out of the sender
wheel hole.
rrectness of i
– When installing sealing flange, ensure that sender wheel re‐

l purpos
mains fixed in assembly tool.

nf
ercia
orm
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76
AG.
Mounting assembly tool - T10134- with sealing flange -1- on

crankshaft flange:
• Crankshaft flange must be free of oil and grease.
• Engine is at “TDC” position.
– Screw on nut -B- until it reaches end of threaded spindle.
– Press threaded spindle of assembly tool - T10134- in
-direction of arrow-, until nut -B- rests against assembly hous‐
ing -C-.
– Align flat side of assembly housing to sealing surface of cyl‐
inder block on oil sump side.
– Attach assembly tool - T10134- together with sealing flange

-1- to crankshaft flange -2-.
– To do this, screw hexagon socket head bolts -E- approx. 5
turns into crankshaft flange using a hexagon key.
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
. Volkswagen AG
gen AG d
– To guide sealing flange -1-, screwVol
kstwo
wa M6×35 mm bolts -2-
oes
not
into cylinder block. e d by gu
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Bolting assembly tool - T10134- onto crankshaft flange:

rrectness of i
– Push assembly housing -C- by hand in -direction of arrow- until

l purpos
sealing lip support ring -1- rests against crankshaft flange

-2-.
nform
ercia
– Make sure that guide pin for petrol engines (red knob) -F- is
properly seated in hole in crankshaft. This ensures that the
m
sender wheel reaches its final installation position.

com
tion in
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The guide pin for diesel engines (black knob) must not be inserted
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– Tighten the two hexagon socket head bolts of assembly tool
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hand-tight.
AG.
– Screw nut -B- by hand onto threaded spindle until it rests

against assembly housing -C-.

Pressing sender wheel onto crankshaft flange using assembly

tool - T10134- :
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.
• After nut has been tightened to 35 Nm, a small gap must still
be present between cylinder block and sealing flange -1-.
AG. Volkswagen AG d
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Checking sender wheel installation position onhcrankshaft:
oris nte
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– Screw on nut -B- until it reaches end of threaded
ss spindle. c
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nl
pt
– Unscrew the two bolts -2- from cylinder block.
du
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itte
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– Pull guide pin for petrol engines (red knob) -F- out of crank‐
erm
ab
ility
shaft flange.
ot p
wit
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– Unscrew knurled screws -H- from sealing flange -1-.
h re
hole
spec
– Unbolt assembly tool - T10134- from crankshaft flange, un‐
es, in part or in w
screwing hexagon socket head bolts -E- from crankshaft
t to the co
flange.
– Remove sealing lip support ring.
rrectness of i
– Position depth gauge - VAS 6082- on crankshaft flange -2-.
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
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for
en
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
– Measure distance -a- between crankshaft flange -2- and send‐
er wheel -1-.
• Specification: dimension -a- = 0.5 mm
– If specification is not achieved, press sender wheel further in
⇒ page 79 .
– If specification is achieved, proceed with subsequent work
steps ⇒ page 79 .

Re-pressing sender wheel:

– Secure assembly tool - T10134- on crankshaft flange -2-.
– Make sure that locating pin of assembly tool - T10134- is prop‐
erly seated in sender wheel hole.
– Tighten hexagon socket head bolts -E- by hand.
– Push assembly tool - T10134- by hand against sealing flange
-1-.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly tool - T10134- .
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
– Screw knurled screws -H- into sealing flange.
– To guide sealing flange, screw two M6×35 mm bolts -2- into
cylinder block.
AG. Volkswagen AG d
– Tighten nut -B- of assembly tool - T10134- to 40 Nm. agen oes
olksw not
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ara
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– Check sender wheel installation position on the crankshaft
orise nte
again ⇒ page 78 . aut
h eo
ra
ss c
– If the specification is not achieved, tighten nut of assembly tool
ce
e
nl
pt
- T10134- to 45 Nm.
du
an
itte
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– Check sender wheel installation position on the crankshaft
erm
ab
ility
again ⇒ page 78 .
ot p
wit
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Assembling
h re
hole
spec
– Tighten bolts for sealing flange (vehicles with manual gearbox)
es, in part or in w
⇒ page 71 .
t to the co
– Install sump
rrectness of i
– Install intermediate plate (vehicles with manual gearbox)
l purpos
⇒ page 71 .
– Install flywheel (vehicles with manual gearbox)
nform
ercia
⇒ “2.2 Removing and installing flywheel”, page 71 .

m
at
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐
om
io
box .
n
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Specified torques
at
do
priv
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♦ ⇒ page 71
for
en
ng
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♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page Cop py
70 ht. rig
rig ht
py by
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♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 161
by c lksw
cted agen
Prote AG.
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation
♦ ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified
torques for gearbox

Ameo 2017 ➤ , Polo 2014 ➤ , Polo 2018 ➤ , wPolo agen KH IN 2015 ➤
AG. Volkswagen AG d
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3-cylinder injection engine (1.0 l engine,by4VV, EA 211) - Edition 05.2019 ot gua
ol
ed ran
oris tee
th or
au
3 Crankshaft
ac
ss
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nl
pt
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⇒ “3.1 Crankshaft dimensions”, page 80
an
itte
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3.1 Crankshaft dimensions
ility
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NOTICE
hole
spec
Risk of damage to bearing pedestals when the crankshaft is
es, in part or in w
t to the co
removed.
If the bolts of the crankshaft bearing cap are loosened, the
bearing pedestals of the cylinder block will be deformed, and
rrectness of i
damage to the bearings will result.
l purpos
– Never remove the crankshaft.
nf
ercia
orm
Note
m
atio
om
n in
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Measuring the main bearing clearance is not possible with normal
thi
e
workshop equipment.
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Honing dimension Crankshaft bearing Conrod journal ∅

t.
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in mm journal ∅ C py
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Basic dimension --- -0.022
p by
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-0.037
AG.

4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 81
⇒ “4.2 Checking pistons and cylinder bores”, page 82
⇒ “4.3 Separating wnew
agen conrod”, pageAG
AG. Volkswagen 84
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⇒ “4.4 Removing
ed
by and installing oil spray jets”, gpage
ua
ra 85
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⇒ “4.5
au Setting piston to TDC position”, page 86
th eo
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4.1 Assembly overview - pistons and con‐
ce
le
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d
rods
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Note
h re
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spec
All bearing points and running surfaces must be oiled before as‐
t to the co
sembly.
rrectne
1 - Retaining ring
ss o
2 - Piston pin
cial p
f inform
❑ If difficult to remove,
mer
heat piston to 60°C.

atio
om
❑ Remove and install us‐

n
c
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or
ing drift - 10 - 14- .

thi
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sd
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3 - Piston
pr
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❑ Checking
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⇒ “4.2 Checking pistons
Cop py
and cylinder bores”,
t. rig
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page 82
p by
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❑ Mark installation posi‐
agen
Prote AG.
tion and cylinder num‐
ber.
❑ Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring
clamp.
4 - Compression rings
❑ Offset gaps by 120°
❑ Remove and install
compression rings with
piston ring pliers.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
page 82 .
❑ Checking backlash be‐
tween annular grooves
page 82
5 - Oil scraper rings
❑ Carefully remove and install 3-part oil scraper rings by hand.
4. Pistons and conrods 81

❑ Checking ring gap ⇒ “4.2 Checking pistons and cylinder bores”, page 82 .
❑ Ring-to-groove clearance not measurable.
6 - Conrod bolt
❑ M8 × 1: 30 Nm + turn 90° further
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to corresponding specified torque but not further.
7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod.
❑ Before removing, mark allocation to cylinder -A-
❑ Installation position: Mark -B- points to belt pulley end (if mark is missing, mark before removing).
8 - Bearing shell
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
Checking radial clearance with Plastigage:
❑ New: 0.020 … 0.060 mm
❑ Wear limit: 0.070 mm
❑ Do not rotate crankshaft when checking radial clearance.
9 - Pressure relief valve
❑ Opening pressure of pressure relief valve: 1.8 … 2.2 bar
❑ 27 Nm
10 - Oil spray jet
❑ For piston cooling.
❑ Removing and installing ⇒ “4.4 Removing and installing oil spray jets”, page 85
11 - Connecting rod
❑ Renew as set only. AG. Volkswagen AG d
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❑ Mark with cylinder number -A-. ed byV gu
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❑ Installation position: Mark -B- points
ut
h to belt pulley end (if mark is missing, mark before
or eo removing).
a ra
❑ Guided axially by piston. ss c
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un
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4.2 Checking pistons and cylinder bores

ility
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h re
ole,
spec
♦ External micrometer 50-75 mm - VAS 6070-

t to the co
Checking piston
– Measure approx. 10 mm from lower edge and 90° in relation
to piston pin axis. Deviation from max. target dimension
rrectne
0.04 mm. Nominal dimension ⇒ page 84

ss o
cial p
f inform
mer
atio
om
n
c
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or
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

. Volkswage
Ameoks2017
wage ➤ , Polo 2014 ➤
n AG n AG d
, sPolo
oe
no
2018 ➤ , Polo KH IN 2015 ➤
ol
3-cylinder
d by injection engine (1.0 l engine,t g4uaV, EA 211) - Edition 05.2019
V
r
e an
ris tee
ho
Measuring piston ring gap s au
t or
ac
s
– Push ring at rights angles from above approx. 15 mm away
ce
le
un
pt
from cylinder wall into lower cylinder bore.
an
d
itte
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erm
ab
Piston ring New Wear limit
ility
ot p
dimensions in mm
wit
is n
h re
1st compression ring 0.20 … 0.35 1.0
ole,
spec
2nd compression ring 0.40 … 0.60 1.0
t to the co
Oil scraper ring 0.20 … 0.90 ---1)
1) No wear limit details available.
rrectne
Measuring ring-to-groove clearance
ss o
cial p
f
Clean annular groove before check.
inform
mer
Piston ring New Wear limit
atio
m
dimensions in mm
o
n
c
i
or
n
1st compression ring 0.04 … 0.08 0.15
thi
te
sd
va
2nd compression ring 0.02 … 0.06 0.15

i
o
pr
cum
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fo
Oil scraper ring Cannot be measured
en
ng
t.
yi Co
op py
Checking cylinder bores
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
♦ Cylinder gauge - VAS 6078-

Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.
Checking cylinder bores
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Using cylinder gauge - VAS 6078- take measurements at 3

positions diagonally in lateral direction -A- and longitudinal di‐
rection -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
– Nominal dimension ⇒ page 84
– Permissible deviation ⇒ page 84
Piston and cylinder dimensions
Piston dimensions
Honing dimension Piston diameter2)
Basic dimension mm 74.454 … 74.482 mm
2) Measure pistons approx. 10 mm from lower edge.
Cylinder dimensions agen

AG. Volkswagen AG d
oes
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Note ut
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ce
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Do not measure cylinder bores when cylinder block is mounted

un
pt
on engine and gearbox support - VAS 6095- , as measurements an
d
itte
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may be incorrect.
erm
ab
ility
ot p
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Honing dimension Inner diameter of cylinder

h re
ole,
Specification m 74.505 … 74.515 mm

spec
m
t to the co
Permissible deviation -15 … +30 µm

rrectne
4.3 Separating new conrod

s
On new conrods it is possible that the breaking point is not fully

s o
separated. Proceed as follows if the conrod bearing cap cannot

cial p
f in
be removed by hand:
form
mer
– Mark the cylinder to which the conrod belongs

atio
om
⇒ Item 11 (page 82) .

n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Lightly clamp the conrod in a vice using aluminium vice

clamps, as shown in the illustration.
Note
♦ Only clamp the conrod lightly

wage
n AG. Vin
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♦ Conrod is clamped
ed
by below the dashed line. ara
ris nte
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– Unscrew
ss both
a bolts -arrows- about 5 turns. c
ce
e
nl
pt
du
an
itte
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erm
ab
– Using a plastic hammer, carefully knock against conrod bear‐
ility
ot p
ing cap in -direction of arrow- until it is loose.
wit
, is n
h re
Specified torque
hole
spec
es, in part or in w
♦ Securing bolts for conrod bearing cap
t to the co
⇒ “4.1 Assembly overview - pistons and conrods”, page 81
rrectness of i
l purpos
nform
mercia
at
om
i
4.4 Removing and installing oil spray jets
on
c
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or
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at
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or
♦ Special wrench XZN 14 - T10545-

f
en
ng
t.
yi Co
Removing t. Cop py
rig
gh ht
– Remove noise insulation ⇒ General body repairs, exterior; pyri by
Vo
co
by lksw
cted agen
Prote
sulation .
AG.
– Remove sump
– Turn crankshaft via vibration damper securing bolt in direction
of engine rotation until the respective bolt is accessible.
Note
♦ The crank web of the respective cylinder must be positioned

so that the socket - T10545- can be inserted in the pressure
relief valve as close to vertical as possible.
♦ Furthermore, the corners of the socket - T10545- and of the
pressure relief valve must engage well.

AG. Volkswagen AG d
– Unscrew pressure relief valve -1- using Torx bit T40 - agen oes
olksw not
T10545- . d byV gu
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– Remove oil spray jets -2-. ut
ho eo
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s
Installing
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un
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an
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itte
NOTICE
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erm
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ility
Risk of damage to oil spray jets caused by deformation.
ot p
wit
is n
– Do not bend oil spray jets.
h re
ole,
spec
t to the co
1- Bolt with pressure relief valve, 27 Nm
rrectne
2- Oil spray jet (for cooling of pistons)
ss
• Installation position: align leading edge of oil spray jet with
o
cial p
f
machined surface of cylinder block
inform
mer
– Install sump
atio
m

o
n
c
i
or
n
– Install noise insulations ⇒ General body repairs, exterior; Rep.
thi
te
sd
a
gr. 66 ; Noise insulation; Assembly overview - noise insula‐

iv
o
r
tion .
p
cum
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fo
en
ng
t.
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Cop py
ht. rig
4.5 Setting piston to TDC position rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
♦ Locating bolt - T10340-
Procedure
sulation .
– Unscrew plug -arrow- from crankcase.
– Lower lifting platform completely.
Note
♦ The lifting platform must be lowered completely so that the

locking pin - T10340- can be screwed into the crankcase.
♦ When the vehicle is raised, the hole is hidden behind the drive
shaft.

– Screw locking pin - T10340- into crankcase from above as far

as it will go.
– The bolt head of locking pin - T10340- must contact cylinder
block when doing this.
– If locking pin - T10340- cannot be screwed in as far as stop,
this indicates that crankshaft is not in the correct position!
– Unscrew locking pin - T10340- .
n AG. Volkswagen A ge G do
swa es
– Turn crankshaft 90°
by
Voin
lk direction of rotation of engine.
not
gu
a d ran
se
– Screw locking ho pin - T10340- into cylinder block as far as stop
ri tee
ut or
and tighten
ss
a to 30 Nm. ac
ce
le
– Rotate crankshaft in normal direction of rotation as far as stop.

un
pt
an
The locking pin - T10340- now rests against the crank web.
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
Locking pin - T10340- locks crankshaft in direction of engine ro‐
tation only.
t to the co
– Unclip line guide from cover.
rrectne
– Remove cover -1- and cover -2-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
• Grooves -1- of inlet camshaft -3- are positioned above the

horizontal camshaft centre line -2-.
• Grooves -1- of exhaust camshaft are positioned above hori‐
zontal camshaft centre line -2-.
• The centre-line of the holes close to hub of the gear -3- is
slightly above the grooves.
– If the grooves of the camshafts are not in the specified position,
turn the crankshaft 360° further in the direction of engine ro‐
tation and check the positions again.
Specified torque:
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 88

AG. Volkswagen AG d
agen oes
olksw not
15 – Cylinder head, valve gear

V gu
d by ara
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or eo
h
aut ra
ss c
1 Cylinder head
ce
e
nl
pt
du
an
itte
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⇒ “1.1 Assembly overview - cylinder head”, page 88
erm
ab
ility
ot p
⇒ “1.2 Removing and installing cylinder head”, page 91
wit
, is n
h re
⇒ “1.3 Removing and installing camshaft housing”, page 97
hole
spec
⇒ “1.4 Checking compression”, page 100
es, in part or in w
t to the co
1.1 Assembly overview - cylinder head
rrectness of i
Note
l purpos
♦ If an exchange cylinder head is installed, all the contact sur‐
nf
ercia
faces between the supporting elements, roller rocker fingers
or
and the running surfaces of the camshaft must be oiled before
m
m
atio
the cylinder head cover is fitted.
om
n in
or c
♦ Do not remove the plastic packing pieces for protecting the
thi
te
open valves until immediately before fitting cylinder head.
sd
iva
o
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rp
cu
♦ If the cylinder head is renewed, the coolant and the engine oil
o
m
f
en
ng
must be renewed.
t.
yi Co
Cop py
t. rig
gh ht
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Removing and installing cylinder head p by
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by c
⇒ “1.2 Removing and installing cylinder head”, page 91 .
lksw
cted agen
Prote AG.
88 Rep. gr.15 - Cylinder head, valve gear

1 - Bolt
❑ Renew
❑ Observe tightening se‐
quence
stalling camshaft hous‐
ing”, page 97
❑ 10 Nm +180°
2 - Inlet camshaft control valve
1 - N205-
❑ Check O-ring for dam‐
age.
❑ O-ring not available as a
separate part; renew to‐
gether with camshaft
control valve 1 - N205- if
damaged.
❑ The O-ring cannot be re‐
newed individually.
3 - Bolt
AG. Volkswagen AG d
❑ 8 Nm agen oes
olksw not
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4 - Bolt rise
d
nte
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❑ Renew aut ra
c
ss
ce
e
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❑ 10 Nm +180°
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5 - Hall sender - G40-
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6 - Bolt
❑ 8 Nm rrectness of i
7 - Ball-head pin
l purpos
❑ 2.5 Nm
8 - Oil seal
nform
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❑ Removing and installing ⇒ “3.3 Removing and installing camshaft oil seal”, page 140
m
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9 - Bolt
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❑ Renew
13 - Crankshaft
❑ For coolant pump drive
14 - Bolt
❑ 8 Nm
15 - Cap
16 - O-ring
❑ Renew if damaged
1. Cylinder head 89
17 - Bolt
❑ 8 Nm
18 - Radiator outlet coolant - G62-
19 - Cylinder head
❑ Removing and installing ⇒ “1.2 Removing and installing cylinder head”, page 91
❑ Reworking the valve seat is not permitted.
❑ Machining the cylinder head sealing surface on the cylinder block
⇒ “3.2 Measuring axial play of camshaft”, page 139
20 - Seal
❑ Renew
21 - Cylinder head bolt
❑ Renew
❑ Follow installation instructions and sequence when loosening and tightening
⇒ “1.2 Removing and installing cylinder head”, page 91
22 - Oil strainer
❑ Renew
❑ Inserted into cylinder head.
Note
♦ Versions with or without oil

strainers are used depending on
production date.
♦ If no strainer was installed at the AG. Volkswagen AG d
factory, a strainer is instead inte‐ lksw
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23 - Seal
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❑ Renew
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24 - Camshaft case
h re
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spec
❑ Removing and installing ⇒ “1.3 Removing and installing camshaft housing”, page 97
Note t to the co
♦ The camshafts cannot be re‐

rrectne
moved.
♦ If repair is required, the camshaft
ss o
housing and the camshafts need

cial p
f in
to be renewed as a complete
form
mer
unit.
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Checking cylinder head for distortion

Check with 500 mm straight edge - VAS 6075- and feeler gauge
-1-.
Max. permissible distortion: 0.05 mm
1.2 Removing and installing cylinder head
Note
♦ When installing a replacement cylinder head, all the contact

surfaces between the supporting elements, roller rocker fin‐
gers and the running surfaces of the camshaft must be oiled
before the cylinder head cover is installed.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ If the cylinder head needs to be renewed, the coolant and the
engine oil must be renewed.
♦ Cylinder head is being removed together with intake manifold.

♦ Special wrench, 30 mm - T10499A-
AG. Volkswagen AG d
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1. Cylinder head 91
♦ Assembly tool - T10476A-

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Conditions
• The engine must be no more than warm to touch.
Removing
– Unscrew bolt -1- from engine support.
– Remove camshaft housing.
⇒ “1.3 Removing and installing camshaft housing”,
page 97

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– Unscrew fastening bolt from catalytic converter and remove
nl
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stud bolts.
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– Secure catalytic converter to prevent it from falling.
ion
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– Open protective covers for senders -arrows-.
– Pull off connectors for coolant temperature sender - G62- -1-

and knock sensor 1 - G61- -2-.
– Release fastener for wiring harness -arrows-.
1. Cylinder head 93
– Open vacuum line fastener -arrow- at intake manifold and pull

off vacuum line.
– Unscrew intake manifold support securing bolt -arrow-.
– Unclip wiring harness -1- under intake manifold.

• Only disconnect roller rocker finger if cylinder head needs to
be renewed:
– Remove rocker fingers -1- and -2- and place them on a clean
surface.
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– Loosen cylinder head bolts -1- through -8- in sequence given

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and then remove completely.

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– Remove cylinder head together with intake manifold.

wit
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– Remove cylinder head gasket.

hole
spec
Installing
es, in part or in w
t to the co
rrectness of i
l purpos
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94
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
Note
♦ Do not use sanding or abrasive media such as sandpaper,

grinding wheels, abrasive or scour pads, or similar.
♦ Sealing surface (see photo) must not project.
♦ Discolouration (dark spots, see photo) need not be removed.
♦ When removing the sealant residue, make sure no loose par‐
ticles get into the open channels of the engine.
♦ Ensure that all adjacent workspaces are clean, and that none
of the above mentioned sanding or abrasive media are used.
♦ Using unauthorised sanding or abrasive media may lead to
secondary damage such as, for example, damage to the tur‐
bocharger or the conrod bearings.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ Carefully remove sealant residue from cylinder head and cyl‐
inder block.
♦ Ensure that no long scores or scratches are made on the sur‐
faces.
♦ Carefully remove remains of emery and abrasives.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
♦ Renew self-locking nuts
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swagaskets,
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♦ If an exchange
ed cylinder head is installed, the contact
by gu
ara surfaces
betweenththeor hydraulic compensation elements, rollerteerocker
is n
fingerss aand running surfaces of cams must be moistened
u or
acwith
oil before fitting the camshaft housing.
s
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♦ Secure all hose connections with hose clips corresponding to

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the series equipment ⇒ Electronic parts catalogue .

rm
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♦ When cylinder head or cylinder head gasket is renewed, the

ot
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entire coolant and the engine oil must be changed.

h re
hole
spec
– Only remove sealant residue from cylinder head and cylinder

es, in part or in w
t to the co
block using scraper - VAS 852 005- or a commercially availa‐

ble ceramic glass scraper.
– Set no. 1 cylinder piston to top dead centre and then turn
rrectness of i
crankshaft back slightly.

l purpos
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1. Cylinder head 95
– Place new cylinder head gasket -1- onto centring bushes

-arrows-. Inscription (Part No.) -2- must be readable.
– Fit cylinder head, install 8 new cylinder head bolts and tighten
by hand.
AG. Volkswagen AG d
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ut
– Tighten cylinder head bolts in sequence
ss a shown in illustration ra
c
(-1- through -8-) to specified torque ⇒ page 96 .
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Specified torques
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Bolt Specified torque Note
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Stage 1 40 Nm Renew bolts
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Stage 2 Turn 90° further With rigid spanner
spec
es, in part or in w
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Note
l purpos
♦ Risk of damage to valves and piston crowns.
nform
ercia
♦ When camshaft is turned, crankshaft must not be at TDC.

m
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tion in
– Install camshaft housing
r
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thi
⇒ “1.3 Removing and installing camshaft housing”, s
iva
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page 97 .
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– Adjust valve timing ⇒ “2.7 Adjusting valve timing”, page 124 .

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– Install coolant pump t. C rig
gh ht
⇒ “2.3 Removing and installing coolant pump”, page 201 . yri
p by
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– Install catalytic converter
agen
Prote AG.
⇒ “2.2 Removing and installing catalytic converter”,
page 297
Specified torques:
♦ Securing bolts for cylinder head and camshaft housing
⇒ “1.1 Assembly overview - cylinder head”, page 88 .
♦ Engine bracket
55
♦ Catalytic converter
♦ Coolant pump
⇒ “2.1 Assembly overview - coolant pump”, page 197
♦ Intake manifold
⇒ “4.1 Assembly overview - intake manifold”, page 260
♦ Engine support
55

1.3 Removing and installing camshaft hous‐

ing
Note
♦ The camshafts cannot be removed.

♦ If repair is required, the camshaft
agen housing andAthe
AG. Volkswagen G d camshafts
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need to be renewed asy Vaolcomplete
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Special tools and aworkshop
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inform
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1. Cylinder head 97
AG. Volkswagen AG d
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Removing
, is n
h re
hole
– First, check whether a coded radio is fitted. If so, obtain anti-
spec
theft coding.
es, in part or in w
t to the co
– With ignition switched off, disconnect battery earth strap.
– Detach toothed belt from camshafts. rrectness of i
⇒ “2.8 Removing toothed belt from camshaft”, page 133
l purpos
– Disconnect connector -arrows- and unclip line guide from

camshaft housing.
nf
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Prote AG.
– Pull out oil dipstick -1- and unscrew securing bolts -2- of igni‐
tion coils with output stages .
– Pull off ignition coils with output stages from spark plugs.

– Loosen securing bolts -1- through -12- of camshaft housing in

sequence given and then remove completely.
– Lift off camshaft housing vertically from cylinder head.
– Remove gasket.
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Condition
• The pistons cannot be positioned at TDC.
Note
If a piston is at TDC, the valves could strike the piston when the
camshafts turn.
– Ensure that all roller rocker fingers are correctly clipped into
the valve stem ends -1- and into their respective support ele‐
ments -2-.
Note
♦ Versions with or without oil strainers are used depending on

production date.
. Volkswagen AG
gen AG
♦ If no strainer was installed at the factory, a strainer is instead a does
ksw not
Vol
integrated in camshaft control valve 1 - N205- . db
y gu
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♦ ho locations!
Damage may result if the strainer is installed in aboth eo
ut ra
ss c
ce
le
– Renew seal and oil strainer -3-.

un
pt
an
d
itte
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rm
ab
– Fit new gasket -1- onto dowel pins -2-.
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ility
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Part number -3- of gasket must be readable from above.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
When fitting the camshaft housing, make sure that the roller rock‐
er fingers do not slip off the valve stem ends and compensation
elements. rrectness of i
l purpos
nform
mercia
– Carefully fit camshaft housing vertically from above onto dowel

com
tion in
pins -arrows-.
r
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s
Note different bolt lengths.

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1. Cylinder head 99
– Tighten new securing bolts of camshaft housing in specified

sequence -1- through -12-.
– Tighten securing bolt -arrow- of earth strap.

Bolt Specified torques
AG. Volkswagen AG d
-Arrow- 8 Nm agen oes
olksw not
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– Fit toothed belt onto camshafts.orise nte
eo
h
⇒ “2.8 Removing toothed belt autfrom camshaft”, page 133 ra
c
ss
Fit thermostat cap
ce
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nl
pt
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⇒ “2.4.2 Removing and installing thermostat (extended circuit)”,
an
itte
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page 208 .
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spec
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Specified torques
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♦ Securing bolts for assembly mountings
rrectness of i
♦ Securing bolts of ignition coil with final output stage
l purpos
⇒ “1.1 Assembly overview - ignition system”, page 303

nf
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1.4 Checking compression

orm
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equipment required
AG. Volkswagen AG d
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♦ Spark plug socket - 3122 B-

nform
ercia
♦ Compression tester - V.A.G 1763-

m
♦ Adapter - V.A.G 1381/1-

com
tion in
♦ Adapter - V.A.G 1381/5A-

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Test conditions
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• The engine oil temperature must be at least 30 °C.

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• Battery voltage at least 12.5 V t. C rig
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Test sequence
co Vo
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Prote AG.
– Remove fuse for fuel pump control unit from fuse holder. Fuse
assignment ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
– Start engine and allow it to run until the engine turns off.
1. Cylinder head 101

– Switch off ignition.

AG. Volkswagen AG d
agen oes
– Remove air filter housing olksw not
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⇒ “3.2 Removing and installing air filter housing”,
ised b page 258 . ara
nte
or eo
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aut ra
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Note
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Always observe
erm
ab
⇒ “1.5 Safety precautions when working on ignition system”, page
ility
ot p
2 before working on the ignition system.
wit
, is n
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hole
– Disconnect connectors -1- from ignition coils.
spec
es, in part or in w
t to the co
– Unscrew securing bolts -2- and pull off ignition coils from spark
plugs.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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– Unscrew spark plugs using spark plug socket and extension -

p
cum
or
3122 B- .
f
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

– Check compression using compression tester - V.A.G 1763- ,

adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- . Using
compression tester: ⇒ Operating instructions .
– Press down accelerator pedal completely, and simultaneously
operate starter until pressure no longer increases on tester
display.
– Repeat procedure on each cylinder.
Note
How to use the test unit is described in the respective operating

instructions.
Compression pressures:
Compression pressures Pressure
New 10 … 15 bar
Wear limit 7 bar
Permissible deviation between Vo3lksbar
wagen AG
cylinders swa
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.
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Assembling edb ara
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Installations is carried out
a u in the reverse order. When installing,ra
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note the following:
s
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un
pt
– Screw in spark plugs using spark plug socket - 3122 B- and

an
d
itte
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tighten to specified torque ⇒ page 103 .

erm
ab
ility
ot p
– Install ignition coils

wit
is n
⇒ “1.2 Removing and installing ignition coils with output stage”,

h re
ole,
page 305 .
spec
– Clear any entries in event memory which may have been stor‐
t to the co
ed when checking ⇒ Vehicle diagnostic tester, Read event

memory , then Generate readiness code .
rrectne
Specified torques
ss o
cial p
Spark plugs 22 Nm
inform
mer
atio
om
n
c
i
or
n thi
te
sd
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rig ht
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by lksw
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Prote AG.
1. Cylinder head 103

2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt cover”, page 104
⇒ “2.2 Assembly overview - toothed belt”, page 105
⇒ “2.3 Removing and installing toothed belt guard”, page 106 AG. Volkswagen AG d
agen oes
lksw not
⇒ “2.4 Removing and installing toothed belt”, page 107 d by V o gu
ara
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⇒ “2.5 Preassembling and installing valve timing tool”,
ut
ho eo
ra
page 114 ss a c
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nl
⇒ “2.6 Checking valve timing”, page 121
pt
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⇒ “2.7 Adjusting valve timing”, page 124 erm
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ility
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2.1 Assembly overview - toothed belt cover
hole
spec
es, in part or in w
t to the co
1 - Lower toothed belt guard
rrectness of i
⇒ “2.3.2 Removing and
installing lower toothed
l purpos
belt guard”, page 106

2 - Bolt
nform
ercia
❑ 8 Nm
m
at
om
i
3 - Engine support
on
c
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or
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tightening sequence
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view - assembly mount‐

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ings”, page 32
Co
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4 - Bolt rig ht
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tightening sequence
AG.

view - assembly mount‐
ings”, page 32
5 - Upper toothed belt guard
installing upper toothed
belt guard”, page 106
6 - Bolt
❑ 8 Nm

2.2 Assembly overview - toothed belt
1 - Toothed belt
chalk or felt-tipped
marker pen.
⇒ “2.4 Removing and in‐ agen
AG. Volkswagen AG d
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stalling toothed belt”, olksw not
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page 107 ed b ara
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2 - Bolt aut ra
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ss
❑ 25 Nm
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❑ Removal and installa‐
pe
ility
tion involve removing
ot
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engine support
h re
hole
spec
stalling engine support”,
es, in part or in w
page 65 .
t to the co
4 - Bolt
rrectness of i
❑ 50 Nm +90°
l purpos
5 - Exhaust camshaft toothed

belt pulley
nform
ercia

m
a
com
tio
stalling toothed belt pul‐
n in
r
ley”, page 149

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s
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6 - Inlet camshaft toothed belt
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❑ With camshaft adjuster
Co
Cop py
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rig ht
by
camshaft adjuster copy Vo
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⇒ “3.4 Removing and in‐ cted agen
Prote AG.
stalling camshaft adjust‐
er”, page 144
7 - Guide bush
8 - Bolt
❑ 50 Nm +135°
9 - O-ring
10 - Plug
❑ 20 Nm
11 - O-ring
❑ Captive, supplied with “item 13”.
12 - Spacer sleeve
❑ Supplied with item “13”.
2. Toothed belt drive 105

13 - Idler roller
14 - Bolt
❑ 40 Nm
15 - Crankshaft pulley
❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
❑ Can only be fitted in one position
❑ Specified torque ⇒ “1.1 Assembly overview - poly V-belt drive”, page 51
Plug for “TDC” drilling in cylinder block - specified torque
Note
AG. Volkswagen AG d
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Plug with integrated y Vseal -arrow-
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♦ Renew if damaged
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– Tighten bolt -arrow- to 30 Nm.
le
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2.3 Removing and installing toothed belt
hole
spec
guard
es, in part or in w
t to the co
⇒ “2.3.1 Removing and installing upper toothed belt guard”, page

106
rrectness of i
⇒ “2.3.2 Removing and installing lower toothed belt guard”, page

106
l purpos
2.3.1 Removing and installing upper toothed

nform
ercia
belt guard
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Removing
n in
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te o
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– Detach hoses from retainer -3-.

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– Release clips -arrows-, and remove upper toothed belt guard
yi Co
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-1-. . C rig
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Installing
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Prote AG.
Further assembly is carried out in the reverse order of removal.
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt cover”, page 104
2.3.2 Removing and installing lower toothed

belt guard
Removing:
– Remove poly V-belt pulley from crankshaft
⇒ “1.1 Assembly overview - poly V-belt drive”, page 51 .


– Remove lower part of toothed belt guard.
Installing:
Install in reverse order of removal. Observe the following:
– Install vibration damper
⇒ “1.1 Assembly overview - poly V-belt drive”, page 51 .
Specified torques:
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 51

equipment required
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t to the co
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♦ Counterhold - T10172- with adapter -T10172/1- and -

t.
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op
T10172/2- C py
ht. rig
rig ht
by
♦ Locating bolt - T10340- copy Vo
by lksw
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Prote
AG.


Removing
– Set piston of cylinder no. 1 to “TDC” position.
⇒ “4.5 Setting piston to TDC position”, page 86
– Remove lower toothed belt guard
⇒ “2.3.2 Removing and installing lower toothed belt guard”,
page 106 .
Note
♦ A small amount of oil can leak out while loosening the plug.
♦ To prevent the toothed belt from coming into contact with en‐
gine oil, place a cloth underneath the plug when loosening it.
– Loosen plug and securing bolt for camshaft adjuster on inlet

side
⇒ “3.4 Removing and installing camshaft adjuster”,
page 144 .
AG. Volkswagen AG d
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– Loosen securing bolt of toothed belt pulley olksw
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⇒ “3.5 Removing and installing toothed belt pulley”, ed b ara
nte
is
page 149 . hor eo
aut ra
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nl
Note
pt
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ab
♦ When adjusting the valve timing, both camshaft pulleys must
ility
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be loose.
wit
, is n
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♦ If a used toothed belt runs in the opposite direction when it is
hole
spec
refitted, it may break.
es, in part or in w
t to the co
♦ Before removing, mark direction of rotation of toothed belt with
chalk or felt-tipped pen for re-installation.
rrectness of i
– Loosen bolt -1- with tool insert - T10500- .
l purpos
– Release tension on tensioning roller at eccentric -2- using

wrench - T10499A- .
nf
ercia
orm
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atio
om
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or c
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Cop py
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rig ht
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by lksw
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Prote AG.

Bend radius of toothed belt
NOTICE
Risk of damage to toothed belt by bending it excessively. The
toothed belt is made of glass fibre fabric which will be damaged
if it is bent excessively.
– Never bend toothed belt to a radius less than r = 25 mm.
• The bend radius -r- on the toothed belt -2- should therefore
never be below 25 mm (approx. half the diameter of gear -1-
on crankshaft).
– Push toothed belt from camshaft pulleys.
– Remove toothed belt -1- together with crankshaft sprocket

-2- from crankshaft stub.
Disregard item -3-.
Installing
Note

♦ Renew the damaged O-ring of the plug at the toothed belt pul‐
ley of the inlet camshaft.
AG. Volkswagen AG d
agen oes
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– Check “TDC” position of camshaft and crankshaft b yV gu
ara
ed
⇒ “4.5 Setting piston to TDC position”, page hori86
s
. nte
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nl
Note
pt
du
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ab
Before installing the camshaft adjusters, ensure that the guide

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sleeves are inserted in the camshafts.

wit
, is n
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hole
spec
– Renew bolts -1- and -2- for camshaft pulleys and screw them
es, in part or in w
in loosely.
t to the co
• It should just be possible to turn the adjusters on the camshafts

but no rocking is permissible.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
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for
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Cop py
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rig ht
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co Vo
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Prote AG.

The sheet-metal tab -arrow- of the tensioning roller must engage

in the cast notch in the cylinder head.
AG. Volkswagen AG d
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– Push crankshaft sprocket onto crankshaft stub to stop.
ce
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nl
pt
du
an
Milled surface of crankshaft sprocket -arrow- must be positioned
itte
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erm
on milled surface of crankshaft stub.
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
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– Fit toothed belt -1- onto toothed belt pulley -2-.

nform
ercia
When existing toothed belt is reused:

m
at
om
Note arrow for direction of rotation.

on
c
in t
or
– Guide toothed belt to camshaft pulleys through console for

his
ate
engine mounting bracket.

do
priv
cum
for
en
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op
Note C py
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♦ The camshaft pulleys are not circular.
co lksw
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cted agen
Prote AG.
♦ If one or both camshaft pulleys have been loosened, they must
be properly aligned with each other.
♦ It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
♦ The toothed belt has not yet been fitted.

Align marked gap -1- in teeth of camshaft adjuster -3- with lug
-2- of camshaft housing.
Align marked tooth -1- of exhaust camshaft pulley -3- with lug
AG. Volkswagen AG d
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– Markings -1- and -2- on camshaft pulleys are aligned as

h re
ole,
shown.
spec
Groove -3- for assembly tool - T10476A- is located on exhaust t to the co

camshaft pulley.
– Insert assembly tool - T10476A- between camshaft pulleys.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
– Arrows -1- on assembly tool are aligned with marks -2- on

t
sd
va
camshaft pulleys.
i
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Note C py
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When the assembly tool - T10476A- is inserted, the marks -2- on
by c lksw
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the camshaft pulleys are slightly offset.
Prote AG.

– Dowel pin -1- of assembly tool - T10476A- must engage in

groove -2- of exhaust camshaft pulley.
– Hand-tighten belt tensioner on cylinder head.

Note
When installing the toothed belt, ensure that the assembly tool -
T10476A- is correctly positioned between the camshaft pulleys.
– Toothed belt must make full contact with crankshaft pulley.

– Check that crankshaft is set to TDC for No. 1 cylinder.
The crankshaft must make contact with the locking pin - T10340-
in direction of engine rotation.
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– Fit toothed belt -1- onto belt tensioner -5- and camshaft
Vol
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– Fit toothed belt on camshaft adjuster -3-, athen
ut
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push onto idler ra
or guide pulley -4-. ss c
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un
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– Remove assembly tool - T10476A- from camshaft pulleys.
an
d
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ility
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spec
t to the co
– Rotate eccentric -2- of belt tensioner using tensioning spanner

rrectne
-T10499A- in -direction of arrow- until adjustment pointer -3-

is located approx. 10 mm to the right from adjustment window.
ss
– Then rotate eccentric of belt tensioner back on 12-point sur‐

o
cial p
face -2- until adjustment pointer -3- is exactly centred in ad‐

inform
justment window.
mer
atio
– Hold eccentric on 12-point surface -2- in this position.

om
n
c
i
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Note
iv
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pr
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When setting the specified torque on the torque wrench - VAS

t.
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op
6583- , the length indicated on insert tool, 13 mm - T10500- must C py
t. rig
be entered in the torque wrench.
gh ht
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Vo
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AG. Volkswagen AG d
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♦ When the engine has been rotated by hand or by engine op‐ ss c
ce
le
eration, the position of the adjustment pointer might be slightly
un
pt
offset from the adjustment window.
an
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♦ However, this has no relevant influence on the valve timing.
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The toothed belt does not need to be retensioned.
wit
is n
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ole,
– Tighten camshaft adjuster and toothed belt pulley in 2 stages.
spec
– Use counter-hold tool - T10554/1- and counter-hold tool -
t to the co
T10172- to hold camshaft in position (apply force »anti-clock‐
wise«).
rrectne
– Tighten bolt -1- to initial specified torque ⇒ page 147 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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fo
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t.
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Cop py
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Vo
co lksw
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cted agen
– Tighten bolt -1- to initial specified torque ⇒ page 150 using Prote AG.
counterhold tool - T10172- with adapters -T10172/2- and -
T10172/1- .
Note
The securing bolts will be tightened further at the end of the work
sequence after the valve timing has been checked.
– Install lower toothed belt guard

⇒ “2.3.2 Removing and installing lower toothed belt guard”,
page 106 .
Note
After completing work, it is essential to make sure that the locking

pin - T10340- has been removed.

quence.
Specified torques
Assembly overview - cylinder block (pulley end)
⇒ “1.2 Assembly overview - cylinder block (pulley end)”,
page 55 .

2.5 Preassembling and installing valve tim‐

ing tool
⇒ “2.5.1 Preassembling valve timing tool”, page 114
⇒ “2.5.2 Installing test tool VAS 611 007 ”, page 117
⇒ “2.5.3 Teaching in test tool VAS 611 007 electronically and
performing basic setting”, page 119
2.5.1 Preassembling valve timing tool

. gen AG Volkswa
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♦ Tester for checking elongation of chainolklinks
swa - VAS 611 007- does no
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♦ Supplement set for MPI engines testing tool - VAS 611 007/18-
rrectness of i
Test tool - VAS 611 007- :
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A - Angle sensor - VAS 611

007/1-
B - Lock ring - VAS 611 007/2-
C - Clamping ring - VAS 611
007/3-
D - Adapter for camshaft hous‐
ing - VAS 611 007/11- for 1.0 l
engine MPI
E - Adapter for angle sensor -
VAS 611 007/12- and adapter
for angle sensor - VAS 611
007/13-
❑ Adapter for angle sen‐
sor - VAS 611 007/12-
blue, for inlet camshaft
❑ Adapter for angle sen‐
sor - VAS 611 007/13-
red, for exhaust cam‐
shaft
AG. Volkswagen AG d
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Preassembling test tool - VAS 611 007- :

nform
ercia
Note
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a
com
tion in
The shape of the adapter for angle sensor -E- may differ depend‐
r
te o
thi
ing on the engine.

s
iva
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– Before inserting adapter for angle sensor - VAS 611 007/12-

en
ng
t.
yi
and adapter for angle sensor - VAS 611 007/13- -E- in angle
Co
op py
sensors - VAS 611 007/1- -A-, verify correct allocation in ac‐
t. C rig
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cordance with colour coding -a-. p by
co Vo
by lksw
cted agen
– Insert adapter for angle sensor - VAS 611 007/912- and adapt‐ Prote AG.
er for angle sensor - VAS 611 007/13- -E- in angle sensors -
VAS 611 007/1- -A-.

– Note position of dowel pins -a- when installing.

– The adapters for angle sensor - VAS 611 007/12- and -VAS
611 007/13- -E- can only be fitted in one position.
– Make sure that brake -b- is released. Do not apply force.
– Insert adapters for angle sensor - VAS 611 007/12- and -VAS
611 007/13- -E- to stop into angle sensor - VAS 611 007/1-
-A-.
– Fit clamping ring - VAS 611 007/3- -C- in groove -a- of adapter
for angle sensor - VAS 611 007/12- and -VAS 611 007/13-
-E-, and clip it in until it can be heard to engage.
AG. Volkswagen AG d
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– Insert angle sensor - VAS 611 007/1- -A- with the red colour ss
ce
e
coding on the side marked in red -arrows a- of adapter for

nl
pt
du
camshaft housing - VAS 611 007/11- -D-.

an
itte
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erm
ab
– To do this, release locking pins -c- by pulling them upwards.

ility
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wit
– Insert angle sensor - VAS 611 007/1- -A-, and push it in until
, is n
h re
locking pin can be heard to engage.

hole
spec
– Repeat the procedure with the angle sensor - VAS 611 007/1-
es, in part or in w
t to the co
-A- with blue colour coding -arrows b-.

rrectness of i
l purpos
– Screw in securing rings - VAS 611 007/2- -B- approx. 2 turns.

nf
ercia
– Note colour coding -arrows a- and -arrows b- when doing this.

orm
m
atio
– Make sure that the shafts are free to move. It must be possible
om
to turn adapter for angle sensor - VAS 611 007/12- and -VAS
n in
or c
611 007/13- -E-.

thi
te
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Cop py
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rig ht
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by lksw
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Prote AG.

2.5.2 Installing test tool - VAS 611 007-

♦ Tester for checking elongation of chain links - VAS 611 007-
AG. Volkswagen AG d
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pt
du
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ab
ility
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Procedure
wit
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– Preassemble test tool - VAS 611 007- ⇒ page 115 .
hole
spec
– Teach in test tool - VAS 611 007- electronically, and perform
es, in part or in w
t to the co
basic setting ⇒ page 119 .
– Turn the two adapter for angle sensor - VAS 611 007/12- and
-VAS 611 007/13- in such a way that the display shows approx.
rrectness of i
»0°«.
l purpos
– Perform the preliminary work for checking the valve timing

⇒ “2.6 Checking valve timing”, page 121 .
nf
ercia
o
– Make sure that the piston in cylinder no. 1 is at “TDC” position
rm
m
atio
for repair work on toothed belt drive
om
n in
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Note
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Before positioning the test tool - VAS 611 007- against the cam‐ Cop py
t.
shaft housing, the grooves of the camshafts must be checked for
rig
gh ht
yri by
damage. cop Vo
by lksw
cted agen
Prote AG.
– Align adapter for angle sensor -E- by hand with grooves of
camshafts -arrows-.
– Check proper alignment through recess, and adapt position by
turning.

Ameo 2017 ➤ , Polo 2014 ➤ , Polo 2018 ➤ , Polo KH
. VolIN
ksw2015
agen A➤
gen AG G do
3-cylinder injection engine (1.0 l engine,V4olkV,
swaEA 211) - Edition 05.2019es n
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– Fit adapter for camshaft housing - ris 007/11-
VAStho611 -D- to eo
camshaft housing, and slide it on. ss
au ra
c
ce
le
– Tighten knurled screws -arrows a- alternately by hand.
un
pt
an
d
itte
y li
– Make sure that adapter for camshaft housing - VAS 611
rm
ab
007/11- -D- is properly seated.
pe
ility
ot
wit
, is n
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hole
Note
spec
es, in part or in w
t to the co
♦ If camshaft housing adapter - VAS 611 007/11- -D- touches
the housing of the coolant pump, the basic setting of the cool‐
ant pump is incorrect.
rrectness of i
♦ In this case, correct adjustment or testing of the valve timing
l purpos
is not possible.
♦ The coolant pump must be removed and readjusted
nform
ercia
⇒ “2.3 Removing and installing coolant pump”, page 201 .

m
a
com
ti
• Test tool - VAS 611 007- must rest flush against camshaft
on in
housing.
r
te o
thi
s
iva
– Make sure that brakes on angle sensor - VAS 611 007/1- are
do
r
rp
c
released on both sides ⇒ page 116 .
um
fo
en
ng
t.
yi Co
op
– Tighten locking ring - VAS 611 007/2- -B- on both sides evenly
C py
ht. rig
by hand. When doing this, ensure that camshaft housing rig ht
py by
Vo
adapter - VAS 611 007/11- -D- always lies flat against cam‐
co lksw
by
cted agen
shaft housing -1-. Prote AG.
• Camshaft housing adapter - VAS 611 007/11- -D- should not

lift off of camshaft housing -1-.
Note
♦ The correct preload is achieved when the camshaft housing

adapter - VAS 611 007/11- lies flat against the camshaft hous‐
ing.
♦ If the locking ring - VAS 611 007/2- is tightened too much, the
camshaft housing adapter - VAS 611 007/11- will lift off of the
camshaft housing. This will falsify the result of the measure‐
ment.

– Make sure that brakes -a- are released on both sides.
2.5.3 Teaching in test tool - VAS 611 007-

electronically and performing basic set‐
ting
AG. Volkswagen AG d
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an
d
– Connect electronic measuring equipment of test tool - VAS

itte
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611 007- ⇒ Operating manual .

rm
ab
pe
ility
– Perform software installation of test tool - VAS 611 007- ⇒

ot
wit
, is n
Operating manual .
h re
hole
spec
– Start test program ⇒ Operating manual .

es, in part or in w
t to the co
– If the angle sensors are not connected, the message shown

in the illustration is displayed.
– Connect test tool - VAS 611 007- , and press CONNECT .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– If the test tool - VAS 611 007- is connected, the display is as

shown in the illustration.
ANW - Exhaust camshaft, red
ENW - Inlet camshaft, blue
– Turn adapter for angle sensor - VAS 611 007/13- -E- of ex‐
haust camshaft.
– If »OK« is displayed, the exhaust camshaft has been taught-
in.
– Turn adapter for angle sensor - VAS 611 007/12- -E- of inlet
camshaft.
– If the display is as shown in the illustration, the exhaust cam‐

shaft has been taught-in.
– Select function MEASURE .
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– When the angle display appears, the valve timing can be

wit
, is n
checked or adjusted h re
hole
⇒ “2.6 Checking valve timing”, page 121 . spec

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
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Cop py
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pyri by
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co lksw
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cted agen
Prote AG.

– Make sure that the brake indicator on the display is »green«.

– Display must not be »yellow« or »red«.
A - »Green«, brake is released
B - »Yellow«, brake is applied
C - »Red«, brake has been tightened to final torque
AG. Volkswagen AG d
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2.6 Checking valve timing aut
hor eo
ra
ss c
ce
le
un
pt
an
d

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erm
ab
ility
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om

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♦ Set of plugs for engine - VAS 6122-
Preliminary work for the procedure:

– Remove upper part of toothed belt guard
⇒ “2.3 Removing and installing toothed belt guard”,
page 106 .
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– Loosen clamp -4- and disconnect hose -3-.

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– Remove cover -2-.

ole,
spec
– Set piston in cylinder no. 1 to “TDC” position for repair work on

t to the co
toothed belt drive

– Preassemble test tool - VAS 611 007-
rrectne
⇒ “2.5.1 Preassembling valve timing tool”, page 114 .

s
– Install test tool - VAS 611 007- ⇒ page 117 .

s o
cial p
f inform
mer
Checking valve timing:

atio
om
n
c
– Make sure that brakes -a- on test tool - VAS 611 007- are re‐
i
or
n thi
e
leased on both sides.

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– Make sure that the brake indicator on the display is »green«

-A-.
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– Turn crankshaft 2 turns in direction of rotation of engine.
– Screw in locking pin - T10340- .
rrectness of i
– Set piston in cylinder no. 1 to »TDC« position
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
– Read valve timing angles on display, and compare values with
cum
for
specifications.
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Cop py
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pyri by
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by
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Specified angle in ° Inlet camshaft Exhaust camshaft

0.0°±1.5° -0.5°±1.5°
NOTICE
Adjust valve timing as precisely as possible. The settings must
be as close to the specifications as possible.
The valve timing must not be outside the tolerance limits.
– If the valve timing is not OK, adjust valve timing

⇒ “2.7 Adjusting valve timing”, page 124 .

Assemble in reverse order of dismantling. The following should

be observed:
– Install upper toothed belt guard
⇒ “2.3 Removing and installing toothed belt guard”,
page 106 .
Note
Renew bolts that are tightened with turning further angle.
– Renew O-rings, seals and gaskets after each removal.

AG. Volkswagen AG d
Specified torques agen oes
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♦ ⇒ “2.2 Assembly overview - toothed belt”, pageri105 se
d
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♦ ⇒ Fig. ““Plug for TDC drilling in cylinder block
ss a - specified tor‐
u ra
c
que”“ , page 106
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♦ ⇒ “2.2 Assembly overview - thermostat”, page 199
ility
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2.7 Adjusting valve timing
h re
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spec
t to the co
rrectness o
cial p
f inform
mer
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♦ Supplement set for MPI engines testing tool - VAS 611 007/18- C py
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♦ Set of plugs for engine r-iseVAS
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6122- ran
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Procedure
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• Toothed belt installed

nform
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– Check valve timing ⇒ “2.6 Checking valve timing”, page 121 .

m
at
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– Do not relieve tension from toothed belt, and do not remove
n
c
in t
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toothed belt from camshafts when adjusting valve timing. Only

o
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loosen camshaft adjuster.

at
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– Loosen camshaft adjuster on inlet side
for
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page 144 . C py
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– Loosen toothed belt sprocket on exhaust side
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⇒ “3.5 Removing and installing toothed belt pulley”, Prote
cted AG.
agen
page 149 .
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
Note
♦ Place a cloth under the camshaft adjusters and over tension‐

ing roller to catch the engine oil which runs out.
♦ The contact points between the toothed belt and components
- such as camshaft pulleys, tensioning roller and idler pulley -
must be kept free of oil.
♦ Catch any engine oil which runs out immediately, and remove
it.
♦ Remove any engine oil which ran out from camshaft adjusters
after the engine has been cranked.
– Place a cloth under the camshaft adjusters and over tension‐

ing roller to catch the engine oil which runs out.

– Renew bolts -1- and -2- and screw in loosely

page 144 .
– It should still be possible to turn the camshaft adjuster and
toothed belt sprocket on the camshafts.
Setting camshafts to »0°«:

– Make sure that bolts -a- for brakes on test tool - VAS 611 007-
are released on both sides.
AG. Volkswagen AG d
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-A-.
ility
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spec
t to the co
rrectness o
cial p
f inform
mer
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c
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or
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– Set both camshafts to »0.0°«.
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– To do this, turn camshafts with adapter for angle sensor - VAS

611 007/12- and -VAS 611 007/13- -E-.
– Hold camshafts in »0.0°« position using adapters for angle
sensor - VAS 611 007/12- and -VAS 611 007/13- -E- and a
hexagon key.
Note
AG. Volkswagen AG d
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♦ The camshafts tend to turn. Volksw
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♦ Use a hexagon key to hold the camshafts ino»0.0°«
ris
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position. nte
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♦ Always remove the hexagon key after the
ss a
camshafts have c
been tightened.
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– Tighten brakes after adjustment has been completed.
erm
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– Tighten bolts -a- for brakes on test tool - VAS 611 007- to
wit
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11 Nm on both sides.
h re
hole
spec
– Make sure that the brake indicator on the display is »red«
es, in part or in w
t to the co
-C-.
– Display must not be »yellow« or »green«.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.

– Tighten camshaft adjuster on inlet camshaft to specified initial
torque ⇒ page 147 .
– Tighten toothed belt sprocket of exhaust camshaft to specified
initial torque ⇒ page 147 .

– Make sure that brakes -a- on test tool - VAS 611 007- are re‐
leased on both sides.
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t to the co
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tion in
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te o
thi
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– Seal camshaft adjusters -2-, as shown, using suitable plugs

-A- from engine bung set - VAS 6122- .
– Fit a piece of paper into plugs to catch the engine oil.
– Insert plugs into camshaft adjusters with the open side facing
towards front, as shown in illustration.
Determining correction angle:
– Read valve timing on display and write down values.

1st measurement example: value read-off display
Note
♦ The correction angle is determined for each individual vehicle.

♦ The value read after the engine has been cranked is used for
determining the correction angle.
♦ Note the algebraic signs of the values.
♦ The correction angle results from the difference between the
specification and the value which has been read after the
crankshaft has been cranked twice.
♦ The correction angle is used to adjust the valve timing.
♦ The difference between the actual value (read after 2 full rev‐
olutions of the engine) and the specification (see table) is
AG. Volkswagen AG d
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♦ The result is the correction angle to be set, with the
ise corre‐
db ua
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sponding algebraic sign/direction of rotation. ut
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Example:
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Index Explanation
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e Inlet camshaft - actual value (after 2 full revolutions of
wit
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the engine)
h re
hole
spec
f Inlet camshaft - specification (+/- tolerance)
es, in part or in w
t to the co
c Direction of correction (+/-)
d Correction value - correction angle
rrectness of i
a Exhaust camshaft - actual value (after 2 full revolutions
of the engine)
l purpos
b Exhaust camshaft - specification (+/- tolerance)
nf
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Angle in ° Inlet camshaft Exhaust camshaft
Co
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Specified value 0.0°±1.5° -0.5°±1.5°
ht
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– Set determined correction angle for camshafts.

Setting valve timing with correction angle:
– Place a cloth underneath camshaft adjuster to catch any en‐
gine oil which runs out.
– Remove plugs taken from engine bung set - VAS 6122- from
camshaft adjuster.
– Remove paper from plugs and camshaft adjusters.
– Clean camshaft adjusters with a cleaning cloth, and remove
as much engine oil as possible.
– Loosen camshaft adjuster on inlet side
page 144 .

AG. Volkswagen AG d
agen oes
olksw not
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Ameo 2017 ➤ , Polo 2014 ➤ , Polo 2018th➤ o , Polo KH IN 2015 ➤
r eo
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3-cylinder injection engine (1.0 l engine,
ss a 4 V, EA 211) - Edition 05.2019 c
ce
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un
pt
– Loosen toothed belt sprocket on exhaust side
an
d
itte
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⇒ “3.5 Removing and installing toothed belt pulley”,
erm
ab
page 149 .
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NOTICE
h re
ole,
spec
Risk of damage to engine caused by incorrect valve timing.
t to the co
– Do not turn crankshaft out of TDC position.
rrectne
ss o
– Make sure that bolts -a- for brakes on test tool - VAS 611 007-
cial p
f in
are released on both sides.
form
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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cted agen
Prote AG.

-A-.
– Set the two camshafts to the determined correction angle
⇒ page 128 .
– To do this, turn camshafts with adapter for angle sensor - VAS

611 007/12- and -VAS 611 007/13- -E-.

If the valve timing has been set:. Volkswage

n AG n AG d
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– Tighten bolts -a-y Vfor
olksbrakes on test tool - VASs n611
ot g 007- to
ua
11 Nm on both
ised b sides. ran
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hole
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es, in part or in w
t to the co
– Make sure that the brake indicator on the display is »red«
-C-.
rrectness of i
– Display must not be »yellow« or »green«.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Tighten camshaft adjuster on inlet camshaft to specified initial
initial torque ⇒ page 147 .
– Release brakes -a- on test tool - VAS 611 007- on both sides.


-A-.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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au ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
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h re
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– Seal camshaft adjusters -2- again, as shown, using suitable
spec
plugs -A- from engine bung set - VAS 6122- .
es, in part or in w
t to the co
– Fit a new piece of paper into plugs -A- to catch the engine oil.
rrectness of i
l purpos

nf
ercia
o
– Check valve timing ⇒ “2.6 Checking valve timing”, page 121 .
rm
m
atio
om
n in
NOTICE
or c
thi
te
Adjust valve timing as precisely as possible. The settings must
sd
iva
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be as close to the specifications as possible.

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cu
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ng
The valve timing must not be outside the tolerance limits.

t.
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– Read valve timing, and compare it with specifications.
p by
co Vo
by lksw
cted agen
Prote AG.
Specified angle in ° Inlet camshaft Exhaust camshaft

0.0°±1.5° -0.5°±1.5°
– If the valve timing is not OK, adjust valve timing again

⇒ “2.7 Adjusting valve timing”, page 124 .
Assembly is carried out in reverse sequence; note the following:
– Make sure that brakes on test tool - VAS 611 007- are released
on both sides.
– Tighten camshaft adjuster on inlet camshaft to specified final
final torque ⇒ page 148 .
Specified torques
♦ ⇒ “2.2 Assembly overview - toothed belt”, page 105

♦ ⇒ Fig. ““Plug for TDC drilling in cylinder block - specified tor‐

que”“ , page 106
♦ ⇒ “2.1 Assembly overview - crankcase breather system”, page
171
2.8 Removing toothed belt from camshaft

equipment required
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ility
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es, in part or in w
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rrectness of i
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om
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ate
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for
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♦ Torque wrench - VAS 6583- C py
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♦ Counterhold - T10172- with adapter -T10172/1- and -
p by
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T10172/2- Prote
cted AG.
agen


Procedure
– Set piston in cylinder no. 1 to TDC position.
– Remove upper part of toothed belt guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”,
page 106 .
– Loosen securing bolt for camshaft adjuster on inlet side
⇒ “3.4 Removing and installing gcamshaft
AG. Volksadjuster”,
wagen AG
page 144 . a en does
olksw not
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– Loosen securing bolt ris of toothed belt pulley on exhaust side ntee
e ra
⇒ “3.5 Removing tho
and installing toothed belt pulley”, or
au ac
page 149 . ss
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un
pt
– Loosen bolt -1- with tool insert - T10500- .
an
d
itte
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– Release tension on tensioning roller at eccentric -2- using
rm
ab
pe
ility
wrench - T10499- .
ot
wit
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– Remove toothed belt from camshaft pulleys.
h re
hole
spec
Installing
es, in part or in w
t to the co
Note
rrectness of i
♦ The camshaft pulleys are not circular.
l purpos
♦ If one or both camshaft pulleys have been loosened, they must

be properly aligned with each other.
nform
ercia
♦ It should just be possible to turn camshaft pulleys on cam‐

m

com
tion in
♦ The toothed belt has not yet been fitted.

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Align marked gap -1- in teeth of camshaft adjuster -3- with lug
Co
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-2- of camshaft housing. t. C rig
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by c lksw
cted agen
Prote AG.
Align marked tooth -1- of exhaust camshaft pulley -3- with lug

– Markings -1- and -2- on camshaft pulleys are aligned as

shown.
Groove -3- for assembly tool - T10476A- is located on exhaust
camshaft pulley.
– Insert assembly tool - T10476A- between camshaft pulleys.
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– Arrows -1- on assembly tool are aligned with marks -2- on
ility
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camshaft pulleys.
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Note
es, in part or in w
t to the co
When the assembly tool - T10476A- is inserted, the marks -2- on
the camshaft pulleys are slightly offset.
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Dowel pin -1- of assembly tool - T10476A- must engage in
om
n in
groove -2- of exhaust camshaft pulley.
or c
thi
te
– Hand-tighten belt tensioner on cylinder head. sd

iva
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Prote AG.

Note
When installing the toothed belt, ensure that the assembly tool -
T10476A- is correctly positioned between the camshaft pulleys.
– Toothed belt must make full contact with crankshaft pulley.

– Check that crankshaft is set to TDC for No. 1 cylinder.
The crankshaft must make contact with the locking pin - T10340-
in direction of engine rotation.

– Fit toothed belt -1- onto belt tensioner -5- and camshaft pulley
-2-.
– Fit toothed belt on camshaft adjuster -3-, then push onto idler
or guide pulley -4-.
– Remove assembly tool - T10476A- from camshaft pulleys.
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pt
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– Rotate eccentric -2- of belt tensioner using tensioning spanner
erm
ab
ility
-T10499A- in -direction of arrow- until adjustment pointer -3-
ot p
is located approx. 10 mm to the right from adjustment window.
wit
, is n
h re
hole
– Then rotate eccentric of belt tensioner back on 12-point sur‐
spec
face -2- until adjustment pointer -3- is exactly centred in ad‐
es, in part or in w
t to the co
justment window.
– Hold eccentric on 12-point surface -2- in this position.
rrectness of i
l purpos
Note
When setting the specified torque on the torque wrench - VAS
nf
ercia
6583- , the length indicated on insert tool, 13 mm - T10500- must
orm
be entered in the torque wrench.
m
atio
om
n in
or c
thi
e

t
sd
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Note
Co
Cop py
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♦ When the engine has been rotated by hand or by engine op‐
p by
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by lksw
eration, the position of the adjustment pointer might be slightly Prote
cted AG.
agen
offset from the adjustment window.
♦ However, this has no relevant influence on the valve timing.
The toothed belt does not need to be retensioned.
– Tighten camshaft adjuster and toothed belt pulley in 2 stages.

T10172- to hold camshaft in position (apply force »anti-clock‐
wise«).
– Tighten bolt -1- to initial specified torque ⇒ page 147 .

– Tighten bolt -1- to initial specified torque ⇒ page 147 using

counter-hold tool - T10172- with adapters -T10172/2- and -
T10172/1- .
AG. Volkswagen AG d
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The securing bolts will be tightened further at the end of
aut the work
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sequence after the valve timing has been checked. ss c
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pe
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Note
h re
hole
spec
After completing work, make sure that the locking pin - T10340-
es, in part or in w
has been removed.
t to the co
Continue installation in reverse order of removal.
rrectness of i
Specified torques
l purpos

♦ ⇒ “2.2 Assembly overview - toothed belt”, page 105
nform
ercia
♦ Plug for hole in cylinder block ⇒ page 106

m
a
com
tion in
r
te o
thi
s
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 51
iva
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fo
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
en
ng
t.
tion; Assembly overview - noise insulation Cop
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Prote AG.

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 138
⇒ “3.2 Measuring axial play of camshaft”, page 139
⇒ “3.3 Removing and installing camshaft oil seal”, page 140
⇒ “3.4 Removing and installing camshaft adjuster”, page 144
⇒ “3.5 Removing and installing toothed belt pulley”, page 149
⇒ “3.6 Removing and installing valve stem seals”, page 152
3.1 Assembly overview - valve gear
1 - Cylinder head
stalling cylinder head”,
page 91
❑ Machining the cylinder
head sealing surface on
the cylinder block
⇒ “3.2 Measuring axial
play of camshaft”,
page 139
2 - Roller rocker fingers AG. Volkswagen AG d
agen oes
❑ Check roller bearing for olksw not
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❑ Before assembly, lightly aut
h
ra
oil contact surfaces to ss c
ce
e
valves and rollers.

nl
pt
du
an
❑ When installing, secure

itte
y li
erm
to supporting element
ab
ility
using securing clip.

ot p
wit
, is n
3 - Support element
h re
hole
spec
❑ Do not interchange
es, in part or in w
❑ With hydraulic valve

t to the co
clearance compensa‐
tion.
rrectness of i
❑ Oil contact surface

l purpos
4 - Valve spring plate

5 - Valve springs
nf
ercia

rm
m

atio
m
stalling valve stem

o
n in
c
seals”, page 152

or
thi
te
sd
iva
6 - Cotters
o
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rp
cu
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f
7 - Valve stem seal

en
ng
t.
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op
❑ Renewing ⇒ “3.6 Removing and installing valve stem seals”, page 152 C py
t. rig
gh ht
yri
8 - Valves
p by
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cted
❑ Do not rework
agen
Prote AG.
❑ Lapping in valve seats is permitted

❑ Before assembly, lightly oil valve stems and ends of valves

3.2 Measuring axial play of camshaft

Special tools and work‐
shop equipment re‐
quired
♦ Universal dial gauge
bracket - VW 387-
lkswage es n
o ot g
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d ran
ir se tee
o
♦ Dial gauge - VAS auth or
ac
6079- ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Checking camshaft axial

clearance
nform
ercia
Take measurements
with camshaft housing
m
a
com
ti
removed.
on in
r
te o
thi
– Apply thumb pres‐

s
iva
sure to one of the

do
r
rp
middle cams of the

um
fo
en
g
camshaft and move

n
t.
yi Co
camshaft back and Cop py
. rig
forth to check axial
t
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play. cop Vo
by lksw
cted agen
Prote
Wear limit: max.
AG.
0.25 mm
Machining cylinder head sealing surface on cylinder block

• The dimension reference point is the centre of hole 14H7
-arrow-
3. Valve gear 139

Measure
Reworking dimension of cylinder head: a (centre of hole 14H7 to
combustion chamber surface of cylinder head) = 58 mm ± 0.1
mm.
Note wage
es n
olks ot g
byV ua
If dimension is less than -a-, machining
ir se
d
the cylinder head is not ran
tee
permitted! autho
or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
3.3 Removing and installing camshaft oil
ility
ot p
seal
wit
, is n
h re
hole
spec
⇒ “3.3.1 Removing and installing camshaft oil seal, pulley end”,
es, in part or in w
page 140
t to the co
⇒ “3.3.2 Removing and installing camshaft oil seal, gearbox end”,
page 142
rrectness of i
3.3.1 Removing and installing camshaft oil
l purpos
seal, pulley end
nf
ercia
orm
m
♦ Extractor hook - T20143/1-
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Assembly tool - T10478B-

♦ Counter-hold - T10172A-
Removing
– Loosen plug of camshaft adjuster and unscrew.
page 144
– Loosen securing bolts of toothed belt pulley and camshaft ad‐
juster.
page 149
Note
AG. Volkswagen AG d
agen oes
lksw not
♦ When adjusting the valve timing, both camshaftd bpulleys must
o
yV gu
ara
be loose. orise nte
eo
h
ut ra
♦ Therefore, both camshaft pulleys must sbe
s loosened even if
a c
only one seal is being renewed.
ce
e
nl
pt
du
an
itte
y li
– Unscrew securing bolt for camshaft pulley and remove toothed
erm
ab
belt pulley or camshaft adjuster.
ility
ot p
wit
, is n
– Remove seal -1- using extractor hook - T20143/1- .
h re
hole
spec
Installing
es, in part or in w
t to the co
Note
rrectness of i
Do not lubricate new seal.
l purpos
– Put together assembly sleeves - T10478/2- and -T10478/3- in

nform
mercia
at
om
ion
c
in t
or

his
ate
T10478/2- .
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Valve gear 141

– Pull off assembly sleeve - T10478/3- in -direction of arrow-.

– Fit assembly sleeve - T10478/2- with seal -1- on camshaft
housing.
Inlet side
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
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ce
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nl
pt
du
an
itte
y li
erm
ab
– Draw in thrust piece - T10478/1- onto stop using old securing
ility
ot p
bolt of camshaft adjuster -2-.
wit
, is n
h re
hole
Exhaust side
spec
es, in part or in w
t to the co
Note
rrectness of i
When installing the seal of the exhaust camshaft, bolt - T10478/4-
is used for this purpose.
l purpos
Continued for inlet and exhaust side
nform
ercia
– Install camshaft adjuster.

m
at
om
io
page 144
n
c
in t
or
his
e
– Install toothed belt pulley

at
do
riv

p
cum
or
page 149 .
f
en
ng
t.
yi Co
– Adjust valve timing ⇒ “2.7 Adjusting valve timing”, page 124 . Cop py
ht. rig
rig ht
Further assembly is basically a reverse of the dismantling se‐ py by
co Vo
quence.
by lksw
cted agen
Prote AG.
Specified torques
♦ Cover for coolant pump toothed belt
♦ Securing bolts for camshaft pulleys and tensioning roller
55
Crankcase plug 30 Nm
3.3.2 Removing and installing camshaft oil

seal, gearbox end


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Extractor hook - T20143-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
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ng
t.
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Removing
Co
Cop py
ht. rig
ht
– Remove toothed belt pulley for coolant pump
rig by
opy Vo
⇒ “2.6 Removing and installing toothed belt pulley for coolant by c lksw
cted agen
pump”, page 214 .
Prote AG.
– Carefully fit extractor hook - T20143/1- between camshaft and

seal -1-.
– Lever out seal -1-.
Installing
Note
Do not lubricate new seal.
– Put together assembly sleeves - T10479/2- and -T10479/3- .

T10479/2- .
3. Valve gear 143

– Disconnect assembly sleeves - T10479/2- and -T10479/3- in

– Fit assembly sleeve - T10479/2- with seal -1- on camshaft.

– Fit thrust piece - T1047971- onto assembly sleeve and draw
it in to stop with securing bolt -2-.
– Install toothed belt pulley for coolant pump
⇒ “2.6 Removing and installing toothed belt pulley for coolant
pump”, page 214 .
• After completing work, it is essential to make sure that the
locking pin - T10340- has been removed.
quence.
Specified torques
♦ Crankcase plug: 30 Nm
♦ Securing bolt of camshaft housing cover
⇒ Item 14 (page 89)
3.4 Removing and installing camshaft ad‐

juster wage
e ks s no
Vol t gu
Camshaft adjuster for inlet camshaft ed by ara
ris nte
Special tools and workshop utho
equipment required eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Counter-hold - T10554/1-
♦ Knurled screws - T10554/2- (not illustrated)

lkswage es n
o ot g
yV
Preparing tools d b ua
ran
ir se tee
o
– Bolt on counter-hold tool - T10172-
auth
and counter-hold tool - or
ac
T10554/1- using knurled screws - T10554/2- -arrows-. ss ce
e
nl
pt
du
Removing
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ Place a cloth under the camshaft adjuster and tensioning roller

spec
to catch the engine oil which runs out.

es, in part or in w
t to the co

rrectness of i
l purpos
– Set piston of cylinder no. 1 to TDC position

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Valve gear 145

Fitting counter-hold tool - T10554-

• The contours of pins -1- and -2- of counter-hold tool -
T10554/1- are not distributed evenly on the bolt circle.
• They correspond to the contour of the bolt circle in the cam‐
shaft adjuster.
Note
♦ When opening the plug on the inlet camshaft, a small amount

of oil may escape.
♦ Therefore, cover the area around the plug with a cloth.

T10172- to lock camshaft in position (push in »clockwise
direction«).
– Loosen plug -1-, and unscrew it.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
146
agen
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
– Fit counter-hold tool - T10554/1- with counter-hold tool -

T10172- again, to loosen securing bolt -1- of camshaft adjust‐
AG. Volkswagen AG d
er. ksw
agen oes
n ol ot g
yV ua
– Loosen bolt
ise
d-1-
b of camshaft adjuster -2-. ran
r tee
ho
– Loosenau securing bolt of toothed belt pulley
t
on exhaustor aside.
c
ss Removing and installing toothed belt pulley”,
⇒ “3.5
ce
e
page 149
nl
pt
du
an
itte
y li
– Remove toothed belt from camshafts
erm
ab
⇒ “2.8 Removing toothed belt from camshaft”, page 133 .
ility
ot p
wit
, is n
– Unscrew securing bolt for camshaft adjuster and remove cam‐
h re
shaft adjuster.
hole
spec
es, in part or in w
Installing
t to the co
Note
rrectness of i
♦ Risk of damage to crankshaft group
l purpos
♦ Camshafts are located in “TDC” position.
nf
ercia
o
♦ The camshaft pulleys are properly aligned with each other.
rm
m
atio
m
♦ Crankshaft is in “TDC position”.

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
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♦ Renew O-ring of plug if damaged.
p by
co Vo
by lksw
cted agen
♦ Make sure to reinstall the guide sleeve ⇒ Item 11 (page 56) .
Prote AG.
– Renew bolt -1- for camshaft adjuster on inlet side. Screw in

bolt onto stop by hand.
– Renew bolt -2- for toothed belt pulley on exhaust side, and
screw it in to stop by hand.
• It should just be possible to turn camshaft pulleys on cam‐
– Align camshaft pulleys. Fit toothed belt onto pulleys
Pre-tightening
Note
♦ If the camshafts are turned when pre-tightening with the crank‐

shaft fixed in place using the locking pin - T10340- , the valve
timing will be changed.
♦ If the crankshaft is not locked in place, the deviations that oc‐
cur when counter holding will be transferred to the crankshaft
via the toothed belt.
♦ The valve timing will not be affected in this case.
– Before pre-tightening, unscrew locking pin - T10340- .

– Hold inlet camshaft in position using counter-hold tool -
T10554- and counter-hold tool - T10172- .
3. Valve gear 147

– Pre-tighten bolt -1- to specified pre-tightening torque in two

stages.
Stage Securing bolt for camshaft Specified torque
adjuster
1 -1- 18 Nm
2 -1- 50 Nm n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
– Hold inlet camshaft in position using counter-hold tool -rised ran
tee
T10172- and adapter - T10172/1- . utho
or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
stages.
wit
, is n
h re
Stage Securing bolt for toothed Specified torque
hole
spec
belt pulley
es, in part or in w
t to the co
1 -1- 18 Nm
2 -1- 50 Nm
rrectness of i
Tightening to final specified torque
l purpos
– Screw locking pin - T10340- back in.
nf
ercia
orm
m
atio
– Tighten bolt -1- for camshaft adjuster to final specified torque.
om
n in
or c
Stage Securing bolt for camshaft Angle to turn bolts
thi
te
sd
a
adjuster
iv
o
r
rp
cu
o
m
1 -1- 135°
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Tighten securing bolt for toothed belt pulley on exhaust side

to final specified torque.
Stage Securing bolt for toothed Angle to turn bolts
belt pulley
1 -1- 90°

– Screw in plug -1-, and tighten it to specified torque.

T10172A- and counter-hold tool - T10554- .
Stage Plug for camshaft adjuster Specified torque
1 -1- 20 Nm
Further assembly is performed in the reverse order of removal.
Specified torques
♦ Assembly overview - cylinder block (pulley end)
55
♦ Assembly overview - cylinder head
n AG. Volkswagen A
♦ Assembly overview - poly V-belt
olks
wagdrive
e G do
es n
o
⇒ “1.1 Assembly overview
d by - poly V-belt drive”, page 51 t gua
V
r e an
ris tee
♦ Assembly overview tho- coolant pump and thermostat or
au
⇒ “2.2 Assembly
s overview - thermostat”, page 199
s ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
pulley
ility
ot p
wit
, is n
Toothed belt pulley for exhaust camshaft
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
♦ Counter-hold - T10554/1- ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Knurled screws - T10554/2- (not illustrated)
3. Valve gear 149

Removing
– Set piston in cylinder no. 1 to TDC position.
– Loosen securing bolt -2- for camshaft adjuster on inlet side
page 144 .
– Loosen bolts -1- approx. 1 turn using counter-hold tool -
T10172- with adapter -T10172/2- and -T10172/1- .
– Detach toothed belt from camshafts.
– Unscrew bolt for toothed belt pulley on exhaust side, and re‐
move toothed belt pulley.
Installing
• Camshafts are located in “TDC” position.
• The camshaft pulleys are properly aligned with each other.
• Crankshaft is in “TDC position”.
AG. Volkswagen AG d
Note agen oes
olksw not
y V gu
d b ara
ise nte
♦ Renew bolts that are tightened
thor with turning further angle. eo
au ra
♦ Renew O-ring of plugs if damaged.
s c
ce
le
un
pt
an
d
itte
y li
– Renew bolt -1- for camshaft adjuster on inlet side, and screw
erm
ab
it in to stop by hand.
ility
ot p
wit
is n
– Renew bolt -2- for toothed belt pulley on exhaust side. Screw
h re
ole,
in bolt onto stop by hand.

spec
• It should just be possible to turn camshaft pulleys on cam‐

t to the co

– Fit toothed belt onto camshafts.
rrectne

Pre-tightening
ss o

cial p
f in
T10554- and counter-hold tool - T10172- .

form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
150
c by lksw
cted agen
Rep. gr.15 - Cylinder head, valve gear Prote AG.

stages.
Stage Securing bolt for camshaft Specified torque
adjuster
1 -1- 18 Nm
2 -1- 50 Nm
T10172- and adapter - T10172/1- .

stages.
Stage Securing bolt for toothed Specified torque
belt pulley
1 -1- 18 Nm
2 -1- 50 Nm
Tightening to final specified torque
– Tighten bolt -1- for camshaft adjuster to final specified torque.
olks
wage es n
ot g
yV ua
db ran
Stage Securing bolt for camshaft Angle to turn boltsorise tee
adjuster au
th or
ac
ss
1 -1- 135°
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Tighten securing bolt for toothed belt pulley on exhaust side
to final specified torque.
rrectness of i
l purpos
Stage Securing bolt for toothed Angle to turn bolts

belt pulley
nform
ercia
1 -1- 90°
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Valve gear 151

swage es n
– Screw in plug -1-, and by V tighten it to specified torque. t gua
o lk o
d ran
ir se
– Hold inlet camshaft
tho in position using counter-hold tool - tee o
T10172A- andss
au counter-hold tool - T10554- . ra
c
ce
le
Stage Plug for camshaft adjuster Specified torque

un
pt
an
d
itte
y li
1 -1- 20 Nm
erm
ab
ility
ot p
Further assembly is performed in the reverse order of removal.
wit
is n
h re
Specified torques:
ole,
spec
• ⇒ “1.2 Assembly overview - cylinder block (pulley end)”, page
t to the co
55
• ⇒ “1.1 Assembly overview - poly V-belt drive”, page 51
rrectne
• ⇒ “1.1 Assembly overview - cylinder head”, page 88
• ⇒ “2.2 Assembly overview - thermostat”, page 199
ss o
cial p
f inform
3.6 Removing and installing valve stem
mer
atio
seals
om
n
c
i
or
n
⇒ “3.6.1 Removing and installing valve stem seals (cylinder head
thi
te
sd
a
installed)”, page 152

iv
o
pr
cum
r
fo
⇒ “3.6.2 Removing and installing valve stem seals (cylinder head

en
ng
t.
removed)”, page 156
yi Co
Cop py
t. rig
3.6.1 Removing and installing valve stem
gh ht
pyri by
Vo
co
seals (cylinder head installed)
by lksw
cted agen
Prote AG.

♦ Spark plug socket - 3122 B-
♦ Removal and installation device for valve cotters - VAS 5161A-

with guide plate - VAS 5161A/32-32- .
♦ Compressed air adapter - VAS 5161 A/35- (not illustrated)

♦ Valve stem seal fitting tool - 3365-
♦ Valve stem pliers - VAS 6770-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
Procedure
h re
hole
spec
– Remove camshaft housing
es, in part or in w
⇒ “1.3 Removing and installing camshaft housing”, page 97 .
t to the co
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.
rrectness of i
– Remove roller rocker fingers together with compensation ele‐
l purpos
ments and place them on a clean surface.

– Unscrew spark plugs with spark plug socket - 3122 B- .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Valve gear 153


– Set piston of respective cylinder to “bottom dead centre”.
Note
♦ The pistons of cylinders no. 1 and no. 4 are at »TDC« position

after the camshaft housing has been removed.
♦ The pistons of cylinders no. 2 and no. 3 are at »bottom dead
centre« position after the camshaft housing has been re‐
moved.
♦ Crank engine via crankshaft half a turn in direction of engine
rotation. The pistons for cylinders no. 1 and no. 4 are at »bot‐
tom dead centre« position.
♦ When cranking the engine, hold and guide the toothed belt bywagen AG. Volkswagen AG doe
hand to prevent it from being damaged. Vol
ks s no
t gu
d by ara
e nte
ris
utho eo
ra
– Fit guide plate -VAS 5161A/32-1- onto cylindersshead
a and se‐ c
cure with knurled screws -VAS 5161/12- .
ce
e
nl
pt
du
an
– Screw compressed air adapter - VAS 5161 A/35- into the re‐
itte
y li
spective park plug thread hand-tight.
erm
ab
ility
ot p
– Connect adapter to compressed air supply using a commer‐
wit
, is n
cially available union and apply pressure continuously.
h re
hole
spec
• Minimum pressure: 6 bar.
es, in part or in w
t to the co
– Insert punch -VAS 5161/3A- into guide plate. Use a plastic
hammer to knock loose the firmly seated valve cotters.
rrectness of i
l purpos
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
nform
ercia
– Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and

m
insert cartridge into guide plate -VAS 5161A/32-3- .
at
om
ion
c
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– Release pressure fork. Prote AG.
– Remove installation cartridge.

– Unbolt guide plate and move to side.
• The compressed air hose remains connected.
– Remove valve spring and valve spring plate.

– Pull off valve stem seal using valve stem pliers - VAS 6770- .
Note
Risk of damage when installing valve stem seals.
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– Release the spring washer. The spring force pushes the wash‐
agen
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er back upwards and holds the valve cotters in place.
– Press assembly cartridge - VAS 5161A/32-1- onto insertion
device from above and pick up valve cotters.
– To do this, move knurled screw back and forth to press apart
valve cotters and capture them in assembly cartridge.
3. Valve gear 155

– Bolt guide plate -VAS 5161A/32-1- onto cylinder head again.

– Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS
5161A/32-3- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Assembling
– Install spark plugs ⇒ Maintenance ; Booklet .
– Install camshaft housing
⇒ “1.3 Removing and installing camshaft housing”, page 97 .
Specified torques
3.6.2 Removing and installing valve stem

seals (cylinder head removed)
♦ Removal and installation device for valve cotters - VAS 5161A-
with guide plate - VAS 5161A/32-32- .
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♦ Cylinder head tensioning device - VAS 6419-
♦ Valve stem pliers - VAS 6770-
♦ Valve stem seal fitting tool - 3365-
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– Remove cylinder head

rrectness of i
– Insert cylinder head tensioning device - VAS 6419- into engine

and gearbox support - VAS 6095- .
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– Tension cylinder head on cylinder head tensioning device as

shown in illustration.
nform
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– Connect cylinder head tensioning device to compressed air.

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3. Valve gear 157

– Fit guide plate -VAS 5161A/32-1- onto cylinder head and se‐
cure with knurled screws -VAS 5161/12- .
– Insert punch -VAS 5161/3A- into guide plate. Use a plastic
hammer to knock loose the firmly seated valve cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and
insert cartridge into guide plate -VAS 5161A/32-3- .
– Attach pressure fork -VAS 5161/2- to toothed piece and press
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove installation cartridge.
– Unbolt guide plate and move to side.
– Remove valve spring and valve spring plate.
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gen AG
– Pull off valve stem seal using valve stem pliers - VASVo6770-
lksw .
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– Lightly oil sealing lip of valve stem seal -A-.

– Carefully press valve stem oil seal -A- onto valve guide using
valve stem seal fitting tool - 3365- .
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If valve cotters have been removed from assembly cartridge:

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– First, insert valve cotters into insertion device - VAS 5161 A/
erm
ab
32-3- .
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– Fit valve cotters into grooves.
spec
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• Larger diameter of valve cotters faces upwards.
t to the co
– Release the spring washer. The spring force pushes the wash‐
er back upwards and holds the valve cotters in place.
rrectness of i
– Press assembly cartridge - VAS 5161A/32-1- onto insertion
l purpos
device from above, and pick up valve cotters.

– To do this, move knurled screw back and forth to press apart
nf
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valve cotters and capture them in assembly cartridge.
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– Bolt guide plate -VAS 5161A/32-1- onto cylinder head again. n in

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– Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS

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5161A/32-3- into guide plate.

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– Press pressure fork downwards and pull knurled screw up‐

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wards, turning it clockwise and anticlockwise. This inserts the Cop py
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– Repeat procedure on each valve.

– Install cylinder head
3. Valve gear 159

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4 Inlet and sexhaust
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⇒ “4.1 Checking valve guides”, page 160
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♦ Universal dial gauge bracket - VW 387-
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♦ Dial gauge - VAS 6079-
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Test sequence
– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Determine lateral play by moving valve in
Wear limit: 0.5 mm
If wear limit is exceeded:
– Repeat measurement with a new valve.
If wear limit is exceeded again:
– Renew cylinder head.

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 161
⇒ “1.2 Engine oil:”, page 164
⇒ “1.3 Removing and installing sump”, page 165
⇒ “1.4 Removing and installing oil pump”, page 168
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 170
1.1 Assembly overview - sump/oil pump
1 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 163 .
2 - Camshaft case
3 - Cap
❑ Renew seal if damaged.
4 - Non-return valve
5 - Seal
6 - Oil separator
❑ To remove, intake mani‐
fold must be removed
stalling intake manifold”,. Volkswagen AG
page 261 .kswagen AG does
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❑ Install by V sealant ⇒
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7 - Bolt
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❑ 9 Nm
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8 - Oil pressure switch - F1-

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❑ Checking oil pressure

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⇒ “3.2 Checking oil

pressure and oil pres‐
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page 176 .
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❑ Specified torque: 20 Nm
❑ Renew O-ring after
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1. Sump, oil pump
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9 - Connector
10 - Oil filter
❑ Observe fitting instructions on oil filter
❑ Remove and install with oil filter tool - 3417- .
❑ If the connecting union for oil filter in sump became loose ⇒ page 163
❑ Specified torque: 20 Nm
11 - Sump
❑ Removing and installing ⇒ “1.3 Removing and installing sump”, page 165
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
12 - Bolt
❑ Renew
13 - Nut
❑ 9 Nm
14 - Oil level and oil temperature sender - G266-
❑ Removing and installing AG. Volkswagen AG d
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⇒ “1.5 Removing and installing by Voil level and oil temperature sender
ol not
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15 - Seal oris tee
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❑ Renew ss
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16 - Suction line
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18 - Seal
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❑ Removing and installing ⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”, page 67
rrectness of i
19 - Bolt
❑ 20 Nm
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20 - Seal
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❑ Renew
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New procedure for all other service

t
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types ⇒ page 164

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21 - Oil drain plug
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Note Prote AG.
Needs to be renewed only on 1st oil

change after assembly in factory
⇒ page 163 .
❑ 30 Nm
22 - Oil pump
❑ Renew only as complete unit
❑ Removing and installing ⇒ “1.4 Removing and installing oil pump”, page 168
162 Rep. gr.17 - Lubrication

23 - Bolt
❑ Renew
24 - Seal
❑ Renew
Tightening connecting union for oil filter

• If the connecting union -2- in the sump -1- became loose, re‐
tighten it as described below.
Use only the two nuts -3 and 4- for this procedure.
• Hexagon nut - 068 115 723- , qty. 2, ⇒ Electronic Parts Cata‐
logue
– Screw nuts -3- and -4- onto connecting union -2-, and coun‐
terlock them.
– Tighten connecting union -2- using nut -3-.
– Loosen the two nuts and remove them, taking care not to
loosen the connecting union.
Specified torques
Connecting union Specified torque
-2- 50 Nm
Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark:waDo
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ss field: top up, max. 0.5 l of
ce
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engine oil!
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Draining engine oil

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Oil drain plug with captive seal (factory-installed)

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1. Sump, oil pump 163

– On first oil change, oil drain plug with captive seal -1- is dis‐
posed of.
– Insert a new oil drain plug -3- with renewable seal -2-.
Oil drain plug with renewable seal (all future oil change services)
AG. Volkswagen AG d
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– Unscrew oil drain plug -2-, and dispose of old seal -3-.
hole
spec
– New oil seal -1- can be renewed individually when oil is
es, in part or in w
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changed in the future.
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1.2 Engine oil:
Note
After adding oil, always check correct oil level on oil dipstick.
⇒ page 163
Engine oil specifications

⇒ Maintenance ; Booklet
Changing engine oil: ⇒ Maintenance ; Booklet “Engine oil: drain”.
Note
The oil level must remain below the max. mark - danger of dam‐
age to catalytic converter! Markings ⇒ page 163 .

1.3 Removing and installing sump

♦ Oil filter tool - 3417-
AG. Volkswagen AG d
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♦ Special wrench d by XZN 14 - T10058-
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♦ Hand drill with plastic brush
agen
Prote AG.
♦ Scraper
♦ Applicator gun - VAS 6966-

♦ Silicone sealant ⇒ Electronic parts catalogue

Removing
Note
Observe ⇒ “3.1 Rules for cleanliness”, page 4 when working on

the lubrication system!
– Drain engine oil.

– Remove oil filter with oil filter tool - 3417- .
Only vehicles with air conditioner
Note
♦ The air conditioning system lines must not be opened.

♦ Prevent damage to condenser and refrigerant lines and hoses.
♦ Do NOT stretch, kink or bend lines and hoses.
Remove poly V-belt

– Remove air conditioner compressor: ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor .
– Secure air conditioner compressor to lock carrier.
Make sure lines are not kinked.
– Disconnect electrical connector -1- on oil level and oil temper‐
ature sender - G266- .
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– Remove securing bolts -arrows- for gearbox.

spec
es, in part or in w
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166
copy Vo
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Rep. gr.17 - Lubrication cted agen
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3-cylinder
horis injection engine (1.0 l engine, 4 V,teEA
e o 211) - Edition 05.2019
ut ra
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ss
– Unscrew all sump securing bolts -arrows-.
ce
le
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– Unscrew sump securing bolts on gearbox side -arrows- using

Allen key, long reach 5 mm - T10058- .
nform
mercia
a
com
tio
Note
n in
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s
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♦ The sump is sealed with liquid sealant.
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♦ When hardened, the sealant has a high adhesive strength.
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Cop py
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– Carefully lever off sump from cylinder block at recess -arrow-

using assembly lever.
– Remove sump. Loosen sump with light blows of a rubber
headed hammer if necessary.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Remove sealant residues on sump with a rotating brush, e.g.

an electric drill with plastic brush attachment (wear eye pro‐
tection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Observe use-by-date of sealant.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ The sump can be positioned more easily and with greater se‐
curity if M6 studs are inserted into the cylinder block flange at
two positions as guides.

– Cut off nozzle on tube at front marking (∅ of nozzle approx.

3 mm).
– Using applicator gun - VAS 6966- , apply silicone sealant to
clean sealing surface of sump as shown in illustration.
Sealant bead must be:
♦ 2 to 3 mm thick
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealing compound bead cannot be thicker, or excessive seal‐

ing compound will enter the sump and may block the oil suction
pipe strainer.
– Fit sump immediately and lightly tighten all sump securing

bolts.
– Tighten new sump securing bolts to 8 Nm + turn 90° further.
Specified torques for gearbox bolts: ⇒ Rep. gr. 34 ; Removing
and installing gearbox; Specified torques for gear box
Note
Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.
– Fill oil filter with engine oil and tighten it with oil filter tool -
3417- .
Specified torque: 20 Nm
– Replenish engine oil.
Engine oil capacity ⇒ “1.2 Engine oil:”, page 164 . agen
AG. Volkswagen AG d
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– Install air conditioner compressor: ⇒ Heating, air conditioning;
d byV gu
ara
Rep. gr. 87 ; Air conditioner compressor; Removingorise
and in‐ nte
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stalling air conditioner compressor . aut
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Install poly V-belt (only applies for vehicles equipped with air con‐
ce
le
un
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ditioning system)
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1.4 Removing and installing oil pump

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Removing
rrectne

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
ss o
nator; Removing and installing alternator .

cial p
f inform
– Remove toothed belt

mer

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168
by lksw
cted agen
Rep. gr.17 - Lubrication Prote AG.
– Remove sump
– Remove crankshaft oil seal on belt pulley end
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 67 .
– Remove tensioner for poly V-belt
62 .
– Unscrew oil pump securing bolts -1- and -2-.
– Pull oil pump in a straight line off dowel pins on cylinder block.
– Remove gasket -1- from dowel pins -arrows-.

AG. Volkswagen AG d
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Installing olksw not
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– Fit new gasket -1- onto dowel pins -arrows-.
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– Rotate oil pump gear to a position where 2 opposing notches t. Cop py
-arrows- are aligned vertically.
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– Fit oil pump onto dowel pins.
lksw
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– Tighten new securing bolts -1- to specified torque

⇒ page 170 .
– Tighten securing bolts -2- to specified torque ⇒ page 170 .
– Install new crankshaft oil seal on belt pulley end AG. Volkswagen AG d
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”, agen oes
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page 67 . d by V gu
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– Install tensioner for poly V-belt utho eo
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62 .
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Removing and installing alternator .
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Component Specified tor‐ Note Qty.
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Removing
Removing
• Engine oil drained ⇒ Maintenance ; Booklet .
– Unscrew bolts -1- and remove oil level and oil temperature
sender - G266- -item 4-.
Installing
Install in reverse order of removal, observing the following:
Note
Renew oil seal -2-. Moisten seal with oil before installing.
– Replenish engine oil, and check oil level ⇒ Maintenance ;

Booklet .
Specified torques
♦ Specified torque: 8 Nm

2 Crankcase ventilation
⇒ “2.1 Assembly overview - crankcase breather system”,
page 171
⇒ “2.2 Removing and installing oil separator”, page 172
2.1 Assembly overview - crankcase breather system
1 - Oil separator
stalling oil separator”,
page 172
2 - O-ring
❑ Renew
❑ Moisten with oil before
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2. Crankcase ventilation 171

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♦ Sealant ⇒ Electronic Parts Catalogue

Removing
Note
The throttle valve module - J338- need not be removed for this
procedure!
– Remove intake manifold

⇒ “4.2 Removing and installing intake manifold”, page 261 .

– Loosen and unscrew bolts in the sequence -9 to 1-.

– Carefully release oil separator from bonded joint.
Installing
Note
♦ Risk of soiling the lubrication system.

♦ Make sure to proceed with care to avoid any damage to the
sealing surfaces leading to leaks.
♦ To ensure this, never clean the sealing surfaces with mechan‐
ical means such as a flat scraper, for example.
♦ Cover open parts of engine.
– Thoroughly clean sealing surfaces on cylinder block and on oil

separator using commercially available sealant remover.
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2. Crankcase ventilation 173

3-cylinder injection engine (1.0 wl aengine,
gen AG 4 V, EA n211)
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The oil separator must be installed within 5 minutes of sealant
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♦ Securing bolts for intake manifold
⇒ “4.2 Removing and installing intake manifold”, page 261

3 Oil filter, oil pressure switch

⇒ “3.1 Removing and installing oil pressure switch F1 ”,
page 175
⇒ “3.2 Checking oil pressure and oil pressure switch”,
page 176
⇒ “3.3 Removing and installing oil filter housing”, page 177
3.1 Removing and installing oil pressure

switch - F1-
♦ Torque wrench - V.A.G 1331- agen
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The alternator must be covered with a cloth in order to avoid
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– Unplug connector -1-.

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Note
♦ The oil pressure switch is fitted with a captive seal.

♦ The seal is not designed for repeated use.
– Unscrew oil pressure switch -2- from cylinder head.

– Cut open the captive seal to renew it.
3. Oil filter, oil pressure switch 175

Installing
– Screw oil pressure switch -2- into cylinder head and tighten it
to specified torque ⇒ page 176 .
– Connect connector -1-.
– Remove cloth from alternator.
Specified torque for oil pressure switch
Oil pressure switch - F1- 20 Nm
3.2 Checking oil pressure and oil pressure switch

equipment required
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♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527 B-
♦ Adapter set - V.A.G 1594C-

Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test sequence
Note
The alternator must be covered with a cloth in order to avoid

damage due to spilled engine oil.
– Unplug connector -1-.
Note

– Unscrew oil pressure switch - F1- -2- from cylinder head.

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– Screw oil pressure switch - F1- into tester.

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– Screw tester into cylinder head in place of oil pressure switch.

ole,
spec
– Connect brown wire of tester to earth (-).

t to the co
– Connect voltage tester - V.A.G 1527B- to battery positive (+)

and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- .
rrectne
– Start engine and increase revolutions slowly. At 0.3…0.6 bar,

the LED must light up, otherwise the oil pressure switch must
ss
be renewed.
o
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– Increase engine speed further. At 2,000 rpm and an oil tem‐

mer
perature of 80°C; the oil pressure should be at least 2.0 bar.

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At higher engine speeds, the oil pressure must not exceed 7.0
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Specified torque Prote
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agen
♦ Specified torque for oil pressure switch ⇒ page 176
3.3 Removing and installing oil filter housing

3. Oil filter, oil pressure switch 177

♦ Oil filter tool - 3417-
Removing
Note
Observe ⇒ “3.1 Rules for cleanliness”, page

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• If connecting union -2- in sump -1- became loose, retighten it

as described below ⇒ page 163 .
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– Replenish engine oil.

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Engine oil capacity ⇒ “1.2 Engine oil:”, page 164

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Specified torque for oil filter

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Component Specified torque Conditions

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Cop py
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19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 179
⇒ “1.2 Checking cooling system for leaks”, page 180
⇒ “1.3 Draining and adding coolant”, page 183
1.1 Connection diagram - coolant hoses

⇒ “1.1.1 Connection diagram - coolant hoses, Polo 2014, Ameo”,
page 179
⇒ “1.1.2 Connection diagram - coolant hoses, Polo 2018”,
page 180
1.1.1 Connection diagram - coolant hoses, Polo 2014, Ameo
1 - Heat exchanger for heater

2 - Expansion tank
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stalling radiator”,
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page 261 rrectness of i
5 - Cylinder head and cylinder

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6 - Thermostat housing with
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page 201
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1. Cooling system/coolant 179

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3-cylinder injection engine (1.0 l engine, 4 sV, EA 211) - Edition 05.2019
au ra
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1.1.2 Connection diagram - coolant hoses, Polo 2018
du
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1 - Expansion tank
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❑ Check for leaks
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⇒ “1.2 Checking cooling
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system for leaks”,
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page 180
2 - Heat exchanger for heater
rrectness of i
3 - Thermostat housing with
l purpos
coolant pump
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page 201
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4 - Radiator/cooler
or
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page 225
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stalling intake manifold”,

page 261
6 - Cylinder head and cylinder
block
1.2 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
180 Rep. gr.19 - Cooling

♦ Adapter for cooling system tester - V.A.G 1274/8-
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To perform the leakage test correctly, first run a self-test on the

t to the co
cooling system tester - V.A.G 1274 B- .

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Self-test of cooling system tester - V.A.G 1274 B-

l purpos
– Operate cooling system tester - V.A.G 1274 B- several times.

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– Build up a pressure of 3.0 bar on cooling system tester .

– Observe pressure on pressure gauge of cooling system tester
for 30 seconds.
If no pressure builds up or if the pressure drops again:
The cooling system tester - V.A.G 1274 B- is leaking and should
not be used.
Test conditions
• Engine at operating temperature.
Test sequence
CAUTION
On a warm engine, the cooling system is under agenhigh pressure.AG does
AG. Volkswagen
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– Carefully open filler cap -1- on coolant expansion tank -2- in
hole
spec
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Note
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The coolant expansion tank and cap may have a different shape
l purpos
depending on the model year.

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– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- to coolant expansion tank.
– Using hand pump on tester, build up a pressure of approx.
1.5 bar.
• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
– If pressure drops by more Athan 0.2 bar, locate leaks and rectify
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un
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♦ The colder the engine, the lower the pressure loss.
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♦ If necessary, repeat the check while the engine is cold.
h re
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Check pressure relief valve in cap.
t to the co
Note
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year.
ss o
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– Screw cap -1- into adapter for cooling system tester - V.A.G
atio
1274/9- -2-.
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cooling system tester - V.A.G 1274 B- using connecting hose

sd
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Blue cap
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♦ The pressure relief valve must open at a pressure of 1.4 bar.
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Black cap
♦ The pressure relief valve must open at a pressure of 1.6 to
1.8 bar.
If the pressure relief valve opens prematurely:
– Renew cap.
1.3 Draining and adding coolant

⇒ “1.3.1 Draining coolant, Polo 2014, Ameo”, page 183
⇒ “1.3.2 Filling coolant, Polo 2014, Ameo”, page 185
⇒ “1.3.3 Draining and filling coolant, Polo 2018”, page 190
1.3.1 Draining coolant, Polo 2014, Ameo


equipment required
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♦ Coolant system charge unit - VAS 6096-

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♦ Cooling system tester - V.A.G 1274 B- C py
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♦ Safety glasses
♦ Safety gloves
CAUTION

sulation .
– Place drip tray for workshop hoist - VAS 6208- underneath.
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Draining coolant from radiator:
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– Open spring-type clip -arrow- and pull coolant hose off.
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♦ Do not reuse coolant which has been drained off.

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♦ Please observe disposal instructions!

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1.3.2 Filling coolant, Polo 2014, Ameo

form
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Special tools and workshop AG. Volkswagen AG d

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AG. Volkswagen
agen 4 V, EA 211)A-GEdition
3-cylinder injection engine (1.0 loengine, no 05.2019
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♦ Safety glasses ir se nte
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♦ The water used for mixing has a major influence on the effec‐
, is n
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tiveness of the coolant. Because the water quality differs from
hole
spec
country to country and even from region to region, the quality
es, in part or in w
of the water to be used in the cooling system has been speci‐
t to the co
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
for topping up or renewing coolant.
rrectness of i
♦ Use only coolant additives which conform with the ⇒ Elec‐
l purpos
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
nform
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damage to the engine.

m
at
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♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
ion
c
rosion damage as well as scaling. Such additives also raise
in t
or
the boiling point of the coolant. For this reason, the cooling
his
ate
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reliability under heavy loads, particularly in countries with trop‐
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must be used to determine the current anti-freeze value. Prote AG.
♦ The scale -1- of the refractometer is calibrated for the coolant

additives G12++ and G12evo.
additive G13.
♦ If it is not possible to ensure that the same type of coolant
additive is filled: always determine anti-freeze protection using
the scale for G13.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
♦ The temperature reading on the refractometer corresponds to
the »ice flocculation point«. Flakes of ice may start forming in
the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Recommended mixing ratios (use only distilled water for mixing):

Frost Coolant additive
protection to
-25℃ 40 %
-36°C 50 %
• Coolant: ⇒ Electronic Parts Catalogue .

– Connect coolant hose on bottom left to radiator.
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– Connect hose -3- to compressed air.
• Pressure: 6 to 10 bar

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to below atmospheric pressure. The needle on the gauge
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– Remove cooling system charge unit - VAS 6096- from coolant
expansion tank.
– Fill coolant up to “max.” mark -arrow- on coolant expansion

tank -1-.
– On vehicles with auxiliary heater, switch on auxiliary heater for
about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
• LED in the button must not light up.
– Start engine and run it for max. 2 min. at a speed of approx.
1,500 rpm.
– Fill coolant up to the overflow hole of the coolant expansion
tank while the engine is running.
– Tighten cap of coolant expansion tank until it engages.
– Run engine at idling speed until the coolant hoses on the ra‐
diator are heated up.
– Switch off engine and let it cool off.

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♦ Safety glasses
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– Open spring-type clip -1- and pull coolant hose off.
– Drain coolant.
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Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- or refractometer - T10007B-
must be used to determine the current anti-freeze value.
additives G12++ and G12evo.
additive G13.
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♦ Frost protection must be guaranteed
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ss conditions, down to approx.
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must be guaranteed down to at least -25°C.

t to the co
♦ The temperature reading on the refractometer corresponds to

the »ice flocculation point«. Flakes of ice may start forming in
the coolant below this temperature.
rrectne
♦ Never reuse old coolant.

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♦ Use only a water/coolant additive mixture as a slip agent for

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coolant hoses.
inform
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Coolant mixture ratio

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Procedure
– Connect coolant hose on bottom left to radiator.
– Engage clip -1- in direction of -arrow- using release tool - VAS

531 001- .
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– Fill coolant expansion oris tank of -VAS 6096- with at least 8 litresante
e
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of pre-mixed coolant
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th in correct mixture ratio: ra
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– Screw adapter for cooling system tester - V.A.G 1274/8- onto
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coolant expansion tank.

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ility
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spec
es, in part or in w
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Note
Exhaust air takes a slight quantity of coolant along with it; this
rrectness of i
should be collected.
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– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
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– Open valve -B-; turn lever in direction of flow to do this.

• The suction-jet pump reduces pressure in the cooling system
to below atmospheric pressure. The needle on the gauge
should move into the green zone.
– Also briefly open valve -A- (turn lever in direction of flow to do
this) so that hose on coolant expansion tank of cooling system
charge unit -VAS 6096- fills with coolant. gen AG
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pt
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– Close valve -B-.
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pressure in the cooling system is then sufficient for subse‐
spec
quent filling.
t to the co
Note
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♦ If the needle does not reach the green zone, repeat the proc‐
ess.
ss o
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♦ If vacuum drops, cooling system must be checked for leaks.
f inform
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– Pull off compressed air hose.
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• The vacuum in the cooling system causes the coolant to be

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drawn out of the coolant expansion tank of -VAS 6096- ; the
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cooling system is then filled.
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– Fill coolant up to “max.” mark.
– Install noise insulations ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
– On vehicles with auxiliary heater, switch on auxiliary heater for
about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor (press AC button).
• LED in the button must not light up.
– Start engine and run it for max. 2 min. at a speed of approx.
1500 rpm.
– Fill coolant up to the overflow hole of the coolant expansion
tank while the engine is running.
– Tighten cap of coolant expansion tank until it engages.
– Run engine at idling speed until both large coolant hoses on
radiator are heated up.
– Switch off engine and let it cool off.

– Check coolant level.

• The coolant level must be between the “min. mark” and the
“max. mark” when the engine is cold.
• When the engine is at operating temperature, it is permissible
that the coolant level is at the “max. mark” or above.
– Fill more coolant if necessary.
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2 Coolant pump, regulation of cooling

system AG. Volkswagen AG d
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⇒ “2.1 Assembly overview - coolant pump”, page 197 by Vo gu
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⇒ “2.2 Assembly overview - thermostat”, page 199 uthor eo
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⇒ “2.3 Removing and installing coolant pump”, page 201
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⇒ “2.4 Removing and installing thermostat”, page 205
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hole
pump”, page 214
spec
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⇒ “2.7 Removing and installing coolant temperature sender G62
”, page 215
2.1 Assembly overview - coolant pump
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1 - Thermostat housing
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(small circuit)”,
page 205
3 - Seal
❑ Observe proper seating
of gasket ⇒ page 199 .
❑ Lightly coat with coolant
before installing.
4 - Coolant pump
page 201
5 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by
hand so that it screws
into old thread Then
tighten bolt to torque.
tightening sequence
⇒ page 199
6 - Seal
2. Coolant pump, regulation of cooling system 197


❑ For toothed belt for coolant pump
8 - Bolt
❑ Renew
9 - Toothed belt
❑ Renew
❑ Removing and installing ⇒ “2.5 Removing and installing toothed belt for coolant pump”, page 211
10 - Camshaft sprocket
Note
♦ Before removing, set No. 1 cyl‐
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❑ Specified torque and tightening sequence ⇒ page 199
l purpos
13 - Cover
❑ For thermostat
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14 - Seal
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15 - Thermostat
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❑ For main coolant circuit (radiator)

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❑ Removing and installing ⇒ page 205
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16 - Bolts
❑ 12 Nm
❑ Observe tightening sequence ⇒ “2.3 Removing and installing coolant pump”, page 201

Note
Removing and installing coolant pump

Installation position of thermostat for large cooling circuit

• Must be positioned with centring pin in guide -arrow- in ther‐
mostat housing.
Installation position of gaskets AG. Volkswagen AG d

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2.2 Assembly overview - thermostat
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1 - Bolt
❑ 7 Nm
quence ⇒ page 201
2 - Thermostat cover
3 - Seal
❑ Ensure proper seating
❑ Renew
4 - Thermostat
❑ For main coolant circuit
(radiator)
❑ Commencement of
opening Polo 2014: ap‐
prox. 80°C
❑ Commencement of
opening Polo 2018: ap‐
prox. 87 °C
(extended circuit)”,
page 208
❑ Note installation posi‐
tion ⇒ page 201
5 - Bolt AG. Volkswagen AG d
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quence ⇒ page 201 d b ara
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❑ Commencement of opening Polo 2018: approx. 97°C
❑ Removing and installing ⇒ “2.4.1 Removing and installing thermostat (small circuit)”, page 205
❑ Note installation position ⇒ page 201
rrectness of i
7 - Seal
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❑ Renew
❑ Check for proper seating ⇒ page 201
nform
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❑ Clean sealing surface thoroughly.

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❑ Removing and installing ⇒ “2.4.1 Removing and installing thermostat (small circuit)”, page 205
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Tightening sequence for tightening thermostat housing to coolant

pump
– Tighten securing bolts -A- through -F- in sequence given.
Tightening sequence for tightening thermostat cover to thermo‐

stat housing
– Tighten securing bolts -A- through -D- in sequence given.
AG. Volkswagen AG d
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2.3 Removing and installing coolant pump


equipment required
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– Drain coolant
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Prote AG.
– Unscrew securing bolts -arrows- of cover -1-.
– Unclip line guide from cover.
– Take off cover -1-.
– Disconnect all coolant hoses -1- from coolant pump.

– Remove retaining ring -arrow- of gear selector cable.

n AG. Volkswagen A ge G do
swa es
– Remove gear selector
by
Vol cable -1- from selector lever
k not
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t to the co
– Unscrew securing bolts -1- through -5- of coolant pump in se‐
quence given.
rrectne
– Remove coolant pump and thermostat housing.
If the coolant pump is to be renewed:
ss o
cial p
f
– Remove thermostat housing
inform
⇒ “2.4.1 Removing and installing thermostat (small circuit)”,
mer
page 205 .
atio
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Installing
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the following:
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– If coolant pump has been renewed, install thermostat housing cop Vo
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⇒ “2.4.1 Removing and installing thermostat (small circuit)”, cted agen
Prote AG.
page 205 .
– Ensure proper seating of seals -arrows-.
– Moisten gasket with coolant.
Note
♦ Always adhere to the sequence of work steps given below

when installing the coolant pump.
♦ This ensures that the toothed belt is correctly tensioned.
♦ The following work steps must be carried out with the aid of a
2nd mechanic.
• Always renew the toothed belts in conjunction with the fitting

of a new coolant pump.
– Set no. 1 cylinder to TDC
– Fit toothed belt centrally onto camshaft pulley and coolant
pump toothed belt pulley.
– Mount coolant pump on cylinder head with securing bolts.
– First tighten securing bolts in sequence -1- to -5- to 10 Nm.

– Then, loosen all bolts by 360°.

– Using hexagon on coolant pump, preload coolant pump in
clockwise direction to 30 Nm using 10 mm hexagon socket,
item -6-, extension and torque wrench - VAS 6583- .
– For ease of use, fit torque wrench - VAS 6583- on vertically.

– Constantly keep torque wrench - VAS 6583- pushed to that
torque. The torque wrench may not be supported by the other
hand when doing this.
• To ensure the V-belt is not over tensioned, do not “over ten‐
sion” the torque wrench - VAS 6583- .
• Have a second mechanic tighten securing bolts -2-, -1- and
-5- to specified torque, while holding the torque wrench - VAS
6583- to the specified torque.
olkswagen AG
en AG. V
– Tighten securing bolts -2-, -1- and -5-
olksto 10 Nm
wag does
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– Tighten securing bolts, in sequence,
orise -3-, -4-, -5-, -1- and -2- to nte
12 Nm. auth eo
ra
ss c
– Install gearbox selector mechanism ⇒ Rep. gr. 34 ; Selector
ce
le
un
pt
mechanism; Removing and installing selector mechanism .
an
d
itte
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erm
ab
ility
ot p
– Install air filter housing wit

is n
⇒ “3.2 Removing and installing air filter housing”, page 258 . h re

ole,
spec
Specified torque:
t to the co

Thermostat housing to coolant pump 8 Nm
rrectne
Coolant pump 12 Nm
s
Toothed belt guard 8 Nm

s o
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f inform
mer
atio
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2.4 Removing and installing thermostat

o
n
c
i
or
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e
⇒ “2.4.1 Removing and installing thermostat (small circuit)”, page

t
sd
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205
i
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pr
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⇒ “2.4.2 Removing and installing thermostat (extended circuit)”, yi

t.
Co
page 208 t. Cop py
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2.4.1 Removing and installing thermostat (small circuit)
p by
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Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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nl
pt
du
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ility
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es, in part or in w
t to the co
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nform
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at
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Removing
– Remove coolant pump -1-
– Remove coolant pump -1- from thermostat housing -2-.
– Remove thermostat -3-.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Fit thermostat to coolant pump.
wage es n
– Centring pin of thermostat must be fitted
yV
olks into guide on coolant ot g
ua
pump. ise
d b ran
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ho
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ac
– Ensure proper seating of ss
gaskets -arrows-.
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nl
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es, in part or in w
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– Fit thermostat housing to coolant pump.

nf
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– Ensure proper seating of thermostat studs in guides -arrows-

orm
of coolant pump.
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Note
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If the guide pins have broken off, it is necessary to renew the

f
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coolant pump.
Co
Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Thread and tighten securing bolts -A- through -F- in sequence

given.
– Install coolant pump -1- n AG. Volkswagen AG do
wage
⇒ “2.3 Removing and installing coolant pump”,
Vo page 201 .
lks es n
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by ua
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– Install selector mechanism to gearbox: ris⇒ Rep. gr. 34 ; Se‐ tee
utho mechanism .
lector mechanism; Overview - selector or
a ac
ss
ce
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un
pt
an
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spec
Specified torque:
es, in part or in w
t to the co
Thermostat housing to coolant pump 8 Nm
rrectness of i
Coolant pump 12 Nm, observing tightening sequence
⇒ “2.3 Removing and installing coolant pump”,
l purpos
page 201
nform
mercia
a
2.4.2 Removing and installing thermostat (extended circuit)
com
tion in
r
te o
thi
s
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fo
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t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
ss c
ce
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un
pt
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ot p
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spec
t to the co
rrectness o
cial p
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form
mer
atio

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c

or
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i
o
pr
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fo

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t.
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op
♦ Special wrench - T10508-
C py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.

Removing
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 183V.olkswa
AG. gen AG
agen does
– Loosen clamp -4- and disconnectVhose
olks -3-.
w not
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y
db ara
– Unscrew bolts -arrows-. rise nte
tho eo
au ra
– Remove cover -2-. ss c
ce
le
un
pt
an
d
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erm
ab
ility
ot p
wit
is n
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spec
t to the co
– Remove thermostat using special wrench - T10508- .
rrectne
– Slightly push down special wrench - T10508- and turn it in
-direction of arrow- while doing so.
ss o
cial p
Installing
f inform
mer
atio
note the following:
om
n
c
i
or
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Cop py
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– Centring pin of thermostat must accurately be fitted into guide pyri by
Vo
o
by c
-arrow- on thermostat housing -1-.
lksw
cted agen
Prote AG.
– Install thermostat using special wrench - T10508- .

– Slightly push down special wrench - T10508- and turn it to stop
in -direction of arrow- while doing so.
– Ensure proper seating of gasket.

– Fit cover -1- on thermostat housing.

– Thread and tighten securing bolts -A- through -D- in sequence
given.
Specified torque:
AG. Volkswagen AG d
agen
Component Volksw
oes
not Specified torque
by gu
ara
Cover on oris thermostat housing
e d
nte 7 Nm
h eo
aut ra
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nl
pt
du
2.5 Removing and installing toothed belt for coolant pump

an
itte
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erm
ab
ility
ot p
wit
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spec
es, in part or in w
t to the co
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nf
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t.
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Cop py
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gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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un
pt
an
d
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ab
pe
ility
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wit
, is n
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hole
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es, in part or in w
t to the co
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nform
mercia
a
com
tion in
r
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thi
s
iva
do
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cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

Note
Renew toothed belt!

AG. Volkswagen AG d
agen oes
olksw not
Removing d by V gu
ara
rise nte
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CAUTIONs au ra
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s
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un
pt
an
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ab
ility
ot p
wit
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spec
– Remove air filter housing t to the co

rrectne
– Drain coolant
ss

o
cial p
f in
– Remove coolant pump -1- and toothed belt guard -2-

form
mer

atio
om
– Remove toothed belt from coolant pump toothed belt pulley.

n
c
i
or
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e
Installing
t
sd
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pr

um
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fo
en
ng
note the following:

t.
yi Co
op py
– Fit new toothed belt centrally onto camshaft pulley and coolant
t. C rig
gh ht
yri
pump toothed belt pulley. p by
co Vo
by lksw
cted agen
Prote AG.
Note
Always make sure to carefully follow the given procedure for in‐
stallation of the coolant pump.
– Install coolant pump -1-

Specified torque:
Coolant pump 12 Nm


Toothed belt guard 8 Nm

pulley for coolant pump
♦ Counterhold - T10172 A- with adapter -T10172/2-
Removing
– Set piston in cylinder no. 1 to TDC position for work on toothed
belt drive ⇒ “4.5 Setting piston to TDC position”, page 86 .
– Remove toothed belt for coolant pump
page 211 . wage
e ks s no
Vol t gu
– Mark position of coolant pump gear d b -1- with a marker -2- at lug
y ara
se
-3-. tho
ri nte
eo
au ra
c
ss
ce
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nl
Note
pt
du
an
itte
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ab
The marking will be used for installing the gear at the correct po‐
ility
ot p
sition at a later point.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Loosen bolt -1- using counterhold - T10172- with adapters -

T10172/2- .
l purpos
– Unscrew bolt -1- and remove toothed belt pulley -2-.

nform
ercia
Installing
m

at
om
ion
c
in t
– Fit toothed belt pulley:

or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Position of camshaft recesses:

• The grooves -1- and -2- in the camshaft are arranged asym‐
metrically.
• Cut-outs -arrows- in toothed belt pulley are also arranged
asymmetrically.
– Fit toothed belt pulley onto camshaft so that the asymmetrical
notches of the camshaft are fully centred within the cut-outs of
the toothed belt pulley.
– Fit toothed belt for coolant pump
page 211 .
Specified torque
♦ ⇒ “2.1 Assembly overview - coolant pump”, page 197
2.7 Removing and installing coolant temperature sender - G62-

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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nl
pt
du
an
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ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
o
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Removing
Fitting location: ⇒ Item 18 (page 90)
• Engine cold.
CAUTION

Note
The coolant expansion tank may have a different shape depend‐

ing on the model year.
. Volkswagen AG
gen AG does
swa
– Unlock and disconnect connector -2- from coolanty Vtempera‐
olk not
gu
ture sender - G62- -1-. rise d b ara
nte
tho eo
– Place a cloth under connecting piece to absorb
s au escaping cool‐ ra
c
ant. s
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
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Insert new coolant temperature sender - G62- immediately into

h re
cylinder head in order to avoid loss of coolant.

hole
spec
es, in part or in w
t to the co
– Unscrew bolt -arrow-.

Installing
rrectness of i

the following:
l purpos
– Check coolant level

nform
mercia
at
Specified torque:
om
ion
c
in t
or

his
ate
do
riv
Coolant temperature sender - G62- 8 Nm

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
216
Prote AG.
Rep. gr.19 - Cooling
3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 217
⇒ “3.2 Removing and installing coolant pipes”, page 218
3.1 Assembly overview - coolant pipes

⇒ “3.1.1 Assembly overview - coolant pipes, Polo 2014, Ameo”,
page 217
⇒ “3.1.2 Assembly overview - coolant pipes, Polo 2018”,
page 218
3.1.1 Assembly overview - coolant pipes, Polo 2014, Ameo
1 - Ball stud
❑ Specified torque 2.5 Nm
2 - Coolant pipe
3 - Coolant hose
❑ Schematic diagram
⇒ “1.1 Connection dia‐
gram - coolant hoses”,
page 179
4 - Coolant hose
page 179
5 - Bolt AG. Volkswagen AG d
agen oes
❑ Specified torque 20 Nm Volksw not
gu
by ara
d
6 - Coolant pipe rise nte
tho eo
au ra
7 - Coolant hose ss c
ce
e
nl
pt
du
an

itte
y li

erm
ab
page 179
ility
ot p
wit
, is n
8 - Coolant hose
h re
hole
spec
es, in part or in w

t to the co

page 179
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Coolant pipes 217

3.1.2 Assembly overview - coolant pipes, Polo 2018
1 - Coolant pipe
❑ Connection diagram
page 179
2 - Coolant pipe
page 179
3 - Bolt
❑ 20 Nm
4 - Coolant pipe
stalling coolant pipes”,
page 218
5 - Coolant hose
page 179
6 - Coolant hose
❑ Connection diagram agen
AG. Volkswagen AG d
oes
⇒ “1.1 Connection dia‐ olksw not
yV gu
gram - coolant hoses”, ised b ara
nte
page 179 ut
hor eo
a ra
s c
7 - Coolant hose s
ce
e
nl
pt
du
an
itte

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erm
ab

ility
ot p
page 179
wit
, is n
h re
8 - Coolant hose
hole
spec
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 179

es, in part or in w
t to the co
3.2 Removing and installing coolant pipes

rrectness of i

l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Drain coolant
– Open spring-type clips -arrows- and pull off coolant hoses.
– Unscrew bolt -1- and remove coolant pipe unit -2-.
Installing
Note
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .

Specified torques
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 217
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
3. Coolant pipes 219

4 Radiator, radiator fan

AG. Volkswagen AG d
agen oes
⇒ “4.1 Assembly overview - radiator/radiator fan”, page 220 Volksw not
gu
by ara
d
⇒ “4.2 Assembly overview - radiator cowl and radiator fan”, page rise nte
ho eo
223 aut ra
c
ss
⇒ “4.3 Removing and installing radiator”, page 225
ce
e
nl
pt
du
an
itte
y li
erm
ab
page 233
ility
ot p
⇒ “4.5 Removing and installing radiator fan V7 ”, page 235
wit
, is n
h re
hole
4.1 Assembly overview - radiator/radiator
spec
es, in part or in w
fan
t to the co
⇒ “4.1.1 Assembly overview - radiator/radiator fan, Polo 2014,
Ameo”, page 220
rrectness of i
⇒ “4.1.2 Assembly overview - radiator/radiator fan, Polo 2018”,
l purpos
page 222
4.1.1 Assembly overview - radiator/radiator
nf
ercia
or
fan, Polo 2014, Ameo
m
m
atio
om
n in
or c
thi
e
Note
t
sd
iva
o
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rp
cu
o
m
The arrows on the coolant pipes and on the ends of the hoses
f
en
ng
t.
yi
must be aligned with each other.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Radiator mounting
❑ Lower radiator mount‐
ing in front end
AG. Volkswagen AG d
2 - Plug ksw
agen oes
not
Vol gu
❑ Renew if damaged ed
by ara
nte
ris
❑ 10 Nm ut
ho eo
ra
a c
ss
ce
e
nl
pt
du
❑ Top
an
itte
y li
erm
ab
4 - Bolt
ility
ot p
❑ 5 Nm
wit
, is n
h re
❑ Qty. 2
hole
spec
5 - Radiator/cooler
es, in part or in w
t to the co
rrectness of i
page 225
l purpos
❑ After renewing, renew

entire coolant
nf
ercia
6 - Coolant hose
orm
m
atio
m

o
n in
c

or
thi
e
page 179
t
sd
iva
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rp
cu
7 - Expansion tank
o
m
f
en
ng
❑ Check cooling system

t.
yi Co
op
for leaks using cooling C py
t. rig
system tester - V.A.G
gh ht
pyri by
1274 B- and adapter for
co Vo
by lksw
cted
cooling system tester -
agen
Prote AG.
V.A.G 1274/8-
8 - Cap
❑ Check using cooling
system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
❑ Pressure relief valve must open at between 1.4 and 1.6 bar
9 - Bolt
❑ 2 Nm
❑ Qty. 2
10 - Connector
11 - Radiator cowl with radiator fan - V7-
❑ Assembly overview ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”, page 223
❑ Removing and installing ⇒ “4.4 Removing and installing radiator cowl with radiator fan”, page 233
❑ With radiator fan control unit - J293-
12 - Coolant hose
4. Radiator, radiator fan 221

AG. Volkswagen AG d
agen oes
lksw n
Ameo 2017 V , Polo 2014 ➤ , Polo 2018 ➤ot,gPolo
y➤
o
ua KH IN 2015 ➤
d b ran
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3-cylinderoris injection engine (1.0 l engine, 4 V, EA 211) tee - Edition 05.2019
th or
au ac
ss
4.1.2 Assembly overview - radiator/radiator
ce
le
un
pt
fan, Polo 2018
an
d
itte
y li
erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
The arrows on the coolant pipes and on the ends of the hoses
must be aligned with each other.
t to the co
rrectne
1 - Bolt
❑ 5 Nm
ss
❑ Qty. 2
o
cial p
f inform
mer
❑ For radiator
atio
om
n
c
i
3 - Radiator/cooler
or
n thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi
page 225
Co
Cop py
ht. rig
❑ Renew coolant after re‐ py
rig by
ht
placing co Vo
by lksw
cted agen
Prote
4 - Coolant hose
AG.
page 179
5 - Radiator cowl with radiator
fan - V7-
❑ Assembly overview
view - radiator cowl and
radiator fan”, page 223
stalling radiator cowl
with radiator fan”,
page 233
❑ With radiator fan control
unit - J293-
6 - Bonded rubber bush
❑ For radiator
7 - Coolant hose
8 - Plug
❑ 10 Nm

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2014, Ameo”, page 223
hole
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⇒ “4.2.2 Assembly overview - radiator cowl and radiator fan, Polo
es, in part or in w
2018”, page 224
t to the co
4.2.1 Assembly overview - radiator cowl and radiator fan, Polo 2014, Ameo
rrectness of i
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1 - Air guide ring

2 - Radiator fan - V7-
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4 - Nut
❑ 8 Nm
❑ Qty. 3
5 - Bracket
❑ For electrical connector
6 - Connector
❑ For radiator fan - V7- .
7 - Spreader rivet
❑ For securing air guide
ring
❑ Qty. 4
❑ Not available as individ‐
ual part

4.2.2 Assembly overview - radiator cowl and radiator fan, Polo 2018
1 - Radiator fan - V7-

stalling radiator fan V7 ”,
page 235
2 - Radiator cowl
page 233
3 - Nut
❑ 8 Nm
❑ Qty. 3
4 - Electrical connector
❑ For radiator fan - V7- .
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equipment required
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♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Guide pins - 3411-
♦ Torque wrench (5 … 13 Nm) - VAS 6854-
♦ Ratchet insert 1/4" - VAS 6234-
Note
Assembly overview - parts of cooling system, body side

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 220 .
Removing
sulation .
– Drain coolant from radiator
– Remove radiator cowl agen AG. Volkswagen AG d
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– Remove front bumper cover ⇒ General body repairs, exterior;
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– Unscrew securing bolts -arrows-.

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NOTICE cted agen
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Risk of damage to coolant pipes caused by deformation.

– Never attempt to reshape the coolant pipe.
CAUTION
Risk of freezing injury caused by refrigerant.
– Do not open refrigerant circuit of air conditioning system.


– Place condenser in lock carrier at front and secure it in place
to prevent it from falling down.
– Removing radiator.
Installing
AG. Volkswagen AG d
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Install in reverse order of removal. During thisVoprocedure,
lksw observe not
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– Tighten securing bolts -arrows- using torque wrench
(5 ... 13 Nm) - VAS 6854- and 1/4 inch ratchet insert - VAS
6234- .
rrectness of i
– Install front bumper cover ⇒ General body repairs, exterior;
l purpos

cover .
nform
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page 233 .
on
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Specified torques
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 220
4.3.2 Removing and installing radiator, Polo

2018

AG. Volkswagen AG d
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Ameo 2017 ➤ , Polo 2014 Vol➤ , Polo 2018 ➤ , Polo KH IN
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d ran
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♦ Torque wrench 2-10 Nm - VAG 1783-
♦ Lever - 3409-
Removing
– Drain coolant

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– Remove assembly frame -1- ⇒ General body
ss
a repairs, exterior;
u ra
c
Rep. gr. 50 ; Lock carrier; Removing and installing lock carri‐
ce
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un
er .
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page 233
wit
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– Pull off coolant hoses -1- from top left of radiator -2-.
nform
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– Separate electrical connector -4- and remove from its retainer

-arrow-.
– Press in locking tab on both sides using removal wedge -
3409- -1-.
– Push cowling -2- in direction of -arrow- slightly to gain access
to radiator mounting -3-.
Vehicles with original radiator mounting carrier

– Release catches -arrows- of radiator mounting -1- on left and
right, or cut through using side cutters.
Note
The radiator mounting carrier will be reused during installation. It

will then be bolted to the lock carrier. Bolts ⇒ ETKA (Electronic
parts catalogue) .

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Vehicles withbyradiator
Vo lk
mounting carrier, bolted ot g
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– Unscrew
tho bolts -2- of radiator mounting carrier -1-teeonor left and
right.
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– Push upper edge of radiator slightly in direction of engine.
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– Raise radiator, disengage from lower mounting points and

push backwards.
nform
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– Press catches -1- on both sides in -direction of arrow A- to

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ion in
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– Pull condenser -3- upwards in direction of -arrow B- and de‐

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– Lift out radiator -1- at bottom from radiator mountings
-arrows-.
– Remove radiator -1- upwards.
Installing
Note
If there are minor dents in the fins, refer to

⇒ “3.7 Fitting radiator and condensers”, page 5 .
– Insert radiator -1- at bottom into radiator mountings -arrows-.

– Bring condenser -3- into installation position.
AG. Volkswagen AG d
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Installation position of radiator mounting

– Fit radiator mountings -1- on left and right onto radiator. When
nf
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doing so, note the installation position -arrow-.
orm
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– Insert radiator in lock carrier. Ensure proper seating of radiator

mountings -1- in lock carrier.

Vehicles with radiator mounting carrier, bolted

– If fastener was cut off, bolt radiator mountings to lock carrier.
Bolts -2- ⇒ Electronic parts catalogue (ETKA) .
• Specified torque: 5 Nm
– Install assembly frame ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier; Removing and installing lock carrier .
– Install front bumper cover ⇒ General body repairs, exterior;
cover .
page 233 .
Specified torques
wage
4.4 Removing Vol and installing radiator t gucowl
ks s no e
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withri radiator fan
ed
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⇒ “4.4.1 Removing
ss and installing radiator cowl with radiator fan, c
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Polo 2014, Ameo”, page 233

nl
pt
du
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⇒ “4.4.2 Removing and installing radiator cowl with radiator fan,

y li
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Polo 2018”, page 234

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with radiator fan, Polo 2014, Ameo

spec
es, in part or in w
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Removing
Rep. gr. 66 ; Noise insulation .
rrectness of i
– Disconnect electrical connector -arrow-.

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nform
mercia
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– Using a suitable tool, release cowling together with radiator

fan - V7- from locking device.
– Remove cowling together with radiator fan - V7- upwards from
mountings. Remove cowling downwards.
– Then, lower the cowling at left, and swing it out at this angle.
Installing
the following:
– Move radiator cowling together with radiator fan - V7- to in‐
stallation position from below.
– Push evenly into all four mountings from above.
AG. Volkswagen AG d
agen oes
• The fan frame must engage audibly on the right and Vleft
olksat the
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top. se
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– Check that it has engaged securely by pulling
au on it.
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Specified torques
ce
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ility
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4.4.2 Removing and installing radiator cowl
wit
, is n
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with radiator fan, Polo 2018
hole
spec
es, in part or in w
Removing
t to the co
– Open catch -arrow- and lay coolant hose of radiator cowl
aside.
rrectness of i
CAUTION
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Danger of injury; the radiator fans can run at any time.
nf
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– Separate electrical connectors.
orm
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– Disconnect connector -arrow- from radiator fan.

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AG. Volkswagen AG d
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– Simultaneously pressblocking yV
o tabs on left and right of radiator
gu
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cowl -A- in direction ris of -arrow-.
ed
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– Pull radiator fan
ss a cowling upwards and remove from radiator ra
c
-arrows-.
ce
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Note
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Disregard item -3-.
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es, in part or in w
– Carefully remove radiator cowl downwards.
t to the co
Installing
rrectness of i
– Electrical connections and routing ⇒ Current flow diagrams,
l purpos
Electrical fault finding and Fitting locations.

• The fan frame must engage audibly on the right and left at the
nf
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o
top.
rm
m
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– Check that it has engaged securely by pulling on it.

o
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Specified torques
thi
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4.5 Removing and installing radiator fan - Cop py
ht. rig
V7-
rig ht
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cted agen
⇒ “4.5.1 Removing and installing radiator fan V7 , Polo 2014,
Prote AG.
Ameo”, page 235

⇒ “4.5.2 Removing and installing radiator fan V7 , Polo 2018”,
page 236
4.5.1 Removing and installing radiator fan -

V7- , Polo 2014, Ameo
Removing
– Remove noise insulation ⇒ Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation .
page 233 .
– Remove connector for radiator fan from retainer.
– Push pins out of spreader rivets -arrows-.

– Carefully lift up fan ring on back of radiator cowling using a

suitable tool. AG. Volkswagen n AG do
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– Remove fan ring. Volks ot g
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– Remove electric cable -1- from cable guide.
t to the co
– Unscrew nuts -arrows- and remove radiator fan - V7- .
rrectne
Installing
ss
the following:
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page 233 . Prote
cted AG.
agen
Specified torques
4.5.2 Removing and installing radiator fan -

V7- , Polo 2018
page 233 .
– Remove electric cable -1- from cable guide.
– Unscrew nuts -arrows-, and remove radiator fan - V7- .
Installing
page 233 .
Specified torques

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 237
⇒ “1.2 Assembly overview - fuel system”, page 244
1.1 Overview of fitting locations - injection

system
⇒ “1.1.1 Overview of fitting locations - injection system, Polo 2014,
Ameo”, page 237 olks
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⇒ “1.1.2 Overview of fitting locationsri-seinjection
d system, Polo nte
2018”, page 240 utho eo
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1.1.1 Overview of fitting locations - injection
ce
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nl
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system, Polo 2014, Ameo
an
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Overview of fitting locations - engine compartment
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1 - N205-
es, in part or in w
t to the co
2 - Ignition coils with output
stages
rrectness of i
♦ Ignition coil 1 with output
stage - N70-
l purpos

stage - N127-
nform
ercia

m
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stage - N291- ion

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stalling ignition coils

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with output stage”, page

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3 - Lambda probe 1 before cat‐
gh ht
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alytic converter - GX10-
op Vo
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❑ Consisting of
Prote AG.
Lambda probe before

catalytic converter - G39-
Lambda probe heater -

Z19-
installing lambda probe
1 before catalytic con‐
verter GX10 , Polo
2014, Ameo”,
page 277
4 - Lambda probe 1 after cata‐
lytic converter - GX7-
❑ Consisting of:
Lambda probe after cat‐
alytic converter - G130-
1. Injection system 237

Lambda probe 1 heater after catalytic converter - Z29-

⇒ “7.2.2 Removing and installing lambda probe 1 after catalytic converter GX7 , Polo 2014, Ameo”, page
279
5 - Engine control unit - J623-
❑ Removing and installing ⇒ “6.2 Removing and installing engine (motor) control unit J623 ”, page 269
6 - Throttle valve module - GX3-
❑ Consisting of:
Throttle valve module - J338-
Throttle valve drive for electronic power control - G186-
Throttle valve drive angle sender 1 for electronic power control - G187-
❑ Removing and installing ⇒ “4.3 Removing and installing throttle valve module GX3 ”, page 263
❑ Cleaning ⇒ “4.4 Cleaning throttle valve module GX3 ”, page 265
❑ Removing and installing ⇒ “1.4 Removing and installing Hall sender G40 ”, page 308
8 - Injectors
♦ Injector, cylinder 1 - N30-
❑ Removing and installing ⇒ “2.2 Removing and installing injectors”, page 246
❑ Checking ⇒ “2.3 Checking injectors”, page 248
9 - Activated charcoal filter solenoid valve 1 - N80-
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Installation location hor overview, intake side
is tee
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238 Rep. gr.24 - Mixture preparation - injection

AG. Volkswagen AG d
agen oes
olksw not
d byV Ameo 2017 ➤g,uaPolo
ran
2014 ➤ , Polo 2018 ➤ , Polo KH IN 2015 ➤
e
oris 3-cylinder injection enginetee (1.0 l engine, 4 V, EA 211) - Edition 05.2019
th or
au ac
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ab
stalling oil pressure
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ility
switch F1 ”, page 175
ot
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hole
and oil pressure switch
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⇒ “3.2 Checking oil
es, in part or in w
t to the co
sure switch”, page 176 .
2 - Intake manifold sender -
rrectness of i
GX9-
l purpos
❑ Consisting of
Intake air temperature
nform
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sender 2 - G299-
m
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Intake manifold pressure
on in
sender - G71-
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page 309
Installation location overview, exhaust side

1 - Knock sensor 1 - G61-

⇒ “1.3 Removing and in‐ agen
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2 - Radiator outlet coolant - aut ra
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ature sender G62 ”,
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1.1.2 Overview of fitting locations - injection

system, Polo 2018
Overview of fitting locations - engine compartment


1 - N205-
❑ Consisting of
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❑ Removing and installing ⇒ “1.2 Removing and installing ignition coils with output stage”, page 305
❑ Removing and installing ⇒ “6 Engine control unit”, page 268
6 - Throttle valve module - GX3-
❑ Consisting of:
Throttle valve module - J338-
Throttle valve drive for electronic power control - G186-
❑ Removing and installing ⇒ “4.3 Removing and installing throttle valve module GX3 ”, page 263
❑ Cleaning ⇒ “4.4 Cleaning throttle valve module GX3 ”, page 265

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♦ No. 1 cyl. injector - N30-
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❑ Removing and installing ⇒ “2.2 Removing and installing injectors”, page 246
t to the co
❑ Checking ⇒ “2.3 Checking injectors”, page 248
9 - Activated charcoal filter solenoid valve 1 - N80-
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Overview of fitting locations, intake side of engine
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2 - Intake manifold sender -

GX9-
❑ Consisting of
Intake air temperature
sender 2 - G299-
Intake manifold pressure

sender - G71-
stalling intake manifold
sender GX9 ”,
page 266
G28-
sender G28 ”,
page 309
Installation location overview, exhaust side

1 - Knock sensor 1 - G61-

stalling knock sensor 1
G61 ”, page 307
2 - Radiator outlet coolant -
G62-
stalling coolant temper‐
ature sender G62 ”,
page 215
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1.2 Assembly overview - fuel system
1 - Air filter
stalling air filter hous‐
ing”, page 258
❑ Consisting of
Lambda probe before
Z19-
❑ Grease only the threads
with “G 052 112 A3”;
“G 052 112 A3” cannot
get into the slots on the
probe body.
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❑ 50 Nm
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control unit J623 ”, page

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269
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If the engine control unit -

J623- needs to be renewed,
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connect ⇒ Vehicle diagnostic

tester and perform “Guided
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❑ If renewed, adapt engine control unit - J623- to electronic immobiliser ⇒ Vehicle diagnostic tester “Guided
nform
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4 - Bolt
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❑ For coolant temperature sender - G62-

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6 - Lambda probe 1 after catalytic converter - GX7-
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❑ Consisting of:
Lambda probe after catalytic converter - G130-
Lambda probe 1 heater after catalytic converter - Z29-

❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
⇒ “7.2.2 Removing and installing lambda probe 1 after catalytic converter GX7 , Polo 2014, Ameo”, page
279

❑ 50 Nm
7 - Bolt
❑ For knock sensor
❑ 20 Nm
8 - Knock sensor
❑ Removing and installing ⇒ “1.3 Removing and installing knock sensor 1 G61 ”, page 307
9 - Bolt
❑ 20 Nm
10 - Intake manifold
❑ Removing and installing ⇒ “4.2 Removing and installing intake manifold”, page 261
11 - Bolt
❑ 8 Nm
❑ Qty. 5
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❑ Injector, cylinder 3 - N32- ss a ra
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❑ Removing and installing ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 246
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13 - Bolt
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❑ 7 Nm
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2 Injectors
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 246
⇒ “2.2 Removing and installing injectors”, page 246
⇒ “2.3 Checking injectors”, page 248
⇒ “2.4 Cleaning injectors”, page 253
2.1 Assembly overview - fuel rail with injectors
1 - Supply line
❑ Black with white marks.
❑ Secure with spring-type
clips
❑ Ensure firm seating
❑ From fuel filter.
2 - Bolt
❑ 7 Nm
3 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
4 - Injection valve
❑ Injector, cylinder 1 -
N30-
N31-
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5 - Retaining clip
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spec
❑ Ensure correct seating

on injector and fuel rail
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6 - Injector seat
❑ Ensure proper seating of retaining clip on fuel rail.
rrectne
7 - Fuel rail with injectors

ss
❑ Checking injectors for leaks and quantity injected ⇒ “2.3 Checking injectors”, page 248
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2.2 Removing and installing injectors

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Rep. gr.24 - Mixture preparation - injection
Removing
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– Remove air filter housing olks
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– Release and pull off connectors
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– Unclip retaining clips -3- for wiring harness from fuel rail.
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in connectors; Disconnecting plug-in connectors . nform
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– Open line guide -3- and remove hoses.

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2. Injectors 247
– Unscrew bolts -2- from intake manifold.

– Pull fuel rail -7- with injectors -4- out of the intake manifold.
– Carefully remove retaining clip -5- of injector to be removed.
– Pull off injector from fuel rail. n AG. Volkswagen AG do
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– Ensure proper seating of injectors -4- on injector seat -6-.
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– If injectors were replaced, adapt learnt values with ⇒ Vehicle
diagnostic tester.
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♦ Guided Engine Functions
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♦ Adapting learnt values of injectors

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♦ Remote control for V.A.G 1348 - V.A.G 1348/3A-
♦ Adapter line - V.A.G 1348/3-2-
♦ Adapter set - V.A.G 1594 C-
♦ Injection rate tester - V.A.G 1602-
Checking injection quantity and spray pattern of injectors
Test conditions
• Fuel pressure OK ⇒ Rep. gr. 20 ; Fuel pump; Checking fuel
system pressurisation pump - G6-
Test sequence
2. Injectors 249
CAUTION
– Remove fuel rail together with injectors

⇒ “2.2 Removing and installing injectors”, page 246 .
Note
Insert fuel rail loosely in intake manifold to prevent any dirt from
entering when the test equipment is being connected.
• Do not disconnect fuel hoses.

• Injectors are not being removed from fuel rail.
• All connectors for the injectors must be disconnected.
– Connect one contact of injector to be checked to remote con‐
trol - V.A.G 1348/3-2- using test lead ( adapter cable - V.A.G
1348/3A- ).
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– Connect ⇒ Vehicle diagnostic tester as follows:

– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
Note
♦ During final control diagnosis, the relay for electronic fuel

pump will only be activated for 30 seconds.
♦ The button on the remote control - V.A.G 1348/3A- must be
pressed at the same moment as the final control diagnosis
begins.
♦ The remote control of V.A.G 1348 - V.A.G 1348/3A- must be
operated until no more fuel escapes from the injector.
– Switch on ignition.
– Press following buttons on display one after the other:
♦ 0001 - Bleed fuel system
Note
♦ After the check of one of the injectors has been completed,

switch the ignition off, on and off again, before beginning the
check of another injector.
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s
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♦ At the end of the final control diagnosis, there is still a small
quantity of fuel in the system which needs to be taken into
account.
♦ This quantity of approx. 6 ml of fuel needs to be subtracted rrectness of i
from the total quantity during calculation.
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♦ A sample calculation is provided in the table below.

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Total Remaining quantity in sys‐ Actual value

atio
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e.g.: - 6 ml = 81 ml
87 ml
Specification: 76…82 ml per injector
2. Injectors 251
If the measured values of one or more injectors are above or be‐

low the prescribed specifications:
– Renew defective injector
⇒ “1.2 Assembly overview - fuel system”, page 244 .
Check for leaks
Test conditions
• Fuel pressure OK.
• Engine and fuel temperature: approx. 20°C.
• Fuel rail is removed.
• Connectors of all injectors are disconnected.
CAUTION
– As a precaution, place a measuring glass - V.A.G 1602/1- un‐

der each injector.
Note
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♦ Injectors will not be actuated.
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♦ If fuel escapes from a valve, the valve is defective.

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– Connect ⇒ Vehicle diagnostic tester as follows:

– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Switch on ignition.
– Press following buttons on display one after the other:
♦ 0001 - Bleed fuel system
Specification: No more than 2 drops must escape during final
control diagnosis. Volkswa AG. gen AG
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– Renew defective injectorhoris tee
⇒ “1.2 Assembly s autoverview - fuel system”, page 244 . or
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Install injectors in the reverse order of removal, observing the fol‐
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Specified torques:
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♦ Fit fuel rail with secured injectors onto intake manifold and
es, in part or in w
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⇒ “1.2 Assembly overview - fuel system”, page 244 .
rrectness of i
2.4 Cleaning injectors
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♦ Ultrasonic cleaning device - VAS 6418-
nform
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♦ Mounting plate - VAS 6418/1-

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♦ Cleaning fluid Cleaning fluid - VAS 6418/2- ⇒ Electronic parts

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– Fill ultrasonic cleaning unit with 2120 ml of distilled water and
AG.
20 ml of cleaning fluid - VAS 6418/2- .
Note
♦ The ultrasonic unit must be filled with cleaning agent to upper

edge of holes (see detail).
♦ Observe safety instructions and operating instructions for the
ultrasonic unit.
Cleaning
– Remove injectors ⇒ page 246 .
2. Injectors 253
– Insert injectors -1- all the way into mounting plate - VAS
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♦ Before starting ultrasonic cleaning unit - VAS 6418- , it is es‐
sential that the safety information described in the operating
ss o
manual is observed.
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♦ The ideal fluid level is reached when the cleaning fluid is ap‐
mer
prox. 1 to 4 mm above the base of the mounting plate
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-magnified area-. The ultrasonic cleaner - VAS 6418- could

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– Set rotary knob -B- to a temperature of 50°C.

– Press button ► -D- to start the cleaning process.
Note
♦ Temperature-controlled cleaning is now activated. During the

warm-up period, ultrasonic waves are activated to mix the
cleaning fluid. Once the preselected temperature is reached,
the ultrasonic waves are switched to continuous operation.
♦ The cleaning time must be at least 30 minutes and cleaning
only starts at a temperature of at least 50°C.
– Immediately after cleaning, remove water residues from the

injectors.
– After cleaning, renew all seals on every injector.
– Installing injectors ⇒ page 246

3 Air filter
⇒ “3.1 Assembly overview - air filter housing”, page 255
⇒ “3.2 Removing and installing air filter housing”, page 258
3.1 Assembly overview - air filter housing

⇒ “3.1.1 Assembly overview - air filter housing, Polo 2014”, page
255
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♦ Self-tapping bolts are used in production to fasten the upper
h re
ole,
part of the air filter to the lower part of the air filter. When these
spec
screws are loosened or tightened using a power tool, the
threads in the intake manifold or the lower part of air filter may
t to the co
be damaged.
♦ For this reason, the use of a power tool is only permitted if the
rrectne
tool speed is max. 200 rpm and a max. specified torque of
1.6 Nm is set.
ss o
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3. Air filter 255

1 - Intake hose
2 - Bolt
❑ Qty. 11
❑ 1.6 Nm
3 - Air filter upper part
4 - Air filter element
❑ ⇒ Maintenance ; Book‐
let 808
5 - Air filter lower part
6 - Rubber mounting
❑ Ensure it is properly
seated.
7 - Seal
seated.
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3.1.2 Assembly overview - air filter housing,

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Polo 2018, Ameo

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Note
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es, in part or in w
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♦ Self-tapping bolts are used in production to fasten the upper

part of the air filter to the lower part of the air filter. When these
screws are loosened or tightened using a power tool, the
rrectness of i
threads in the intake manifold or the lower part of air filter may
be damaged.
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♦ For this reason, the use of a power tool is only permitted if the
tool speed is max. 200 rpm and a max. specified torque of
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4 - Air filter element
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❑ ⇒ Maintenance ; Book‐
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5 - Air filter lower part
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3. Air filter 257

3.2 Removing and installing air filter hous‐

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– Pull air filter housing upwards off studs at positions -2- and
-3-.
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– Push air filter housing and intake connecting pipe in
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-direction of arrow- out of mounting -4-.

– Remove air filter housing from engine compartment.
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– Unscrew bolts ⇒ Item 2 (page 256) for dismantling.
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– Ensure proper seating of air filter.

3.2.2 Removing and installing air filter hous‐

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points -3-.
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– Push air filter housing and intake connecting pipe in
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ole,
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– Remove air filter housing from engine compartment.
t to the co
– Unscrew bolts ⇒ Item 2 (page 257) for dismantling.
Installing
rrectne
the following:
ss o
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– Ensure proper seating of air filter.
inform
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3. Air filter 259

4 Intake manifold
⇒ “4.1 Assembly overview - intake manifold”, page 260
⇒ “4.2 Removing and installing intake manifold”, page 261
⇒ “4.3 Removing and installing throttle valve module GX3 ”, page
263
⇒ “4.4 Cleaning throttle valve module GX3 ”, page 265
4.1 Assembly overview - intake manifold
1 - Bolt
❑ Qty. 3
❑ 7 Nm
2 - Throttle valve module -
GX3-
❑ Consisting of:
Throttle valve module -
J338-
Throttle valve drive for

electronic power control -
G186-
Throttle valve drive angle

sender 1 for electronic
power control - G187-
Throttle valve drive angle

sender 2 for electronic
power control - G188-
❑ Cleaning
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- J338- ⇒ Vehicle diag‐

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❑ When bolted 3 Nm
7 - O-ring
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8 - Intake manifold
❑ Removing and installing ⇒ “4.2 Removing and installing intake manifold”, page 261
nform
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4.2 Removing and installing intake manifold

♦ Release lever - 80 - 200-
4. Intake manifold 261

Removing
– Release connector -2- and pull off.
– Pull hose -3- off intake manifold.
• If the intake manifold needs to be renewed, unscrew bolts
-arrows-, and detach throttle valve module - GX3- -1-. agen
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– Release and pull off connectors -1- and -2-.
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– Unclip wiring harness from retainers -3- on fuel rail and lay to
es, in part or in w
side.
t to the co
– Unclip line -4- from retainers -arrows-.
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– Remove line -4- together with activated charcoal filter system
solenoid valve 1 - N80- and lay to side.
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Specified torque:
Upper bolts on intake manifold ⇒ Item 4 (page 260) . 8 Nm
Lower bolts on intake manifold ⇒ Item 9 (page 261) . 20 Nm
♦ Remove intake manifold
♦ Specified torques, throttle valve module
⇒ “4.3 Removing and installing throttle valve module GX3 ”,
page 263 .
4.3 Removing and installing throttle valve

module - GX3-
Throttle valve module - GX3- consists of
♦ Throttle valve module - J338-
♦ Throttle valve drive for electronic power control - G186-
♦ Throttle valve drive angle sender 1 for electronic power control
- G187-
♦ Throttle valve drive angle sender 2 for electronic power control
- G188-

Removing
– Release and disconnect connector -2- from throttle valve mod‐
ule - GX3- -1-.
– Pull off hose -3-.
– Remove bolts -arrows- and detach throttle valve module -
GX3- .
Installing
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– Check throttle valve module - GX3- for cleanliness.
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h re
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trol unit - J623- with ⇒ Vehicle diagnostic tester.

spec
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♦ Adaption of throttle valve module - J338

rrectness of i

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Throttle valve module - GX3- to intake manifold 7 Nm

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4.4 Cleaning throttle valve module - GX3-
Note
♦ If a new engine control unit - J623- is installed the throttle valve

module must be adjusted. Adaptation is only allowed to be
made with a new or cleaned throttle valve module.
♦ Contamination and coking in throttle valve end stop can result
in incorrect adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.
– Remove throttle valve module

page 263 .
– Open throttle valve by hand, and use a suitable object to lock
it in open position (e.g. wood or plastic wedge) -arrow-.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.
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– Thoroughly clean throttle valve connection,
utho especially around eo
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closed throttle valve -arrows- using
ss acommercially available c
acetone to DIN 53247 and a brush.
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throttle valve module - GX3-

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spec
page 263 .
es, in part or in w
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– Adapt engine control unit - J623- to throttle valve module -

GX3- ⇒ Vehicle diagnostic tester “Guided Functions”.
rrectness of i
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au sender GX9 ”,
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5.1 Removing and installing intake manifold
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♦ Intake air temperature sender 2 - G299-
spec
es, in part or in w
♦ Intake manifold pressure sender - G71-
t to the co
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agen
– Release and disconnect connector from intake manifold send‐

er - GX9- .
– Carefully release locking lug -arrow-, and remove intake mani‐
fold sender - GX9- -2-.
Note
♦ If lug -arrow- breaks off, securing bolts ⇒ Electronic Parts

Catalogue (ETKA) may be used for securing instead.
♦ The intake manifold sender - GX9- may then also be bolted to
intake manifold -2-.
♦ In this case unscrew the bolts from holes -3-.
Installing
the following:
– Check seal for damage and renew if necessary.
Ensure that intake manifold sender - GX9- is properly seated and
securely engaged in intake manifold.
Note
♦ The intake manifold sender - GX9- may also be bolted to intake

manifold -2-.
♦ Observe allocation of bolts ⇒ Electronic Parts Catalogue (ET‐
KA) .

Specified torque:
Intake manifold sender - GX9- to intake manifold 3 Nm
AG. Volkswagen AG d
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5. Senders and sensors 267

6 Engine control unit

⇒ “6.1 Assembly overview - engine control unit”, page 268
⇒ “6.2 Removing and installing engine (motor) control unit J623
”, page 269
⇒ “6.3 Removing and installing engine (motor) control unit J623
with protective housing”, page 271
6.1 Assembly overview - engine control unit
1 - Bracket
control unit J623 ”, page
269
3 - Locking bar
control unit J623 with
protective housing”,
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❑ Allocation ⇒ Electronic rrectness of i
parts catalogue (ETKA)
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6 - Protective housing
7 - Bolt
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6.2 Removing and installing engine (motor)

control unit - J623-
⇒ “6.2.1 Removing and installing engine/motor control unit J623 ,
Polo 2014, Ameo”, page 269
⇒ “6.2.2 Removing and installing engine control unit J623 , Polo
2018”, page 270
6.2.1 Removing and installing gen AG

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♦ Risk of damage to the electronic components when discon‐

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– Disconnect engine control unit from protective housing

J623 with protective housing”, page 271 .
All versions
6. Engine control unit 269

– Using a screwdriver, lever out locking bar -1- of upper wiring

harness in direction of -arrow-.
– Using a screwdriver, lever out locking bars -2- of lower wiring
harness in direction of -arrow-.
– Pull connectors off engine control unit.
– Remove engine control unit.
Installing
Install in reverse order of removal.
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Note Prote AG.
Contact between the positive battery terminal and the engine

control unit will cause engine control unit damage. For this rea‐
son, the battery always needs to be disconnected prior to remov‐
ing the engine control unit from its bracket ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

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Volksw➤
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d b ua
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– Release catches in uthdirection of -arrow- and remove engine
o
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ss -1-.
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– Release and pull off connectors -2- for engine control unit -
pt
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J623- .
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– Remove engine control unit -1-.
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h re
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spec
t to the co
– Connect vehicle battery ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and connecting battery .
After a new engine (motor) control unit has been installed, the
rrectne
following work procedure must be carried out:
s
s o
cial p
f inform
– Switch on ignition and select the following menu options on
mer
vehicle diagnostic tester :
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♦ 01 - Engine electronics
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♦ Guided Functions
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control unit - J623- with protective hous‐

ing
⇒ “6.3.1 Removing and installing engine/motor control unit J623
with protective housing, Polo 2014, Ameo”, page 271
⇒ “6.3.2 Removing and installing engine control unit J623 with
protective housing, Polo 2018”, page 272
6.3.1 Removing and installing engine/motor

control unit - J623- with protective hous‐
ing, Polo 2014, Ameo
♦ Angle grinder e.g. axial grinder - VAS 6682-
Note
The protective housing is secured with shear-head bolts. The

shear-head bolts cannot be removed without being damaged.
Use e.g. the axial grinder - VAS 6682- or a commercially available
angle grinder to remove the shear-head bolts. If the protective
housing is damaged, it must be renewed.
Removing
– Remove engine control unit from holder
J623 ”, page 269 .
– Move clear wiring harness, and push it to one side as far as
possible.

– Remove bolts -A-. Remove retainer -B-.

– Remove engine control unit from protective housing.
Installing
the following:
– Push engine control unit into protective housing as far as it will
go.
– Fit locking element -B- onto protective housing, and secure it
with new shear bolts -A- ⇒ Electronic Parts Catalogue (ET‐
KA) .
– First, insert engine control unit into tab -2- of holder.

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6.3.2 Removing and installing engine control
t to the co
unit - J623- with protective housing, Polo
2018
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♦ Wiring harness repair kit - VAS 1978 B-
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♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle -2- from
wiring harness repair set - VAS 1978 B-
♦ Small grinder (commercially available)

♦ Vehicle diagnostic tester

Removing
Note

functions”.
Note
The protective housing is secured with shear-head bolts. The

shear-head bolts cannot be removed without being damaged.
Use e.g. the axial grinder - VAS 6682- or a commercially available
angle grinder to remove the shear-head bolts. If the protective
housing is damaged, it must be renewed.
– Switch off ignition and remove key from ignition lock.
Note
♦ If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence.
♦ Therefore, the battery must be disconnected before the engine
control unit is removed ⇒ Electrical system; Rep. gr. 27 ;
AG. Volkswagen AG d
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To remove protective housing -1-,bunscrew
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as follows: ris
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– Make groove (for a screwdriver) in head of shear bolt -1- using

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Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
– Set the hot air blower as shown in illustration. Meaning poten‐

tiometer for temperature regulation -2- set to maximum heat‐
ing power and 2-stage switch for air volume -3- set to position
3.
NOTICE
Risk of damage to adjacent components caused by hot air
blower. Risk of overheating.
– If necessary, cover adjacent components.
– Heat head of shear bolt -1- for approx. 20 to 30 seconds.
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– Unscrew shear bolt -1- with
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– Release catches in direction of -arrow- and remove engine

control unit - J623- -1-.
– Release and pull off connectors -2- for engine control unit -
J623- .
– Remove engine control unit -1-.
Installing
– It is essential that the engine (motor) control unit - J623- be
provided with the protective housing again.
– Clean the threaded holes for the shear-head bolts of locking
compound residues. A thread chaser is suitable for cleaning.
– Use new bolts.
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
– Connect vehicle battery ⇒ Electrical system; Rep. gr. 27 ;
– Switch on ignition and select the following menu options on
vehicle diagnostic and service information system :
♦ 01 - Engine electronics AG. Volkswagen AG d
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7 Lambda probe
⇒ “7.1 Assembly overview - Lambda probe”, page 276
⇒ “7.2 Removing and installing Lambda probe”, page 277
7.1 Assembly overview - Lambda probe
Note
♦ New lambda probes are coated with an assembly paste. Do

not allow any paste to enter the slots on the probe body.
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. Do not allow any paste to enter
the slots on the probe body. High-temperature paste ⇒ Elec‐
tronic parts catalogue (ETKA) .
♦ During installation, the electrical connecting cable of the
Lambda probe must be secured at the same points. The wire
must be prevented from touching the exhaust pipe.
1 - Electrical connector, brown

AG. Volkswagen AG d
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stalling Lambda probe”,
nform
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page 277
❑ 55 Nm
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Z29-
page 277
❑ 55 Nm

7.2 Removing and installing Lambda probe

⇒ “7.2.1 Removing and installing lambda probe 1 before catalytic
converter GX10 , Polo 2014, Ameo”, page 277
⇒ “7.2.2 Removing and installing lambda probe 1 after catalytic
converter GX7 , Polo 2014, Ameo”, page 279 AG. Volkswagen AG d
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⇒ “7.2.3 Removing and installing lambda probe 1 before catalytic
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⇒ “7.2.4 Removing and installing lambda probe 1ss after catalytic
a ra
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converter GX7 , Polo 2018”, page 282
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7.2.1 Removing and installing lambda probe 1
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Lambda probe 1 before catalytic converter - GX10- consists of
es, in part or in w
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♦ Lambda probe - G39-
♦ Lambda probe heater - Z19-
rrectness of i
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♦ Tool insert, AF 17 mm - T10395-
nform
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♦ Lambda probe open ring spanner set - 3337-
7. Lambda probe 277

Removing
⇒ “3.2 Removing and installing air filter housing”, page 258 . n AG. Volkswagen AG do
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– Unlock and disconnect connector underneath lambda probe d by-V ua
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GX10- -arrow-. o
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ss
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– Unscrew lambda probe - GX10- -1- from catalytic converter
rrectne
-2-.
s
Installing
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mer
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Note
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paste must not get into the slots on the Lambda probe body.
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with high-temperature paste. This paste must not get into the p by
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slots on the Lambda probe body. High-temperature paste ⇒
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Electronic parts catalogue .
AG.

If seal is leaking, nip open and renew.

Specified torque:
Lambda probe - GX10- 50 Nm


after catalytic converter - GX7- , Polo
2014, Ameo
Lambda probe 1 after catalytic converter - GX7- consists of
♦ Lambda probe after catalytic converter - G130-
♦ Lambda probe 1 heater after catalytic converter - Z29-
♦ Tool insert, AF 17 mm - T10395-
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♦ Lambda probe open ring spanner set - 3337- orise nte
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7. Lambda probe 279

Removing
– Unlock and disconnect connectors above lambda probe after
catalytic converter - GX7- -arrow-.
Steckerfarbe braun - Lambda probe before catalytic converter -
GX10-
Steckerfarbe schwarz - Lambda probe after catalytic converter -
GX7-
– Unscrew lambda probe after catalytic converter - GX7- -1-

from catalytic converter -2- from below.
Installing AG. Volkswagen AG d
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Install in reverse order of removal. During this procedure,ised observe
b ara
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the following: hor eo
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♦ New lambda probes are coated with an assembly paste. This
pe
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paste must not get into the slots on the Lambda probe body.
ot
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hole
spec
with high-temperature paste. This paste must not get into the
es, in part or in w
slots on the Lambda probe body. High-temperature paste ⇒
t to the co
Electronic parts catalogue .
rrectness of i
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nform
ercia
Specified torque:
m
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tion in
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Lambda probe after catalytic converter - GX7- 50 Nm

do
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before catalytic converter - GX10- , Polo
co lksw
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2018
Lambda probe 1 before catalytic converter - GX10- consists of
♦ Lambda probe - G39-
♦ Lambda probe heater - Z19-


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– Release and pull off connector -2- of Lambda probe - GX10- .

7. Lambda probe 281

– Unscrew lambda probe 1 before catalytic converter - GX10-

-1- from catalytic converter -3-; use lambda probe ring spanner
set - 3337/7- to do this.
Installing
Note
♦ New lambda probes are coated with anAassembly

G. Volkswagepaste.
n
Do
not allow any paste to enter the lkslots
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♦ In the case of a used Lambda
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spec
Specified torques
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♦ ⇒ “7.1 Assembly overview - Lambda probe”, page 276
rrectne
after catalytic converter - GX7- , Polo
ss o
2018
cial p
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mer
Lambda probe 1 after catalytic converter - GX7- consists of

atio
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♦ Lambda probe after catalytic converter - G130-

n
c
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♦ Lambda probe 1 heater after catalytic converter - Z29-

t
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Removing
– Release and pull off connector of lambda probe after catalytic
converter - GX7- -1-.
AG. Volkswagen AG d
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– Unscrew lambda d by
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probe after catalytic converter gu - GX7- -2-
ara
from top oris of catalytic converter -3-; use lambda probe
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spanner
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t to the co

with high-temperature paste. Do not allow any paste to enter
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Specified torques
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7. Lambda probe 283

26 – Exhaust system
lkswage es n
1 Exhaust pipes and silencers
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⇒ “1.1 Assembly overview - silencers”, page a284
ut or
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⇒ “1.2 Separating exhaust pipes from silencers”, page 287
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⇒ “1.3 Removing and installing silencer”, page 288
y li
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⇒ “1.4 Aligning exhaust system free of stress”, page 291
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⇒ “1.5 Checking exhaust system for leaks”, page 291
h re
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⇒ “1.6 Installation position of clamp”, page 292
es, in part or in w
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1.1 Assembly overview - silencers
⇒ “1.1.1 Assembly overview - silencers, Polo 2014, Ameo”, page
rrectness of i
284
l purpos
⇒ “1.1.2 Assembly overview - silencer, Polo 2018”, page 286
1.1.1 Assembly overview - silencers, Polo
nform
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2014, Ameo
m
at
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Note
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♦ After working on the exhaust system, ensure that the system

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♦ If necessary, loosen double clamp(s). Align silencer and ex‐ cted agen
Prote AG.
haust pipe so that sufficient clearance is maintained to the
bodywork and the support rings are evenly loaded.
♦ Renew self-locking nuts.
♦ Before installing, coat threads of lock nuts and stud bolts with
high-temperature paste - N 052.112.00- according to TL 521
12.
284 Rep. gr.26 - Exhaust system

1 - Clamping sleeve
⇒ “1.6 Installation posi‐
tion of clamp”,
page 292
tion of clamp”,
page 292
2 - Tunnel cross-piece
❑ Note installation posi‐
tion (mark before re‐
moval, if necessary).
⇒ Rep. gr. 66 ; Under‐
body cladding; Remov‐
ing and installing tunnel
cross-piece
3 - Securing nuts
❑ 20 Nm
4 - Front silencer
5 - Bracket
6 - Bolts
❑ 23 Nm
7 - Mounting
wage es n
8 - Coupling point yV
olks ot g
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❑ ⇒ “1.2 Separating oris ex‐
e ran
tee
haust pipes fromau silenc‐
th or
ac
ers”, page 287
ss
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nl
pt
9 - Rear silencer
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10 - Bracket
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11 - Securing bolts
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❑ 23 Nm
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12 - Mounting
es, in part or in w
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Prote AG.
1. Exhaust pipes and silencers 285

1.1.2 Assembly overview - silencer, Polo

2018
Note

is not under tension
♦ and that there is sufficient clearance to the bodywork.
♦ If necessary, loosen double clamp(s). Align silencer and ex‐
haust pipe so that sufficient clearance is maintained to the
bodywork and the support rings are evenly loaded.
12. AG. Volkswagen A
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1 - Clamping sleeve tho tee
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❑ Removing and installing ss
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page 292
erm
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⇒ page 292
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2 - Front silencer
spec
es, in part or in w
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installing front silencer”,
page 288
3 - Mounting rrectness of i
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4 - Bracket
nf
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5 - Securing bolt
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❑ 20 Nm
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6 - Coupling point
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❑ ⇒ “1.2 Separating ex‐

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haust pipes from silenc‐

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installing rear silencer”,

page 289
8 - Mounting
9 - Bracket
10 - Bracket
11 - Securing bolt
❑ 20 Nm

1.2 Separating exhaust pipes from silencers

♦ Chain-type pipe cutter - VAS 6254-
♦ Pneumatic sabre saw - V.A.G 1523B-

AG. Volkswagen AG d
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CAUTION
Risk of injury from swarf being flung into air.
rrectne
Irritation and injury to skin and eyes possible.

s

s o
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inform
mer
atio
♦ Separating points are provided in the exhaust system for the

om
individual removal of exhaust system parts.

c
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♦ The separating points are indicated with markings on the out‐

sd
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side of the exhaust pipe.

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Separating point on rear silencer

– Cut through exhaust pipe at centre separating point
-upper arrow- at right angles, e.g. with pneumatic sabre saw -
V.A.G 1523B- or chain pipe cutter - VAS 6254- .
– Position repair double clamp centrally between outer markings
-lower arrow-.
– Take installation position of clamp into account
⇒ “1.6 Installation position of clamp”, page 292 .
1.3 Removing and installing silencer

⇒ “1.3.1 Removing and installing front silencer”, page 288
⇒ “1.3.2 Removing and installing rear silencer”, page 289
1.3.1 Removing and installing front silencer

AG. Volkswagen AG d
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Removing
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CAUTION
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Risk of accident caused by high weight of silencers.

t to the co
– Seek help from a second a mechanic for the following work.

rrectne
Separating point without clamp

– Separate rear silencer from front silencer
ss

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mer
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Separating point with clamp

– Loosen clamp -1- between catalytic converter and front si‐
lencer, and push it in direction of travel -arrow-.
– Loosen clamp between front and rear silencer, and push it in
opposite direction of travel.
Polo 2014
– Bend heat shield -1- in direction of -arrow-.

• Bracket -2- needs to be guided past heat shield -1-.
– Unscrew bolts -3- from bracket -2-. Guide bracket -2- past heat
shield -1-.
– Detach front silencer, and guide it out.
lkswage es n
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Install in reverse order of removal, observing the following: h re

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– Align exhaust system free of stress.
es, in part or in w
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– Note installation position of clamps
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Specified torques
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• ⇒ “1.1 Assembly overview - silencers”, page 284

nf
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orm
1.3.2 Removing and installing rear silencer

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, is n
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hole
Risk of accident caused by high weight of silencers.
spec
es, in part or in w
– Seek help from a second a mechanic for the following work.
t to the co
Separating point without clamp
rrectness of i
– Separate silencers
l purpos
Separating point with clamp
nform
ercia
– Unbolt bracket on rear silencer, and remove it.

m
at
om
– Loosen clamp -1-, and push it to one side towards front si‐
ion
c
lencer -2-.
in t
or
his
ate
– Remove rear silencer.

do
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or
Installing
f
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t.
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Cop py
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rig ht
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Prote AG.

• Note installation position of clamp
Note
Make sure to obtain the dimension -a = approx. 5 mm- between

the marks -arrows-.
– Align exhaust system free of stress.

Align end exhaust pipes
– Unfasten rear silencer mounting to align tailpipes.

– Align rear silencer maintaining distance -a- and -b- between

bumper cut-out and exhaust pipe.
Adjustment dimension agen
AG. Volkswagen AG d
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Dimension a: 25 mm ed by ara
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Dimension b: 30 mm
aut
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ss c
Specified torques
ce
le
un
pt
an
d
• ⇒ “1.1 Assembly overview - silencers”, page 284

itte
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ility
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wit
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spec
1.4 Aligning exhaust system free of stress
t to the co
Procedure
• The exhaust system must be aligned when cold.
rrectne
– Loosen bolt connections for front clamp -arrow-.
ss o
cial p
f inform
mer
atio
om
n
c
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or
n thi
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Cop py
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– Push exhaust system towards front of vehicle until preloading
AG.
at mounting for exhaust pipe -a- = 5 mm.

– Fit front clamp
Specified torques
♦ ⇒ “1.1 Assembly overview - silencers”, page 284
1.5 Checking exhaust system for leaks

Procedure
– Start engine and run it at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.
– Check (by listening) points of connection between exhaust
manifold and the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.
– Repair any leaks found.

1.6 Installation position of clamp

⇒ “1.6.1 Installation position of clamp, Polo 2014, Ameo”,
page 292
⇒ “1.6.2 Installation position of clamp, Polo 2018”, page 293
1.6.1 Installation position of clamp, Polo 2014,

Ameo
Note AG. Volkswagen AG d

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olksw not
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Make sure to use clamps with continuous clip only.
ise
d by ara
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th
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Position of clamp ss c
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un
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itte
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ab
ility
ot p
wit
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spec
Make sure that installation dimension -a- is obtained.
t to the co
a - Distance to marking: approx. 5 mm
rrectne
1 - Clamping sleeve
2 - Front exhaust pipe
ss o
3 - Securing nut
cial p
f inform
mer
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Installation position of clamp

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op py
• Bolted connection faces downwards (towards the road). t. C rig
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• Angle -α- (= approx. 15°) must not be exceeded.
co Vo
by lksw
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Prote AG.
Specified torque:
Clamping sleeve 23 Nm

1.6.2 Installation position of clamp, Polo 2018
Note
Make sure to use clamps with continuous clip only.
Position of clamp
Make sure that installation dimension -a- is obtained.
a - Distance to marking: approx. 8.5 mm
2 - Securing nut
3 - Clamping sleeve
Installation position of clamp
• Do not exceed angle -α- = approx. 20°.
AG. Volkswagen AG d
agen oes
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Specified torques
hole
spec
es, in part or in w

t to the co
Clamping sleeve 25 Nm
rrectness of i
l purpos
nform
mercia
a
com
tion in
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te o
thi
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Cop py
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Prote AG.

2 Emission control
⇒ “2.2 Removing and installing catalytic converter”, page 297
2.1 Assembly overview - emission control

⇒ “2.1.1 Assembly overview - emission control, Polo 2014,
Ameo”, page 294
⇒ “2.1.2 Assembly overview - emission control, Polo 2018”, page
296
2.1.1 Assembly overview - emission control, Polo 2014, Ameo
1 - Engine
2 - Seal
❑ Renew
3 - Lambda probe - G39-
with “G 052 112 A3”;
“G 052 112 A3” cannot
probe body.
1 before catalytic con‐
verter GX10 , Polo
2014, Ameo”, page 277
❑ If seal is leaking, nip
open and renew.
❑ 50 Nm AG. Volkswagen AG d
agen oes
lksw not
4 - Nut d by Vo gu
ara
se nte
❑ Observe assembling
thori
eo
procedure ⇒ page
s au 295 ra
c
s
❑ 23 Nm
ce
e
nl
pt
du
an
5 - Lambda probe after catalyt‐

itte
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erm
ic converter - G130-
ab
ility
ot p

wit
, is n
with “G 052 112 A3”;

h re
“G 052 112 A3” cannot

hole
spec

es, in part or in w
probe body.
t to the co

rrectness of i

1 after catalytic convert‐
l purpos
er GX7 , Polo 2014,

Ameo”, page 279
nf
ercia
❑ If seal is leaking, nip open and renew.

orm
❑ 50 Nm
m
atio
om
n in

or c
thi
te
sd
7 - Subframe with bracket

iva
o
r
rp
cu
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and in‐
o
m
f
en
ng
stalling subframe without steering rack .

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
294
AG.
Rep. gr.26 - Exhaust system
8 - Bolt
❑ Catalytic converter to bracket
❑ 23 Nm
9 - Bolt
❑ Bracket to cylinder block
❑ 23 Nm
10 - Bracket
❑ to cylinder block
❑ Observe assembling procedure ⇒ page 295
11 - Bracket
12 - Bolt
❑ 23 Nm
AG. Volkswagen AG d
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Note uth o eo
ra
s a c
s
Before installing, coat threads of lock nuts and stud bolts with
ce
le
un
high-temperature paste - N 052.112.00- according to TL 521 12. pt

an
d
itte
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rm
ab
pe
Assembly sequence for mounting catalytic converter to cylinder ility

ot
wit
head
, is n
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hole
Tightening sequence:
spec
es, in part or in w
t to the co
Step Component Specified torque

(se‐
quen
ce)
rrectness of i
1) Secure bracket -10- to cylinder head. 23 Nm

l purpos
2) Loosely bolt bracket -11- to bracket

-10-
nform
ercia
3) Guide gasket -2- onto stud

m
a
com
ti
4) Screw on nuts -4- by 2 to 3 full turns

on in
r
te o
5) Tighten the three nuts -4- 23 Nm

thi
s
iva
do
6) Screw bolt -8- onto bracket -11-

r
rp
cum
through hole in catalytic converter

fo
en
ng
t.
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7) Tighten bolt -8- 23 Nm
Co
Cop py
ht. rig
8) Secure brackets -10- and -11- with 23 Nm
rig ht
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bolts -12- co Vo
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9) Tighten 4th nut -4- 23 Nm
AG.
2. Emission control 295

AG. Volkswagen AG d
agen oes
2.1.2 Assembly overview - emission control, Polo 2018 d byV
olksw not
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ara
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1 - Engine ss c
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nl
2 - Seal
pt
du
an
itte
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❑ Renew
erm
ab
ility
ot p
wit
, is n
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hole
❑ Consisting of:
spec
es, in part or in w
Lambda probe - G39-
t to the co
Z19-
rrectness of i
❑ Only grease threads
l purpos
with “G 052 112 A3”. “G

052 112 A3” must not
get into slots of probe
nf
ercia
o
body.
rm
m
atio
m

o
n in
c

or
thi
te
sd
iva
page 277
o
r
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cu
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m
❑ If seal is leaking, nip
f
en
ng
t.
open and renew.
yi Co
Cop py
❑ 55 Nm ht. rig
rig ht
py by
o Vo
4 - Nut
by c lksw
cted agen
Prote AG.
❑ Observe assembling
procedure ⇒ page 297
❑ 23 Nm
❑ Consisting of:
Lambda probe 1 heater

after catalytic converter - Z29-
❑ Only grease threads with “G 052 112 A3”. “G 052 112 A3” must not get into slots of probe body.
❑ Removing and installing ⇒ “7.2 Removing and installing Lambda probe”, page 277
❑ If seal is leaking, nip open and renew.
❑ 55 Nm
6 - Bolt
❑ Catalytic converter to bracket
❑ 23 Nm
7 - Front exhaust pipe with catalytic converter
❑ Do not allow the flexible joint to kink by more than 10°. It could become damaged.
❑ Install flexible joint so that it is not under tension
❑ Take care not to damage wire mesh on decoupling element.
❑ Protect catalytic converter from damage by knocks and impact
❑ Removing and installing ⇒ “2.2 Removing and installing catalytic converter”, page 297
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
8 - Bolts
❑ Catalytic converter to subframe

❑ 20 Nm
9 - Subframe with bracket
❑ Removing and installing ⇒lksRunning
wage gear, axles, steering;
es n Rep. gr. 40 ; Subframe; Removing and in‐
stalling subframe without
d by V steering rack .
o ot g
ua
e ran
ris tee
10 - Bolt ut
ho or
a ac
❑ Bracket to cylinder
ss block
ce
le
un
❑ 23 Nm
pt
an
d
itte
y li
11 - Bracket
erm
ab
ility
ot p
❑ to cylinder block
wit
is n
h re
ole,
spec
12 - Bracket
t to the co
13 - Bolt
rrectne
❑ 23 Nm
ss o
cial p
f inform
Note
mer
atio
om
Before installing, coat threads of lock nuts and stud bolts with
n
c
i
or
n
high-temperature paste - N 052.112.00- according to TL 521 12.
thi
te
sd
iva
o
pr
cum
Sequence for installation of catalytic converter
r
fo
en
ng
t.
yi
Specified torques
Co
Cop py
t. rig
gh ht
yri
Step Component Specified torque
p by
co Vo
(se‐
by lksw
cted agen
Prote
quen
AG.
ce)
1) Screw bracket -11- on cylinder block 23 Nm
2) Loosely bolt bracket -12- to bracket
-11-
3) Guide seal -2- onto studs
4) Screw on nuts -4- by 2 to 3 full turns
5) Tighten the three nuts -4- 23 Nm
6) Screw bolt -6- onto bracket -12-
through hole in catalytic converter
7) Tighten bolt -6-. 23 Nm
8) Secure brackets -11- and -12- with 23 Nm
bolts -13-
9) Tighten 4th nut -4- 23 Nm
2.2 Removing and installing catalytic con‐

verter
⇒ “2.2.1 Removing and installing catalytic converter, Polo 2014,
Ameo”, page 297
⇒ “2.2.2 Removing and installing catalytic converter, Polo 2018”,
page 300
2.2.1 Removing and installing catalytic con‐

verter, Polo 2014, Ameo

Ameo 2017 ➤ , Polo 2014 ➤ , Polo 2018 ➤ , Polo KH
. VolkIN
sw2015 ➤
agen AG
gen AG
3-cylinder injection engine (1.0 l engine,Vo4lkV,
swaEA 211) - Edition 05.2019
does
not
by gu
ara
ed nte
♦ Torque wrench - V.A.G 1331- oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ High-temperature paste ⇒ Electronic parts catalogue .
ss o
cial p
f inform
Note
mer
atio
m
The catalytic converter is removed together with the front exhaust

o
n
c
i
or
n
pipe.
thi
te
sd
iva
o
pr
c
Removing
um
r
fo
en
ng
t.
yi
– Release and pull off connectors -3-.
Co
Cop py
ht. rig
– Lay wires -2- to one side. rig ht
py by
co Vo
by lksw
– Unclip wires -4- from retainer -1-. cted agen
Prote AG.
– If necessary, disconnect exhaust system

⇒ “1.2 Separating exhaust pipes from silencers”, page 287 .
– If fitted, loosen clamp -arrows-.


– Unscrew securing bolt ⇒ Item 8 (page 295) from catalytic con‐
verter and remove bracket -2-.

stud bolts.
Note
Qty. 4 ⇒ Item 4 (page 294) .
swage es n
– Pull retaining rings -1- for exhaust pipe off subframe b-2-. yV
olk ot g
ua
d ran
ir se
Installing tho tee
or
au ac
Install in reverse order of removal. During this procedure, observe ss
ce
e
the following:
nl
pt
du
an
itte
Adhere to assembling sequence ⇒ page 295 .
y li
erm
ab
ility
Note installation position of clamp
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
is not under stress and that there is sufficient clearance to the
rrectness of i
bodywork. If necessary, loosen double clamp and align si‐
l purpos
lencer and exhaust pipe so that sufficient clearance is main‐

tained to the bodywork and the support rings are evenly
loaded.
nf
ercia
or

m
m
atio
m
o
n in
or c

thi
e
12.
t
sd
iva
o
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rp
cu
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f
en
ng
t.
yi
Specified torque:
Co
Cop py
t. rig
gh ht
Component yri
Specified torque
p by
co Vo
by lksw
cted
Catalytic converter ⇒ page 295
agen
Prote AG.
Clamping sleeve ⇒ “1.6 Installation position of clamp”, page 292

2.2.2 Removing and installing catalytic con‐

verter, Polo 2018
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Transport lock - T10403-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
♦ High-temperature paste ⇒ Electronic parts catalogue (ETKA) .

o
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
Cop py
The catalytic converter is removed together with the front exhaust
t. rig
gh ht
yri
pipe.
p by
co Vo
by lksw
cted agen
Prote AG.
Removing
Only if catalytic converter if renewed
– Remove Lambda probes
⇒ “7.2 Removing and installing Lambda probe”, page 277 .
Continued for removal
– Disconnect connectors -1- and -2-, and unclip wiring harness
from retainer.
Note
Attach cable ties in all the same places when installing.


stud bolts.
Note
Qty. 4 ⇒ Item 4 (page 296) .
– If fitted, remove underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐
AG. Volkswagen AG d
view - underbody cladding . lkswagen oes
n o ot g
yV ua
db ran
ir se tee
ho
aut or
ac
– Loosen clamp -arrow-,
ss and push it to rear.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove securing bolt -1- on catalytic converter.
nf
ercia
orm
m
Note
atio
om
n in
or c
Disregard items -2 and 3-.

thi
te
sd
iva
o
r
rp
cu
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Ameo 2017ut
ho ➤ , Polo 2014 ➤ , Polo 2018 ➤ , Polo KHe oIN r a 2015 ➤
a
3-cylinder
ss injection engine (1.0 l engine, 4 V, EA 211) - Edition c 05.2019
ce
e
nl
pt
du
an
– Place transit lock - T10403- on decoupling element.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
When removing the catalytic converter from its fitting location,
ensure that the Lambda probes and their connections are not
damaged.
rrectness of i
– Remove catalytic converter with front exhaust pipe and pull
l purpos
out between tunnel of underbody and subframe.

Installing
nf
ercia
orm
m
atio
om
n in
c
– Observe sequence for installation of catalytic converter

or
thi
⇒ page 297
te
sd
iva
o
r
Note installation position of clamp

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
o Vo
by c lksw
cted agen
Prote AG.
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double clamp and align si‐
lencers and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork at all points and the mountings are
evenly loaded.
12.
Specified torques
♦ ⇒ “2.1 Assembly overview - emission control”, page 294
♦ Specified torques and tightening sequence for catalytic con‐
verter ⇒ page 297
♦ ⇒ “1.6 Installation position of clamp”, page 292

28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 303
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 305
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 307
⇒ “1.4 Removing and installing Hall sender G40 ”, page 308
⇒ “1.5 Removing and installing engineespeed
n AG. Vosender
lkswagenG28
AG do”, page
309 olkswag es n
o
yV t gu
db ara
1.1 Assembly overview - ignition system
ho
ir se nte
eo
aut ra
ss c
ce
le
1 - Cylinder head cover

un
pt
an
d
itte
y li
2 - Spark plug
rm
ab
pe
ility
❑ Remove and install with
ot
wit
spark plug socket and
, is n
h re
extension - 3122 B-
hole
⇒ Maintenance ; Book‐
spec
es, in part or in w
let 819
t to the co
❑ 22 Nm
❑ Change interval ⇒
rrectness of i
Maintenance tables
l purpos
3 - Ignition coil 1 with output

stage - N70-
❑ Ignition coil 2 with output
nform
ercia
stage - N127-
m
❑ Ignition coil 3 with output

com
tion in
stage - N291-
r
te o
thi
❑ Observe notes on disas‐

s
iva
do
sembly
r
rp
cum

fo
en
g

n
t.
yi Co
op
with output stage”, page C py
t. rig
305
gh ht
pyri by
Vo
co
❑ To remove, use puller -
by lksw
cted agen
Prote
T10530- .
AG.

with output stage”, page
305
4 - Bolt
❑ 8 Nm
❑ Black, 4-pin.
6 - Bolt
❑ for Hall sender - G40-
❑ 10 Nm
1. Ignition system 303

❑ Black, 3-pin.
❑ for Hall sender - G40-
9 - Seal
10 - Bolt
❑ The specified torque influences the function of the knock sensor.
❑ 20 Nm
❑ Black, 2-pin.
❑ For knock sensor 1 - G61- . AG. Volkswagen AG d
agen oes
olksw
❑ Connector contacts are gold-plated. not
yV gu b ara
ed
12 - Knock sensor 1 - G61- ris nte
utho eo
❑ Removing and installing s a ⇒ “1.3 Removing and installing knock sensor 1 rG61
ac ”, page 307
s
ce
le
❑ Connector contacts are gold-plated.

un
pt
an
d
itte
13 - Engine speed sender - G28-
y li
erm
ab
❑ Removing and installing ⇒ “1.5 Removing and installing engine speed sender G28 ”, page 309
ility
ot p
wit
is n
h re
ole,
❑ Black, 3-pin.
spec
❑ For engine speed sender - G28-
t to the co
15 - Bolt
❑ For engine speed sender - G28-
rrectne
❑ 8 Nm
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
304 Rep. gr.28 - Ignition system

1.2 Removing and installing ignition coils with output stage

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
♦ Torque wrench -VAS 6854-
AG.
♦ Puller -T10530-
Note
♦ The ignition coils are easier to remove when the engine is

warm.
♦ The grease used when assembling at the factory makes it
easier to remove the spark plug connectors when the engine
is warm.
♦ When installing used ignition coils with output stage, the igni‐
tion coils must be lubricated with silicone paste ⇒ Electronic
parts catalogue (ETKA) .
♦ Ignition coils with output stage and spark plug connectors are
available individually for repairs ⇒ Electronic parts catalogue
(ETKA)

Removing
– Unscrew bolts -2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Push puller - T10530- as far as stop into hole in ignition coil
es, in part or in w
-1-.
t to the co
– Tighten knurled nut -2- in -direction of arrow-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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– Apply a thin bead of silicone paste around sealing hose of ig‐

nition coil ⇒ Electronic parts catalogue (ETKA) .
– Slide spark plug connector -1- by hand onto ignition coil as far
as stop.
• The vent drilling -2- must be centred relative to connector
housing -3- while doing so.
– Insert all ignition coils loosely into spark plug hole.
– Align ignition coils with connectors and simultaneously push
all connectors onto ignition coils.
– Press ignition coils evenly onto spark plugs by hand (do not
use tools).
– Using torque wrench - VAS 6854- , tighten securing bolt to
specified torque ⇒ page 307 .
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Fitting location ⇒ Item 5 (page 89)


– Unscrew bolt -arrow-.
– Remove Hall sender - G40- -1-.
Installing
the following:
Renew seal ⇒ Item 9 (page 304) if damaged.
Specified torque:
Hall sender - G40- 10 Nm
Air filter ⇒ “3 Air filter”, page 255
1.5 Removing and installing engine speed

sender - G28-
⇒ “1.5.1 Removing and installing engine speed sender G28 , Polo
2014, Ameo”, page 309
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sulation .
Fitting location ⇒ Item 3 (page 70) .
– Remove securing bolts -arrows- of pendulum support.
Note
Bolt -1- must not be loosened.

– Fit tensioning strap - T10038- -3- to engine -1- and subframe

-2- as shown.
– Pull engine -1- in -direction of arrow- using tensioning strap -
T10038- .
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– Bring engine speed sender - G28- in installation position mak‐

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Secure bolt -2- against falling.
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manifold.
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3-Cyl. Injection Engine (1.0l Engine, 4 V, EA 211) CHYA CHYB CHYC CHYD PDF

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3-Cyl. Injection Engine (1.0l Engine, 4 V, EA 211) CHYA CHYB CHYC CHYD PDF

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Service

Workshop Manual olkswage

3-cylinder injection engine (1.0 l engine, 4 V, EA 211)

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B8040D52F

3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.4 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

17 - Lubrication . . . . . . . . . . . . V.ol.ks.w.ag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

2 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

2.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

2.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.1 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

2.1 Assembly overview - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

2.2 Assembly overview - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

2.7 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 215

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

⇒ “1.4 Safety precautions when working on the cooling system”,

⇒ “1.5 Safety precautions when working on ignition system”, page

Risk of injury from highly pressurised fuel.

Before opening the fuel system:

– Wear protective goggles.

– To release pressure, wrap a clean cloth around the connection

Danger of fire caused by escaping fuel

1.2 Safety measures when working on vehicles with a start/stop system

– Have a second person operate the test and measuring equip‐

On a warm engine, the cooling system is under high pressure.

Danger of scalding by steam and hot coolant.

– Wear protective gloves.

– Reduce excess pressure by covering cap of coolant expan‐

Risk of injury due to electric shock

Risk of damage to components

2 Rep. gr.00 - Technical data

2.1 Engine number/engine data

Four-place engine codes are being introduced, starting with letter

engine control unit.

Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;

3.1 Rules for cleanliness

aging until immediately before installing. Do not use parts that

have been kept unpackaged (for example in toolboxes).

♦ If system is open, do not work with compressed air. Do not

move the vehicle.

3.2 General information

♦ The engine control unit has a self-diagnosis capability. Before

ory. Also the vacuum hoses and connections must be checked

♦ For trouble-free operation of electrical components, a voltage