VW 3-cylinder injection engine (1.0 l, natural gas, 4 V EA 211, turbocharger) OEM Workshop Manual

VW 3-cylinder injection engine (1.0 l, natural gas, 4 V EA 211, turbocharger) OEM Workshop Manual with high-quality graphics and illustrations.

Format: PDF

Pages: 328

Delivery: The download link will be sent to your email instantly after checkout.

Covered VW Vehicles

• Polo 2018 ➤

Covered Engine IDs: DBYA

Repair Group:

• Technical data
• Removing and installing engine
• Crankshaft group
• Cylinder head, valve gear
• Lubrication
• Cooling
• Turbocharging/supercharging
• Mixture preparation – injection
• Exhaust system
• Ignition system

Contents:

• Technical data
• Safety information
• Safety measures when working on fuel supply
• Safety precautions when working on vehicles with a gas system
• Safety measures when working on vehicles with a start/stop system
• Safety precautions when using testers and measuring instruments during a road test
• Safety precautions when working on the cooling system
• Safety precautions when working on ignition system
• Identification
• Engine number/engine data
• Repair instructions
• Rules for cleanliness
• General information
• General repair instructions
• Foreign objects in engine
• Contact corrosion
• Routing and attachment of lines
• Fitting radiator and condensers
• Checking vacuum system
• Removing and installing engine
• Removing and installing engine
• Removing engine
• Separating engine and gearbox
• Securing engine on engine and gearbox support
• Installing engine
• Assembly mountings
• Assembly overview – assembly mountings
• Removing and installing engine mounting
• Removing and installing gearbox mounting
• Removing and installing pendulum support
• Checking adjustment of assembly mountings (engine and gearbox mountings)
• Adjusting assembly mountings
• Supporting engine in installation position
• Crankshaft group
• Cylinder block (pulley end)
• Assembly overview – poly V-belt drive
• Removing and installing poly-V belt
• Removing and installing tensioner for poly V-belt
• Removing and installing vibration damper
• Removing and installing engine support
• Renewing crankshaft oil seal – belt pulley end
• Cylinder block, gearbox end
• Assembly overview – cylinder block, gearbox end
• Removing and installing flywheel
• Removing and installing sealing flange on gearbox side
• Crankshaft
• Crankshaft dimensions
• Measuring axial clearance of crankshaft
• Pistons and conrods
• Assembly overview – pistons and conrods
• Removing and installing pistons
• Checking pistons and cylinder bores
• Separating new conrod
• Checking radial clearance of conrods
• Removing and installing oil spray jets
• Setting piston to TDC position
• Cylinder head, valve gear
• Cylinder head
• Assembly overview – cylinder head
• Assembly overview – camshaft housing
• Removing and installing cylinder head
• Removing and installing camshaft housing
• Checking compression
• Toothed belt drive
• Assembly overview – toothed belt cover
• Assembly overview – toothed belt
• Removing and installing toothed belt guard
• Preassembling and installing test tool VAS 611 007
• Checking valve timing
• Adjusting valve timing
• Removing toothed belt from camshaft
• Removing and installing toothed belt
• Valve gear
• Assembly overview – valve gear
• Removing and installing camshaft adjuster
• Measuring axial play of camshaft
• Removing and installing camshaft oil seal
• Removing and installing camshaft control valve 1 N205
• Removing and installing exhaust camshaft control valve 1 N318
• Removing and installing valve stem seals
• Inlet and exhaust valves
• Checking valve guides
• Checking valves
• Valve dimensions
• Lubrication
• Sump, oil pump
• Assembly overview – sump/oil pump
• Engine oil:
• Removing and installing sump
• Removing and installing oil level and oil temperature sender G266
• Removing and installing oil pump
• Engine oil cooler
• Assembly overview – engine oil cooler
• Removing and installing engine oil cooler
• Crankcase ventilation
• Assembly overview – crankcase breather system
• Removing and installing oil separator
• Oil filter, oil pressure switch
• Assembly overview – oil filter/oil pressure switch
• Removing and installing oil filter housing
• Removing and installing oil pressure sender G10
• Removing and installing oil pressure regulating valve N428
• Checking oil pressure
• Cooling
• Cooling system/coolant
• Connection diagram – coolant hoses
• Draining and adding coolant
• Checking cooling system for leaks
• Coolant pump, regulation of cooling system
• Assembly overview – coolant pump, thermostat
• Assembly overview – electric coolant pump
• Assembly overview – coolant temperature sender
• Removing and installing coolant pump
• Removing and installing toothed belt pulley for coolant pump
• Removing and installing thermostat
• Removing and installing electric coolant pump
• Removing and installing coolant temperature sender G62
• Removing and installing radiator outlet coolant temperature sender G83
• Coolant pipes
• Assembly overview – coolant pipes
• Removing and installing coolant pipes
• Radiator, radiator fan
• Assembly overview – radiator/radiator fan
• Assembly overview – radiator cowl and radiator fan
• Removing and installing radiator
• Removing and installing radiator cowl
• Removing and installing radiator fan V7
• Turbocharging/supercharging
• Turbocharger
• Assembly overview – turbocharger
• Removing and installing turbocharger
• Removing and installing charge pressure positioner V465
• Removing and installing connection for turbocharger
• Charge air system
• Assembly overview – charge air system
• Removing and installing air pipe
• Removing and installing charge pressure sender GX26
• Removing and installing charge air cooler
• Checking charge air system for leaks
• Mixture preparation – injection
• Injection system
• Overview of fitting locations – injection system
• Air filter
• Assembly overview – air filter housing
• Removing and installing air filter housing
• Intake manifold
• Assembly overview – intake manifold
• Removing and installing intake manifold
• Removing and installing throttle valve module GX3
• Cleaning throttle valve module GX3
• Checking natural gas supply system for leaks
• Distinguishing between pressure sections of natural gas supply system
• Determining pressure in gas system
• Determining operating mode of natural gas vehicles
• Activating and deactivating natural gas mode
• Checking gas system for leaks
• Gas pressure regulator
• Assembly overview – gas pressure regulator
• Removing and installing gas pressure regulator
• Removing and installing tank pressure sensor G400
• Gas injectors
• Assembly overview – gas rail
• Removing and installing gas rail with gas injector N366 / N367 / N368
• Removing and installing gas rail temperature and pressure sensor GX21
• Injectors
• Assembly overview – fuel rail with injectors
• Removing and installing fuel rail
• Removing and installing injectors
• Cleaning injectors
• Senders and sensors
• Removing and installing intake manifold sender GX9
• Removing and installing fuel pressure sender G247
• Checking fuel pressure sender G247
• High-pressure pump
• Assembly overview – high-pressure pump
• Removing and installing high-pressure pump
• Removing and installing high-pressure pipe
• Lambda probe
• Assembly overview – Lambda probe
• Removing and installing Lambda probe
• Engine control unit
• Removing and installing engine (motor) control unit J623
• Exhaust system
• Exhaust pipes and silencers
• Assembly overview – silencers
• Removing and installing silencer
• Aligning exhaust system free of stress
• Checking exhaust system for leaks
• Emission control
• Assembly overview – emission control
• Removing and installing catalytic converter
• Ignition system
• Ignition system
• Assembly overview – ignition system
• Removing and installing ignition coils with output stage
• Removing and installing knock sensor 1 G61
• Removing and installing Hall sender G40
• Removing and installing engine speed sender G28