Polo Arun Cfwa

Service
Workshop Manual
Polo 2010 ➤
3-cylinder common rail engine (1.2 l, EA189)
Engine ID
CFW
A
Edition 06.2019
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Service Department. Technical Information

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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
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust 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 D3E80270E6B

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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.1 Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 3
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
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2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.6 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.2 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.1 Assembly overview - poly V-belt drive (vehicles without air conditioner compressor) . . . . 25
1.2 Assembly overview - poly V-belt drive (vehicles with idler roller and air conditioner
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3 Assembly overview - poly V-belt drive (vehicles with tensioning element and air conditioner
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4 Removing and installing poly V-belt (vehicles without air conditioner compressor) . . . . . . 28
1.5 Removing and installing poly V-belt (vehicles with idler roller) . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Removing and installing poly V-belt (vehicles with tensioning element) . . . . . . . . . . . . . . 30
1.7 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.8 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.9 Ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.10 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.3 Measuring piston projection at “TDC” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.5 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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Polo 2010 ➤
3-cylinder common rail engine (1.2 l, EA189) - Edition 06.2019
4.6 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.1 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.3 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.5 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.6 Checking compression AG. V. o.lk.s.w.ag. e.n.A.G.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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2.1 Assemblyoris overview - toothed belt drive . . . . . .n.tee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Removing,
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3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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3.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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3.4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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3.5 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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3.7 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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1.1 Assembly overview - sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 120
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1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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1.4 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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2.2 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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3.1 Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 131
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3.2 Removing and installing oil filter bracket with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 132
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3.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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3.4 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.1 Removing and installing oil supply line and oil return (turbocharger support) . . . . . . . . . . 138
4.2 Oil spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.1 Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.2 Removing and installing balance shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.4 Cooling system - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Assembly overview - coolant pump and 4/2-way valve with thermostat . . . . . . . . . . . . . . 157
2.2 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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Polo 2010 ➤
3.1 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3.2 Assembly overview - with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.3 Removing and installing cowling with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.1 Assembly overview - turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.3 Fitting charge air system hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.1 Instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.2 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.3 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.4 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.1 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3 Injectors, fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.1 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.2 Adapting correction values for injectors . . . . . .g.en. A. G. ..V.ol.ks. w. a.g.en. A. G. d. . . . . . . . . . . . . . . . . . 195
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3.3 Checking return flow rate of injectors with yengine ksw running . . . . . . . . . e.s.no. t. . . . . . . . . . . . . . 195
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3.4 Removing and installing injectors . . r.ise. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . 197
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3.5 Removing and installing high-pressure uth
lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . o. r .a . . . . . . 202
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3.6 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
s 206
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3.7 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
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4.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
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4.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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4.3 Checking vacuum at high-pressure fuel pump (venturi nozzle) . . . . . . . . . . . . . . . . . . . . 219

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4.4 Checking vacuum between high-pressure fuel pump (venturi nozzle) and injectors . . . . t to the co
221
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.1 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 224
5.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
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5.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

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5.4 Removing and installing pressure differential sender G 505 . . . . . . . . . . . . . . . . . . . . . . . . 229

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6 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

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6.1 Assembly overview - lambda probe and exhaust temperature sensors . . . . . . . . . . . . . . . . 232
mer
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6.2 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 232
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7 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

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7.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

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7.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

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8 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

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8.1 Assembly overview - intake manifold with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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8.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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9.1 Reading and deleting engine control unit event memory . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.3 Removing and installing engine control unit with no ant-theft protection . . . . . . . . . . . . . . 242
Contents iii
Polo 2010 ➤
9.4 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

1 Exhaust pipes and silencers . . . . . . . . . . n. A. G . ..V.o.lk.sw
. a. g.e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . 244
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1.1 Assembly overview - silencers . . V. o.lk.s.w.a . . . . . . . . . . . . . . . .oe. s.n.ot. g. . . . . . . . . . . . . . . . . . . 244
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1.2 Separating exhaust pipes fromisesilencers
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. . . . . . . . . . . . . . . . . . . . .ar.an.t . . . . . . . . . . . . . . . 244
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1.3 Aligning exhaust system free aut of stress . . . . . . . . . . . . . . . . . . . . . . . . . . o. r .a . . . . . . . . . . . .
ho
246
1.4 Installation position of clamp
ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . . . . . . 247
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2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
du 248
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2.1 Assembly overview - particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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2.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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3.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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spec
3.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 267
es, in part or in w
t to the co
3.3 Checking changeover for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . 270
3.4 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3.5 Cleaning exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
rrectness of i
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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1.2 Removing and installing ceramic glow pin plugs; carrying out resistor test . . . . . . . . . . . . 281
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1.3 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

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1.4 Removing and installing knock sensor G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
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1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

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iv Contents
Polo 2010 ➤
AG. Volkswagen AG d
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00 – Technical data
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1 Technical data
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(VRL013149; Edition 06.2019)
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1.1 Engine number/engine data
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Four digit engine codes
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The first 3 digits refer to the mechanical configuration of the en‐
t to the co
gine. The first 3 digits are embossed on engine.
The fourth digit indicates the output of the engine. It depends on
rrectness of i
the engine control unit.
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The four-digit engine code can be found on the identification plate,

the vehicle data sticker and on the engine control unit.
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The engine number (“engine code” and “serial number”) can be
or
found at the joint between engine and gearbox -arrow-.
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In addition, there is a sticker on the toothed belt guard with “engine

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code” and “serial number”.
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The engine codes can also be found on the vehicle data sticker.
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The engine number consists of up to 9 characters (alphanumeric). yi

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The first part (maximum 4 characters) makes up the “engine t. Cop py
code”, and the second part (6 characters), the “serial number”. If
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Engine data
Codes CFWA
Manufactured 01.10 ►
Displacement l 1.2
Power kW at rpm 55/4200
Torque Nm at rpm 180/
2000
Bore ∅ mm 79.5
Stroke mm 80.5
Valves per cylinder 4
Compression ratio 16.5
Fuel: acc. to DIN EN 590
Firing order 1-2-3
Catalytic converter Yes
Diesel particle filter Yes
Exhaust gas recirculation Yes
Charging Yes
Charge air cooling Yes
1. Technical data 1
Polo 2010 ➤
2 Safety information
Volkswagen AG
⇒ “2.1 Safety measures when working on fuel supply”, swagen AG. does
page 2 by
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⇒ “2.2 Safety measures when working on vehicles
tho with a start/
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stop system”, page 3 ss
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⇒ “2.3 Safety precautions when using testers and measuring in‐
un
pt
an
struments during a road test”, page 3
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⇒ “2.4 Safety precautions when working on the cooling system”,
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page 3
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⇒ “2.5 Safety precautions when working on the SCR system”,
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spec
page 3
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⇒ “2.6 Safety precautions when working on exhaust system”,
page 4
2.1 Safety measures when working on fuel
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supply
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When working on the fuel system please note the following:
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WARNING
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Danger of scalding from very hot fuel.
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♦ In extreme cases, the temperature of the fuel and the fuel
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lines can reach 100 °C after the engine is switched off.
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Allow the fuel to cool down before disconnecting the lines
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- risk of scalding.
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♦ Wear protective gloves.
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♦ Wear protective goggles.
Risk of injury from highly pressurised fuel.

The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connection
and carefully loosen the connection.
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.
2 Rep. gr.00 - Technical data

Polo 2010 ➤
2.2 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.
2.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing andenmeasuring
AG. Volkswaginstruments
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dangerous projectiles. Volkswag does
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– Secure testingoriand
se measuring instruments on the rear rseat.
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– Have a second person operate the test and measuring equip‐

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2.4 Safety precautions when working on the cooling system

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Danger of scalding by hot coolant

On a warm engine, the cooling system is under high pressure.
rrectness of i
Danger of scalding due to steam and hot coolant.

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– Reduce excess pressure by covering cap of coolant expan‐

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sion tank with cloths and opening it carefully.

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2.5 Safety precautions when working on the SCR system

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Risk of damage caused by reducing agent
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If reducing agent gets onto trim panels and body components, the
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reducing agent may solidify after a while and thus damage the
surface.
– Make sure that no reducing agent gets onto the trim panels or
body components.
– If any reducing agent does get onto surfaces, remove it im‐
mediately using water and a cloth.
Risk of injury due to reducing agent

The reducing agent may cause eye and skin irritations as well as
injuries to the respiratory system and poisoning.
2. Safety information 3
Polo 2010 ➤

– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied. In
closed areas, switch on the exhaust gas extractor system.
WARNING
♦ Information concerning storage and disposal ⇒ Service‐

Net → Environmental protection → Workshop disposal !
Request country specific information from importer con‐
cerning storage and disposal.
Risk due to escaping reducing agent:
♦ To prevent large amounts of reducing agent from escap‐
ing when the metering line is opened, it is necessary to
wait until automatic return of the reducing agent is com‐
pleted ⇒ page 4 .
Automatic return of reducing agent

• After the ignition has been switched off, the reducing agent is
returned from the metering line leading to the reducing agent
injector - N474- back to the reducing agent tank.
• Before any work is done in this area, it is necessary to wait
until all the reducing agent has been returned to the tank; this
n AG. Volkswagen AG do
can take up to 10 minutes after the ignition
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• Similarly, it is not permissible to disconnect
ris
ed the battery until all nte
the reducing agent has been returnedtho
to the tank, i.e. 10 mi‐ eo
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nutes after the ignition is switched
ss off ⇒ Electrical system; c
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
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2.6 Safety precautions when working on exhaust system

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Risk of poisoning due to chemical substances

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Exhaust gas temperature senders may contain chemical sub‐

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stances. There is a risk of poisoning or injuries to respiratory

system.
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– Never open an exhaust gas temperature sender by cutting,

sawing or any other means.
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Risk of injury due to hot condensate and particles in the exhaust

system.
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The exhaust system could contain hot condensate and/or parti‐

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cles. There is a risk of injury to the eyes, skin and respiratory

form
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system, as well as poisoning.

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– Always wear protective gloves and eye protection when cut‐

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– When cutting, use an extraction system or otherwise ensure

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sufficient ventilation.
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AG. Volkswagen AG d
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3-cylinder common
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Caution
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Risk of damage to flexible joint.
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♦ Do not allow the flexible joint to kink by more than 10°.
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♦ Install flexible joint so that it is not under tension.
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♦ Do not damage wire mesh on decoupling element.
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2. Safety information 5
Polo 2010 ➤
3 General repair notes

⇒ “3.1 Rules for cleanliness”, page 6
3.1 Rules for cleanliness

⇒ “3.1.1 When working on fuel supply/injection system”,
page 6
⇒ “3.1.2 When working on turbocharger”, page 6
3.1.1 When working on fuel supply/injection

system
When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ When the system is open: Do not work with compressed air.
The vehicle should not be moved.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.1.2 When working on turbocharger agen

AG. Volkswagen AG d
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When working on the turbocharger, pay careful attention ed to the
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following rules for cleanliness: horis
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♦ Thoroughly clean all unions and adjacent areas
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♦ Place removed parts on a clean surface and cover them over.

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Use lint-free cloths only.

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♦ Carefully cover opened components or seal them if repairs

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cannot be carried out immediately.

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spec
♦ Install only clean parts; do not remove new parts from pack‐
es, in part or in w
t to the co
aging until immediately before installing. Do not use parts that

have been kept unpackaged (for example in toolboxes).
♦ Transportation and protective packaging and sealing caps
rrectness of i
must be removed only immediately before fitting.

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♦ When making repairs, remove oil from connection and hose

ends.
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♦ If system is open, do not work with compressed air. Do not

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move vehicle unless absolutely necessary.

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Polo 2010 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 7
⇒ “1.2 Securing engine on engine and gearbox support”,
page 15
⇒ “1.3 Installing engine”, page 17
1.1 Removing engine
Special tools and workshop

equipment required
AG. Volkswagen AG d
agen oes
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♦ Hose clamps to 25 mm - 3094-

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♦ Torque wrench - V.A.G 1331-

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♦ Engine and gearbox jack - V.A.G 1383 A-

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♦ Stepladder - VAS 5085-

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♦ Engine support - T40076-

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1. Removing and installing engine
AG.
AG. Volkswagen AG d
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Polo 2010 ➤ by Vol
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3-cylinder common orise rail engine (1.2 l, EA189) - Edition 06.2019 nte
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♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clamp pliers - VAS 6340-
♦ Gearbox support - T10412-
♦ Grease (vehicles with manual gearbox) - G 000 100-
♦ Cable tie
8 Rep. gr.10 - Removing and installing engine

Polo 2010 ➤
Transportation lock - T10403-

Engine bung set - VAS 6122- (not shown)
Note
♦ Engine is removed forwards.

♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route lines of any kind so that the original routing can be
restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
»Carry out the following work sequence«

Removing
– Remove engine cover panel ⇒ page 24 .
– With ignition switched off, disconnect battery earth strap. ⇒ gen AG. Volkswagen AG d
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
Vol
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– Remove battery and battery tray ⇒ Electrical system;
au
th Rep. gr. or
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27 ; Removing and installing battery . ss
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– Remove air filter.
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– Drain coolant ⇒ page 146 .
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Vehicles with air conditioning system
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– Extract refrigerant ⇒ Rep. gr. 87 .
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Continued for all vehicles

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– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 .
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– Unscrew positive cable -1- from battery positive distributor.

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– Lay cable down on engine during further work sequence.

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1. Removing and installing engine 9

Polo 2010 ➤
– Remove vacuum hoses with bracket -1- from air filter.

– Remove connector from charge pressure control solenoid
valve - N75- -3-.
– Unbolt charge pressure control solenoid valve - N75- with
bracket -2-.
– Place charge pressure control solenoid valve - N75- with
olks
wagevac‐ es n
ot g
uum lines on engine. db
y V ua
ran
e
ris tee
– Remove charge air pipe »hot« side ⇒ page
ut 180 .
ho or
a ac
ss
– Remove charge air pipe »cold« side ⇒ page 181 .
ce
le
un
pt
an
d
itte
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erm
ab
– Remove AC compressor ⇒ Rep. gr. 87 ; Removing and in‐
ility
ot p
stalling air conditioner compressor .
wit
is n
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ole,
spec
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
t to the co
and installing starter .
– Remove vacuum hose between vacuum pump and brake ser‐
vo.
rrectne
– Detach vacuum line -arrow- on brake servo.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Pre-heater line -arrow 2- is not necessarily installed.
– Disconnect connectors -1 … 4-.

♦ -1- Exhaust gas temperature sender 1 - G235-
♦ -4- lambda probe - G39-
– Guide lines out of brackets on plenum chamber bulkhead and
on turbocharger.

Polo 2010 ➤
– Separate electrical connector -2- on pressure differential

sender - G505- .
– Unscrew bolt -3- from pressure differential sender - G505-
bracket.
– Lay pressure differential sender - G505-
agen with lines down
AG. Volkswagen AG dto
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th or
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spec
t to the co
rrectne
– Unscrew coolant return line bolts -arrows-.
s
– Lay coolant return line to side.
s 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.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
– Remove fuel supply line and return line -arrows- at high-pres‐ cted agen
Prote AG.
sure pump.
– Disconnect connecting hose -2- from cylinder head cover.

– Unscrew bolt -3- (attached), turn intake hose clockwise out of
its bracket and remove.
– Remove engine control unit from its bracket ⇒ page 241 .
– Release engine wiring harness connector from engine control
unit and remove.

Polo 2010 ➤
– Disconnect connector -arrow-.

n AG. Volkswagen A age G do
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oris tee
th or
au ac
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nl
pt
du
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itte
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ab
ility
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spec
es, in part or in w
t to the co
– Carefully loosen engine wiring harness at its fastening points
-arrows-.
rrectness of i
– Place engine wiring harness on engine.
l purpos
– Separate all remaining connectors to engine.
nf
ercia
orm
m
atio
om
n in
or c
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op
– Loosen particulate filter. C py
t. rig
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1) Remove securing clamp between particulate filter and
cop Vo
by lksw
cted
turbocharger
agen
Prote AG.
2) Unscrew bolts -2 … 3-
3) Loosen bolt -4-

4) Unscrew nuts -5-
– Push particulate filter aside and secure on plenum chamber
bulkhead by suitable means.
Caution
Bolt -1- must not be loosened.
– Unscrew securing bolts -arrows- for pendulum support.

Polo 2010 ➤
– Unscrew bolt -2-.
– Install gearbox support - T10412- .

The -arrow- on gearbox support points forwards.
– Tighten securing bolts -arrows- hand tight.
AG. Volkswagen AG d
agen oes
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Note d by ara
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u ra
♦ The gearbox support - T10412-
ss a prevents lowering of the gear‐ c
box when the engine is removed and installed.
ce
le
un
pt
an
d
♦ The pendulum support must be reinstalled once engine is re‐

itte
y li
installed.
erm
ab
ility
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– Disconnect quick-release couplings for heat exchanger
ole,
spec
-arrows- on plenum chamber bulkhead.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
– Unscrew bolts -arrows- on engine mounting approx. 2 turns.

sd
iva
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pr
cum
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fo
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Note
Co
Cop py
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♦ Check that all hoses and line connections between engine and cop Vo
by lksw
body have been released. cted agen
Prote AG.
♦ Guide »engine« carefully when removing to prevent damage

to bodywork.
– Seal open lines and unions with clean plugs from engine seal‐
ing plug set - VAS 6122- .

Polo 2010 ➤
– Open fasteners -arrows- and remove noise insulation -1- for

sump.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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r
– Remove heat shield for right drive shaft -1-. aut
ho eo
ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
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ole,
spec
t to the co
rrectne
– Unscrew all remaining securing bolts for engine to gearbox.
ss o
-5- Small cover plate for flywheel
cial p
f inform
Item -A-: dowel sleeves for centring
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
by c lksw
cted agen
Prote AG.
– During further procedure, engine bracket - T40076- is secured
with a longer bolt -6-.

Polo 2010 ➤
– Screw engine support - T40076- with nut -1- to cylinder block

to approx. 20 Nm.
– Fit M12 nut -3- between engine bracket - T40076- and cylinder
block.
– Secure engine bracket - T40076- with M10 × 50 nut -2- on
cylinder block.
– Fit engine and gearbox jack - V.A.G 1383 A- to engine support
- T40076- .
– Insert engine bracket - T40076- in engine and gearbox jack -
V.A.G 1383/A- .
– Raise engine/gearbox assembly slightly.
Note
. Volkswagen AG
gen AG does
swa
Use a stepladder y V - VAS 5085- to unscrew theobolts
olk n t
gu for the as‐
sembly mountings.
risedb ara
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– Completely unscrew securing bolts -arrows- for engine mount‐ ce
e
nl
ing. pt
du
an
itte
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erm
– Remove entire engine mounting upwards. ab

ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove engine bracket ⇒ page 20 .

nform
mercia
at
Caution
om
ion
c
in t
or
Danger of damage to hose and line connections as well as

his
ate
engine compartment.
do
priv
cum
or
♦ Check that all hose and line connections between engine,

f
en
ng
t.
yi
gearbox, subframe and body have been disconnected.
Co
Cop py
t. rig
♦ When lowering, carefully guide engine out of engine com‐
gh ht
pyri by
partment.
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cted agen
Prote AG.
– Pull engine out of gearbox.

– Then swivel engine forwards and lower.
1.2 Securing engine on engine and gearbox support

Polo 2010 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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tho eo
au ra
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nl
pt
du
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ab
ility
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hole
spec
es, in part or in w
t to the co
♦ Lifting tackle - 2024 A-
♦ Workshop hoist - VAS 6100-
rrectness of i
♦ Engine and gearbox support - VAS 6095-
l purpos

nf
ercia
Before carrying out repair work, secure engine with universal

or
mounting - VAS 6095/1- to engine and gearbox bracket - VAS

m
m
atio
6095- .
om
n in
or c

thi
te
sd
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
– Attach lifting tackle - 2024A- as follows, and lift from engine

and gearbox jack - VAS 6100- using workshop crane - V.A.G
1383/A- .
WARNING
Use locking pins -arrows- to secure hooks and locating pins.
– Secure engine on engine and gearbox support - VAS 6095/1-

using universal mounting - VAS 6095- .
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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nl
pt
du
an
itte
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erm
ab
ility
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1.3 Installing engine
h re
hole
spec
⇒ “1.3.1 Notes on installing ”, page 17
es, in part or in w
t to the co
⇒ “1.3.2 Additional information and assembly work for vehicles
with air conditioner”, page 19
rrectness of i
1.3.1 Notes on installing
l purpos
Caution nform
ercia
When installing a new short engine, it is compulsory to fix and

m
at
om
tighten the clamping jaws of the injectors with the specified

on
c
in t
torque after installing the high-pressure lines ⇒ page 193 .

or
his
e
Clamping jaws are only secured »hand-tight« for setting the

at
do
riv
injectors while installing high-pressure lines. Non-observance

p
cum
or
of these notes may lead to damage to engine.

f
en
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Cop py
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Install in reverse order of removal. During this procedure, observe yri
p by
o Vo
the following:
by c lksw
cted agen
Prote AG.
Repairing the clutch:
♦ Vehicles with manual gearbox ⇒ Manual gearbox; Rep. gr.
34 .
– Check clutch release bearing for wear and renew if necessary.
– Lightly grease clutch release bearing, release bearing guide
and splines on input shaft with G 000 100.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.

Polo 2010 ➤
– Secure release lever using a suitable bolt -2- -arrow-.

– When swinging engine/gearbox assembly in, ensure that there
is clearance between drive shafts.
– Bolt gearbox flange to cylinder block.
– Release again clutch release lever, remove previously fitted
bolt.
– Fit genuine bolt again.
Gearbox specified torques: ⇒ Manual gearbox; Rep. gr. 34 ;
Removing and installing gearbox .
Specified torque for starter: ⇒ Electrical system; Rep. gr. 27 .
– Rock engine to align engine mountings stress-free.
– When installing »engine«, ensure that there is sufficient clear‐
ance to subframe.
– Adjusting assembly mountings ⇒ page 20 .
wage es n
Vehicles with air conditioning system yV
olks ot g
ua
b
ed ran
– Install air conditioning system
hor compressor ⇒ Heating, air con‐
is tee
ditioning system; Rep. sgr.au 87 .
t or
ac
s
ce
e
nl
pt
du
an
itte
– Electrical connections and routing: ⇒ Electrical system; Rep.
y li
erm
ab
gr. 97 .
ility
ot p
wit
– Install poly V-belt ⇒ page 25 .
, is n
h re
hole
– Add coolant ⇒ page 150 .

spec
es, in part or in w
– Connect vehicle diagnostic tester.

t to the co
For example ⇒ Vehicle diagnostic tester
rrectness of i
– Erase learnt values and adapt engine control unit - J623- to

throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
l purpos
tions”.
nf
ercia
Note
rm
m
atio
om
♦ Specified torques for engine/gearbox assembly mountings

n in
or c
⇒ page 20
thi
te
sd
iva
♦ After working on particulate filter, ensure it is installed free of

r
rp
cu
o
stress.
f
en
ng
t.
yi Co
op
♦ Renew self-locking nuts, seals, gaskets and securing clamps. C py
t. rig
gh ht
yri
♦ The further procedure must be followed in the specified se‐
p by
co Vo
by lksw
quence to ensure that the particulate filter is installed stress- Prote
cted AG.
agen
free.
Caution
Avoid damage to flexible joint behind particulate filter:

♦ Do not allow the flexible joint to kink by more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Do not damage wire mesh on decoupling element.

Polo 2010 ➤
Observe sequence when installing particulate filter.

– Secure particulate filter ⇒ page 253 .
– Install heat shield for drive shaft (right side) -1-.

Specified torque ⇒ Manual gearbox; Rep. gr. 34
– Secure refrigerant lines free of stress to air conditioner com‐
pressor and to condenser ⇒ Heating, air conditioning; Rep.
gr. 87 .
– Charge air conditioner ⇒ Heating, air conditioning; Rep. gr.
87 .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery . . Volkswage n AG n AG d
wage oes
– Observe notes after connecting battery
yV
olks ⇒ Electrical system; not
gu
Rep. gr. 27 ; Disconnecting and
ise
d breconnecting battery . ara
nte
r
ho eo
– Fill fuel system ⇒ page 188
sa
ut . ra
c
s
– Carry out a vehicle system test ⇒ Vehicle diagnostic tester
ce
e
nl
pt
du
“Guided Fault Finding”.
an
itte
y li
erm
ab
– Finish the vehicle system test so that any event entries stored
ility
ot p
during assembly can be erased automatically.
wit
, is n
h re
Note safety precautions applicable to a road test.
hole
spec
– Carry out road test.
es, in part or in w
t to the co
– Then carry out vehicle system test again, rectify any faults
which may have occurred.
rrectness of i
Specified torques
l purpos
Bolted connection Specified torque

Nuts and bolts M6 10 Nm
nf
ercia
M7 15 Nm orm
m
atio
m
M8 20 Nm
o
n in
or c
M10 40 Nm
thi
te
sd
iva
M12 65 Nm1)
o
r
rp
cu
o
m
f
en
ng
1) Specified torque for M12 flange bolts: 75 Nm

t.
yi Co
Cop py
t. rig
1.3.2 Additional information and assembly
gh ht
pyri by
Vo
co lksw
by
work for vehicles with air conditioner cted agen
Prote AG.
Note
♦ When engine is to be removed, air conditioner refrigerant cir‐

cuit must be opened.
♦ To prevent damage to condenser and refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or
bent.
– Extract refrigerant from air conditioner refrigerant circuit. Open

air conditioner refrigerant circuit ⇒ Rep. gr. 87 .
Note
The air conditioner compressor can remain installed.

AG. Volkswagen AG d
agen oes
olksw not
V
Polo 2010 ➤ d by gu
ara
ise nte
thor - Edition 06.2019 eo
au ra
ss c
ce
e
nl
2 Assembly mountings
pt
du
an
itte
y li
erm
ab
⇒ “2.1 Assembly overview - assembly mountings”, page 20
ility
ot p
wit
⇒ “2.2 Supporting engine in installation position”, page 22
, is n
h re
hole
2.1 Assembly overview - assembly mount‐
spec
es, in part or in w
ings
t to the co
Assembly overview - assembly mountings
rrectness of i
1 - Bolt
l purpos
❑ Fastening the engine

bracket to engine
nform
ercia
❑ Renew
m
at
om
❑ Specified torque and
ion
c
tightening sequence
in t
or
⇒ page 21
his
ate
do
priv
c
2 - Engine support
um
for
en
g
❑ Removing and installing

n
t.
yi Co
op
⇒ page 20 C py
t. rig
gh ht
yri
3 - Bolt
p by
co Vo
by lksw
cted
❑ Fastening the engine
agen
Prote AG.
bracket to engine
❑ Renew
tightening sequence
⇒ page 21
4 - Engine assembly mounting
to body
tightening sequence
⇒ page 21
5 - engine mounts
6 - Engine carrier bolts to en‐
gine bracket
❑ Renew
tightening sequence
⇒ page 21
7 - Pendulum support
8 - Pendulum support bolt to
subframe
❑ Specified torque and tightening sequence ⇒ page 21
9 - Pendulum support bolts to gearbox
10 - Assembly mounting bolts, gearbox to gearbox mounting
❑ Renew
11 - Assembly mounting bolts, gearbox to body
❑ Renew

Polo 2010 ➤
12 - Gearbox mounting
13 - Nuts for particulate filter bracket
❑ Renew
❑ 25 Nm
Engine bracket - specified torques and tightening sequence

– Tighten bolts in 3 stages in the sequence shown:
Stage Bolts 1) Specified torque/turning further angle
1) -1 … 3- 7 Nm
2) -1 … 3- 40 Nm
3) -1 … 3- Turn 180° further
1) Renew
Engine mounting
-A- 1) 20 Nm + turn 90°

-B- 1) 30 Nm + turn 90° agen
AG. Volkswagen AG d
oes
olksw not
-Arrow- Must not be looseneded by V gu
ara
ris nte
1) Renew ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Pendulum support
spec
es, in part or in w
t to the co
Note
rrectness of i
Position bolts -A- in elongated holes of pendulum support so that
the clearance between the gearbox and mountings is at its max‐
l purpos
imum.
nform
ercia
-A- 1) 30 Nm + turn 90°

m
at
1) 40 Nm + turn 90°
om
-B-
ion
c
in t
r
-Arrow- Must not be loosened

o
his
ate
1)
do
riv
Renew
p
cum
for
en
ng
t.
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Gearbox mounting
Co
Cop py
t. rig
gh ht
yri
-A- 1) 40Nm + turn 90° p by
o Vo
by c lksw
cted agen
-B- 1) 40 Nm + turn 90° Prote AG.
1) Renew
2. Assembly mountings 21
Polo 2010 ➤
2.2 Supporting engine in installation posi‐

tion
⇒ “2.2.1 Installing support bracket (Polo) ”, page 22
2.2.1 Installing support bracket (Polo) n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
d ran
Special tools and workshop ir se tee
tho
or
equipment required au ac
ss
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
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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 AG.
♦ Support - 10-222 A-
♦ Adapter - 10 - 222 A /8-
♦ Hook - 10-222 A/10-
♦ Shackle - 10-222 A/12-

Polo 2010 ➤
To prevent damage to edges of wings, cover lower areas of both

adapters - 10 - 222 A /8- with duct tape -arrow- ⇒ Electronic parts
catalogue (ETKA, chemical substances) .
Procedure
– Set up support bracket - 10 - 222 A- with necessary adapters

as illustrated and support engine in installation position.
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
– Pay attention to paintwork on edges -arrows-.

wit
, is n
h re
It is only necessary to secure the two adapters - 10 - 222 A /8-

hole
with the tensioning straps - T10038- when removing the gearbox.

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
co lksw
by
cted agen
Prote AG.
2. Assembly mountings 23
Polo 2010 ➤
3 Engine cover panel

Removing
Caution
The engine cover retainer on the cylinder head cover can break
if not removed correctly. Remove engine cover panel accord‐
ing to following instructions under all circumstances.
– Pull engine cover panel upwards in areas of -arrows- and in

sequence shown. To do this, reach as far as possible under
engine cover.
Installing
– Position engine cover panel on securing points and press cor‐
ners into fasteners.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive (vehicles without air
conditioner compressor)”, page 25
⇒ “1.2 Assembly overview - poly V-belt drive (vehicles with idler
roller and air conditioner compressor)”, page 27
⇒ “1.3 Assembly overview - poly V-belt drive (vehicles with ten‐
sioning element and air conditioner compressor)”, page 28
⇒ “1.4 Removing and installing poly V-belt (vehicles without air
conditioner compressor)”, page 28
⇒ “1.5 Removing and installing poly V-belt (vehicles with idler
roller)”, page 29
⇒ “1.6 Removing and installing poly V-belt (vehicles with tension‐
ing element)”, page 30
⇒ “1.7 Removing and installing tensioner for poly V-belt”,
page 32
⇒ “1.8 Removing and installing vibration
gen AG
. Vodamper”,
lkswagen AGpage 33
a does
lksw not
⇒ “1.9 Ancillary bracketd ”,
by page 34
Vo gu
ara
e nt
ris
⇒ “1.10 Removingutand
ho installing sealing flange on pulley end”, ee or
page 36 ss
a ac
ce
le
1.1 Assembly overview - poly V-belt drive (vehicles without air conditioner com‐
un
pt
an
d
itte
y li
pressor)
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
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.
1. Cylinder block (pulley end) 25

Polo 2010 ➤
1 - Belt pulley and vibration

damper
❑ Fitting possible in one
position only. The holes
are offset.
⇒ page 33
2 - Alternator
⇒ Rep. gr. 27
3 - Ancillary bracket
Assembly overview
⇒ page 34 .
⇒ page 34 .
4 - Poly V-belt AG. Volkswagen AG d
agen oes
ksw
❑ Renew. byV
ol not
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❑ Removing and installingoris nte
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⇒ page 28 th
au ra
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nl
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ility
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in t
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ate
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Cop py
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Prote AG.
26 Rep. gr.13 - Crankshaft group

Polo 2010 ➤
1.2 Assembly overview - poly V-belt drive (vehicles with idler roller and air con‐
ditioner compressor)
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
❑ Removing and instal‐ olkswage es n
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ling: vehicles with air d byV ua
ran
conditioner compressor o
ir se tee
and tensioning roller auth or
ac
⇒ page 27 ss
ce
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nl
❑ Do not kink
pt
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❑ When installing, make
erm
ab
sure it is properly seated
ility
ot p
on poly V-belt pulleys.
wit
, is n
h re
2 - Idler roller for poly V-belt
hole
spec
es, in part or in w
⇒ page 29
t to the co
❑ Coat guide surfaces in
ancillary bracket with lu‐
rrectness of i
bricating paste; lubricat‐
ing paste ⇒ Electronic
l purpos
Parts Catalogue .
3 - Vibration damper
nform
ercia
❑ With poly V-belt pulley

m
at
om
❑ Installation position:
ion
c
hole in vibration damper
in t
or
must align over protru‐
his
ate
do
riv
sion on crankshaft pul‐

p
ley. cum
for
en
ng
t.
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op
⇒ page 33
C py
t. rig
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4 - Bolt cop Vo
by lksw
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❑ Renew
Prote AG.
❑ Use only genuine bolts ⇒ Electronic parts catalogue

❑ 10 Nm +90°
5 - Dowel sleeve
❑ Check for correct seating in ancillary bracket.
6 - Ancillary bracket
Assembly overview ⇒ page 34 .
❑ Removing and installing ⇒ page 34 .
7 - Alternator
❑ Removing and installing ⇒ Rep. gr. 27
8 - Air conditioner compressor
❑ Removing and installing ⇒ Rep. gr. 87
9 - Dowel sleeve
10 - Bolt

Polo 2010 ➤
1.3 Assembly overview - poly V-belt drive (vehicles with tensioning element and
air conditioner compressor)
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
⇒ page 30
2 - Poly V-belt tensioning ele‐
ment
❑ Swing with open-end
spanner to slacken poly
V-belt ⇒ page 30
3 - Belt pulley and vibration
damper
❑ Offset holes make as‐
sembly possible in one
position only
4 - 25 Nm
5 - Dowel sleeves
❑ Check for correct seat‐
ing in ancillary bracket. AG. Volkswagen AG d
agen oes
lksw not
6 - Ancillary bracket by Vo gu
ara
d
❑ Removing and installing rise nte
ho eo
⇒ page 34 . s aut ra
c
s
7 - 20 Nm + 90° further
ce
e
nl
pt
du
an
itte
8 - Alternator
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erm
ab
ility
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⇒ Rep. gr. 27
wit
, is n
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9 - Air conditioner compressor
hole
spec
es, in part or in w
t to the co
⇒ Rep. gr. 87
10 - Dowel sleeves
rrectness of i
l purpos
1.4 Removing and installing poly V-belt (ve‐

nf
ercia
hicles without air conditioner compres‐

rm
m
atio
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sor)
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n in
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The poly V-belt repair kit with tools contains tool -T10367- and Cop py
illustrated instructions.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
»Carry out the following work sequence« Prote AG.

Polo 2010 ➤
Removing and installing

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
tion .
– Cut through poly V-belt.
– Further work sequence is carried out as described in illustrated
instructions.
The illustrated instructions accompany the spare part.
Install in reverse order, noting the following:
On completing work:
– Start engine, and check belt running.
– Secure front part of right wheel housing liner again.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front; Assembly overview - noise insulation .

hicles with idler roller)
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331- .
lkswage es n
o ot g
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d ran
ir se tee
tho
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ss
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nl
pt
du
an
itte
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erm
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co

Removing
rrectness of i
– Noise insulation ⇒ General body repairs, exterior; Rep. gr.

50 ; Body - front; Assembly overview - noise insulation .
l purpos
– Unscrew bolt for poly V-belt idler roller -arrow- until poly V-belt
can be removed easily.
nform
ercia
– Remove poly V-belt.

m
at
om
ion
c
Installing
in t
or
his
ate
– Using a brush, coat guide surfaces of idler roller with lubricat‐

do
priv
ing paste. ⇒ ETKA (Electronic Parts Catalogue) G 052 751

cum
for
A1.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
– Fit poly V-belt on poly V-belt pulley:

1- Vibration damper
2- Idler roller
3- Alternator
4- Air conditioner compressor
– Now insert idler roller, with its bolt, into guide of ancillary
bracket.
Tightening sequence for poly V-belt idler roller.

– Tighten bolt in 5 stages. wage
es n
olks ot g
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Stage Bolt Specified torque/turning further angle ised b ua
ran
or tee
1) -2- Screw in by hand as far as stop auth or
ac
• the poly V-belt is tensioned ss
ce
le
un
pt
an
d
2) -2- turn until tensioning roller bolt reaches

itte
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stop
rm
ab
pe
ility
• the poly V-belt is tensioned further
ot
wit
, is n
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3) -2- Turn back 90°
hole
spec
4) -2- 30 Nm
es, in part or in w
t to the co
5) -2- Turn 90° further
• As shown in illustration, check whether the end of the bolt for
rrectness of i
idler roller/poly V-belt protrudes over the running surface of the
l purpos
idler roller. Dimension -a- = approx. 2.5 mm.

This ensures that the idler roller bolt was tightened up to its end
nform
ercia
position.
m
a
Continued for all vehicles:
com
tion in
– Turn engine at least one turn in direction of rotation at the belt
r
te o
thi
pulley/vibration damper central bolt.
s
iva
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r
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fo
en
ng
t.
Note
yi Co
Cop py
t. rig
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♦ Before installing poly V-belt, ensure that all ancillaries (alter‐ p by
co Vo
nator, air conditioner compressor) are secure.
by lksw
cted agen
Prote AG.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.
On completing work:

hicles with tensioning element)

Polo 2010 ➤
♦ Locking pin - T10060 A-
lkswage es n
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ir se tee
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s a ac
s
ce
le
un
pt
Removing
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
– Mark running direction of poly V-belt.
hole
spec
– Swing tensioning element in direction of arrow to relieve ten‐
es, in part or in w
t to the co
sion on poly V-belt.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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– Align holes -arrows- and lock tensioning element in position

fo
en
g
with locking pin - T10060 A- .

n
t.
yi Co
Cop py
– Remove poly V-belt.
t. rig
gh ht
pyri by
Vo
co
Installing
by lksw
cted agen
Prote AG.
– Install in reverse order.
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secure.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.

Polo 2010 ➤ n AG. Volkswagen AG do
3-cylinder common rail engine (1.2 l, EA189)l wage
k-sEdition 06.2019 es n
Vo ot gu
y
db ara
ise nte
– Fit poly V-belt on poly V-belt pulleys. tho
r eo
au ra
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1- Crankshaft ss
ce
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nl
pt
du
2- Tensioning element
an
itte
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erm
ab
3- Alternator
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4- Air conditioner compressor
, is n
h re
hole
On completing work:
spec
es, in part or in w
t to the co
rrectness of i
1.7 Removing and installing tensioner for
l purpos
poly V-belt
nform
ercia
⇒ “1.7.1 Removing and installing tensioning element for poly V-

m
belt”, page 32
at
om
ion
c
⇒ “1.5 Removing and installing poly V-belt (vehicles with idler
in t
or
his
e
roller)”, page 29
at
do
priv
c
1.7.1 Removing and installing tensioning ele‐
um
for
en
ng
t.
ment for poly V-belt
yi Co
Cop py
t. rig
gh ht
Special tools, testers, measuring instruments and auxiliary items pyri by
Vo
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by c
required
lksw
cted agen
Prote AG.
Torque wrench - V.A.G 1332-
♦
Removing
– Remove poly V-belt ⇒ page 30 .
– Unscrew securing bolt -bottom arrow- from charge air pipe.
– Unscrew coolant line bolts -arrows-.

– Remove air conditioner compressor; do not detach refrigerant
lines on air conditioner compressor.
– Refrigerant circuit remains closed.
– Using a suitable tool, suspend air conditioner compressor to
body ⇒ Rep. gr. 87 ; Removing and installing air conditioner
compressor .

Polo 2010 ➤
– Unscrew securing bolt -2-, remove tensioning element for

poly-V belt -1-.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
♦ ⇒ Rep. gr. 87 ; Installing air conditioner compressor
♦ Specified torques for poly V-belt drive with tensioning element
⇒ page 28 . . Volkswage AG n AG d
agen oes
♦ Install poly V-belt ⇒ page 30 . olksw not
yV gu
db ara
rise nte
tho eo
s au ra
c
1.8 Removing and installing vibration damp‐ s
ce
le
un
pt
er
an
d
itte
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rm
ab
pe
ility
ot
wit
Removing
, is n
h re
hole
spec
es, in part or in w
– Unscrew coolant line bolts -arrows-.
t to the co
– Move coolant lines aside slightly.
rrectness of i
– Remove charge-air pipe »cold« side.
l purpos
– Cover cap for vibration damper.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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– Loosen bolts -arrows- for vibration damper, counterhold on

n
t.
yi Co
op
crankshaft pulley bolt with a ring spanner to do this. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew bolts and remove vibration damper.

Installing
Installation is in the reverse sequence of removal. The following
should be observed:
Specified torques ⇒ Item 27 (page 84)

Polo 2010 ➤
– Install vibration damper with new bolts ⇒ Electronic parts

catalogue .
• The vibration damper can only be installed in one position. The
hole in the vibration damper must be located over the projec‐
tion on the toothed belt pulley -arrow-.
lkswage es n
o ot g
yV
1.9 Ancillary bracket ir se
d b ua
ran
tee
tho
or
⇒ “1.9.1 Assembly overview - ancillary
au bracket”, page 34 ac
ss
ce
e
⇒ “1.9.2 Ancillary bracket (removing and installing)”, page 34

nl
pt
du
an
itte
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1.9.1 Assembly overview - ancillary bracket
erm
ab
ility
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Note
hole
spec
es, in part or in w
Renew securing bolts for ancillary bracket.
t to the co
– Install bolts as follows:
rrectness of i
♦ Bolts -1- and -2- M10 x 52.
l purpos
♦ Bolts -3- and -4- M10 x 30.

♦ Bolts -5- and -6- M10 x 60.
nform
ercia
♦ Lifting eye bolts -A- and -B- 25 Nm.

m
at
om
ion
– Tighten bolts -1 to 6- in 4 stages in the sequence shown:
c
in t
or
his
ate
Sta Bolts Specified torque/turn‐

do
priv
ge ing further angle

cum
for
en
ng
t.
1) -1 … 6- Screw in by hand as far op
yi Co
as stop
C py
t. rig
gh ht
yri
2) -1 … 6- 40 Nm
p by
co Vo
by lksw
cted agen
3) -3- and Turn 45° further Prote AG.
-4-
4) -1, 2, 5, 6- Turn 90° further
1.9.2 Ancillary bracket (removing and instal‐

ling)
Removing
– Remove high-pressure pump ⇒ page 214 .

Polo 2010 ➤
– Remove the generator ⇒ Electrical system; Rep. gr. 27 .

WARNING
Do not open the air conditioner refrigerant circuit.
– Unbolt air conditioner compressor from ancillary bracket and

secure to lock carrier ⇒ Heating, air conditioning; Rep. gr. 87 ;
Removing and installing air conditioner compressor .
– Unbolt idler rollers -1 + 2-, unscrew bolt -arrow- for toothed belt
guard.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
nl
pt
du
– Loosen securing bolt for engine bracket -1-.

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
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 AG.

lkswage es n
o ot g
byV ua
d ran
Polo 2010 ➤ ho
ir se tee
t or
3-cylinder common rail engine (1.2
au l, EA189) - Edition 06.2019 ac
ss
ce
e
nl
– Unscrew bolts -6…1-, remove ancillary bracket.
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
Specified torque and tightening sequence ⇒ page 34
wit
, is n
h re
hole
spec
lowing:
es, in part or in w
t to the co
♦ Note any fitted sleeves in ancillary bracket and renew missing
ones if necessary.
♦ Renew all bolts to be tightened with torque angle.
rrectness of i
♦ Tack engine bracket bolt before tightening ancillary bracket
l purpos
securing bolt.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Tighten securing bolts in sequence -1…6-.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Renew and tighten bolt for engine bracket -1- ⇒ page 20 .

– Installing high-pressure pump ⇒ page 214 .
– Install toothed belt (adjust valve timing) ⇒ page 92 .
– Installing the generator ⇒ Electrical system; Rep. gr. 27 .
– Remove air conditioner compressor from lock carrier and in‐
stall on ancillary bracket ⇒ Heating, air conditioning; Rep. gr.
87 ; Removing and installing air conditioner compressor .
– Filling/bleeding high-pressure pump/fuel system
⇒ page 188 .
1.10 Removing and installing sealing flange on pulley end

Polo 2010 ➤

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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 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 tool - 3415-

♦ Assembly tool - T10053-
♦ Torque wrench - V.A.G 1331- (5 … 50 Nm)
♦ Torque wrench - V.A.G 1332- (40 … 200 Nm)
Not illustrated:
Sealant as per ⇒ ETKA (Electronic Parts Catalogue)
Hand drill with plastic brush attachment
Safety glasses
Scraper
1.10.1 Removing
– Remove toothed belt ⇒ page 88 .

Polo 2010 ➤
wage es n
– Remove crankshaft toothed belt pulley. by locking the toothed-
yV
olks ot g
ua
belt pulley using counterhold - 3415- . ise
d b ran
r tee
ho
– Drain engine oil. aut or
ac
ss
– Remove sump ⇒ page 121 .
ce
le
un
pt
an
d
itte
– Unbolt front sealing flange.
y li
erm
ab
ility
– Remove sealing flange; if necessary, loosen using light blows
ot p
wit
with a rubber headed hammer.
is n
h re
ole,
– Remove sealant residues from cylinder block with a flat scra‐
spec
per.
t to the co
– Sealing surfaces must be free of oil and grease.
rrectne
1.10.2 Installing
– Push guide sleeve - T10053/1- onto crankshaft.
ss o
cial p
f
– Fit sealing flange and lightly tighten all bolts.
inform
mer
– Tighten sealing flange securing bolts diagonally and alternate‐
atio
ly. Specified torque: ⇒ Item 7 (page 40) .
om
n
c
i
or
n
– Install oil pan.
thi
te
sd
va
Specified torque ⇒ page 118

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
o
by c
♦ Note expiration date of sealant as per ⇒ ETKA (Electronic
lksw
cted agen
Prote
Parts Catalogue) .
AG.
♦ Leave the sealant to dry for approx. 30 minutes after assem‐

bly. Only then fill with engine oil.
– Cut off tube nozzle at front marking (∅ of nozzle approx.

3 mm).
– Apply sealant as per ⇒ ETKA (Electronic Parts Catalogue) on
clean sealing surface of sump as shown in illustration. Sealant
bead must be:
♦ Run bead along inner side of bolt holes -arrows-.
Caution
Danger of blocking lubrication system with excess sealant.

♦ Do not apply sealant bead thicker than specified.

Polo 2010 ➤
• Thickness of sealant bead: 2…3 mm.
Note
♦ Take particular care when applying sealant bead in area of

rear sealing flange -arrows-.
♦ Oil sump must be installed within 5 minutes after applying
sealant.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
– Position oil sump and tighten bolts ⇒ page 118 .

itte
y li
erm
ab
• The sump must be flush with the gearbox flange at the inter‐
ility
ot p
mediate plate.
wit
is n
h re
ole,
spec
Note
t to the co
♦ When installing sump with engine removed, ensure that sump
is flush with crankcase at flywheel end.
rrectne
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
ss o
cial p
f in
Further assembly is performed in the reverse sequence.
form
mer
atio
om
n
c
Note
i
or
n thi
te
sd
va
Leave the sealant to dry for approx. 30 minutes after assembly.

i
o
pr
cum
r
Only then fill with engine oil.

fo
en
ng
t.
yi Co
Cop py
– Install crankshaft pulley. by locking the toothed-belt pulley us‐
t. rig
gh ht
yri
ing counterhold - 3415- . p by
co Vo
by lksw
cted agen
Tighten crankshaft pulley bolt ⇒ Item 2 (page 83) . Prote AG.
Install toothed belt and adjust the valve timing ⇒ page 88 .

– Replenish engine oil and check oil level ⇒ page 125 .

Polo 2010 ➤
2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 40
⇒ “2.2 Removing and installing flywheel”, page 41
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 42
Note
Repairing the clutch: ⇒ Rep. gr. 30
2.1 Assembly overview - cylinder block, gearbox end
1 - Seal ⇒ page 41
❑ Can only be renewed
complete with sealing
flange ⇒ page 36 .
❑ Do not apply additional
oil or grease the sealing
lip of the oil seal.
❑ Before installing, re‐
move oil residues from
crankshaft journal and
cylinder block using a
clean cloth.
2 - Sealing flange
⇒ page 41
❑ Renew
❑ Must seat on dowel
sleeves. agen
AG. Volkswagen AG d
oes
lksw not
❑ Removing and installing d by
Vo gu
ara
⇒ page 36 orise nte
h eo
ut ra
3 - Cylinder block ss a c
ce
e
❑ Assembly overview -
nl
pt
du
crankshaft ⇒ page 51
an
itte
y li
erm
❑ Dismantling and assem‐

ab
ility
bling pistons and con‐

ot p
wit
rods ⇒ page 54
, is n
h re
hole
4 - Flywheel
spec
es, in part or in w
❑ When removing and in‐

t to the co
stalling flywheel, lock

with counterhold -
3386- .
rrectness of i
5 - 60 Nm + 1/4 turn (90°) fur‐

l purpos
ther
❑ Renew
nform
ercia
6 - Adapter
m
at
om
❑ Must seat on dowel sleeves.

on
c
in t
or
❑ Do not damage or bend when assembling.

his
ate
do
riv
7 - 15 Nm
p
cum
for
en
g
8 - Sealing flange with oil seal

n
t.
yi Co
op py
❑ Only renew as entire unit together with seal and sender wheel t. C rig
gh ht
pyri by
Vo
o
by c lksw
40
cted agen
Prote
Rep. gr.13 - Crankshaft group
AG.
Polo 2010 ➤
❑ To remove, first remove sump ⇒ page 121 .
❑ Removing and installing ⇒ page 42
. Volkswage
n AG n AG d
wage oe
9 - Engine speed Vol sender - G28-
ks s no
t gu
d by ara
❑ Removing
orise and installing ⇒ page 287 nte
th eo
s au ra
c
s
ce
le
un
Sealing flange with rubber gasket and seal
pt
an
d
itte
y li
1- Seal: can only be renewed together with sealing flange
rm
ab
pe
ility
2- -Arrows- Rubber gasket: Renew sealing flange if damaged
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
2.2 Removing and installing flywheel

m
a
com
tion in
r
♦ Counter-hold tool - 3067-

te o
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do
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cum
fo
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t.
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Cop py
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Vo
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by c lksw
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Prote AG.
To remove and install flywheel ⇒ Power transmission; Rep.

gr. 34 ; Removing and installing gearbox .
When removing and installing flywheel, arrest the flywheel
with counterhold - 3067- .
Assembly through offset holes in the flywheel is only possible
in one position.
Specified torques ⇒ page 40
2. Cylinder block, gearbox end 41

Polo 2010 ➤
2.3 Removing and installing sealing flange

on gearbox side
⇒ “2.3.1 Pressing out sealing flange with sender wheel”,
page 43
⇒ “2.3.2 Pressing in sealing flange with sender wheel”,
page 44 wage
e ks s no
Vol t gu
⇒ “2.3.3 A - Assemble seal with
ed sender wheel on assembly tool
by ara
T10134 .”, page 45 ho
ris nte
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t
au ra
⇒ “2.3.4 B - Fitting assembly
ss tool T10134 with sealing flange to c
crankshaft flange”, page 47
ce
le
un
pt
an
d
itte
⇒ “2.3.5 C - Bolting assembly tool T10134 onto crankshaft flange”,
y li
erm
ab
page 48
ility
ot p
wit
⇒ “2.3.6 D - Pressing sender wheel onto crankshaft flange using
is n
h re
assembly tool T10134 ”, page 48
ole,
spec
⇒ “2.3.7 E - Checking sender wheel installation position on crank‐
t to the co
shaft”, page 48
⇒ “2.3.8 f) Re-pressing sender wheel”, page 50
rrectne
s
equipment required
s 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
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
Volksw Polo
not2010 ➤
gu
y
3-cylinder common riserail engine (1.2 l, EA189) - Edition 06.2019
d b ara
nte
tho eo
au ra
♦ Torque wrench - V.A.G 1331- ss c
ce
le
un
♦ Tool insert 24 mm - V.A.G 1332/11-
pt
an
d
itte
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erm
ab
♦ Depth gauge - VAS 6082-
ility
ot p
wit
is n
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ole,
spec
t to the co
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cial p
f inform
mer
atio
om
♦ 3 hexagon bolts M6 x 35 mm
n
c
i
or
n thi
e
♦ 2 hexagon bolts M7 x 35 mm
t
sd
iva
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pr
cum
2.3.1 Pressing out sealing flange with sender
r
fo
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ng
t.
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wheel
Co
Cop py
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– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing p by
co Vo
gearbox .
by lksw
cted agen
Prote AG.
– Remove flywheel.
– Detach intermediate plate at sealing flange and dowel pins
-arrows-.
– Turn crankshaft at bolt for toothed belt pulley until crankshaft

is at “TDC” of cyl. 1.
– Remove sump ⇒ page 121 .
Note
♦ The work procedures are depicted with engine removed to

simplify explanation.
♦ The procedure is identical whether the engine is installed or
removed.

Polo 2010 ➤
– Remove engine speed sender - G28- -1- ⇒ page 287 .
– Remove bolts for sealing flange -1 … 6-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
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pt
Note
an
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ab
Press sealing flange together with sender wheel from crankshaft.

pe
ility
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wit
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– To press out, screw in 3 bolts M6x35 -arrows- alternately into

hole
spec
sealing flange not more than 1/2 turn at a time.

es, in part or in w
t to the co
– Remove sealing flange with sender wheel.

rrectness of i
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2.3.2 Pressing in sealing flange with sender

nform
ercia
wheel
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tion in
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Note
te o
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♦ The sealing flange with a PTFE seal is equipped with a sealing

rp
cum
fo
lip support ring. This support serves as an assembly sleeve.

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Do not remove the support ring before installation.
Co
Cop py
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♦ Do not separate or turn the sealing flange and sender wheel
ht
pyri by
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after removal from packaging.
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Prote AG.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
♦ The sealing flange and seal are one unit. The unit can only be
renewed together with sender wheel.
♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara Polo 2010 ➤
rise nte
3-cylinder
autho
common rail engine (1.2 l, EA189) - Edition
e o 06.2019
ra
ss c
ce
e
Assembly tool - T10134-
nl
pt
du
an
itte
A - Clamping surface
y li
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ility
B - Hexagon nut
ot p
wit
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C - Assembly housing
h re
hole
spec
D - Locating pin
es, in part or in w
t to the co
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
rrectness of i
G - Guide pin for petrol engines (red knob)
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2.3.3 A - Assemble seal with sender wheel on
nform
ercia
assembly tool - T10134- .

m
at
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ion
– Screw on hexagon nut -B- until just before it touches the
c
in t
or
clamping surface -A- of the threaded spindle.
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ate
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for
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co lksw
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Prote AG.
– Clamp assembly tool - T10134- in a vice on clamping surface

-A- of threaded spindle.
– Press assembly housing -C- downwards until it lies on hexa‐
gon nut -B- -arrow-.
Note
Inner part of assembly tool and assembly housing must be at

same height.
– Remove securing clip -arrow- from new sealing flange.
Note
Do not remove the sender wheel from the sealing flange or turn
it.

Polo 2010 ➤
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side facing down on a clean,
level surface.
– Push sealing lip support ring -A- downwards in direction of ar‐

row until it lies on flat surface.
– Upper edge of sender wheel and front edge of sealing flangen AG. Volkswagen AG do
wage
must align -arrows-. yV
olks es n
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ed ran
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itte
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ility
ot p
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hole
spec
es, in part or in w
t to the co
– Fit sealing flange with front side facing downwards onto as‐
sembly tool - T10134- so that locating pin -B- can be inserted
rrectness of i
in sender wheel hole -A-.

l purpos
Note
nform
ercia
Ensure sealing flange lies flat on assembly tool.

m
at
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ion
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ate
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Prote AG.

Polo 2010 ➤
– Press sealing flange and sealing lip support ring -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A-.
This prevents locating pin from slipping out of sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly tool.
2.3.4 B - Fitting assembly tool - T10134- with

sealing flange to crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC of cylinder no. 1.
– Screw hexagon nuts -B- to end of threaded spindle.
– Press threaded spindles of assembly tool - T10134- in direc‐
tion of arrow, until hexagon nut -B- lies against assembly
housing -A-. AG. Volkswagen A gen G do
swa es
– Align flat side of assembly
yV
olk housing to crankcase's sealing
not
gu sur‐
face on the oil sumped b side. ara
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s au ra
c
s
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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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– Secure assembly tool - T10134- to crankshaft flange with hex‐

hole
agon socket head bolts -A-.

spec
es, in part or in w
t to the co
Note
rrectness of i
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
– To guide sealing flange into cylinder block, screw in 2 M7 ×

at
do
riv
35 mm bolts -A-.
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for
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Prote AG.

Polo 2010 ➤
2.3.5 C - Bolting assembly tool - T10134- onto

crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- touches crankshaft flange -A-.
– Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
Note
Do not insert the guide pin for petrol engines (red knob) -F- into
the threaded hole of crankshaft.
– Tighten the two hexagon socket head bolts of the assembly

tool hand-tight.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies on assembly housing -C-.
2.3.6 D - Pressing sender wheel onto crank‐

shaft flange using assembly tool -
T10134-
– Tighten hexagon nut of assembly tool - T10134- with torque
wrench - V.A.G 1331- and tool insert - V.A.G 1332/11- to 35
Nm.
Note
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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2.3.7 E - Checking sender wheel installation s a c
s
ce
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position on crankshaft
un
pt
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– Screw hexagon nut -E- to end of threaded spindle.

rm
ab
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ility
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– Unscrew the two bolts -A- from the cylinder block.

wit
, is n
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– Unscrew the three knurled screws -B- out of sealing flange.

hole
spec
es, in part or in w
– Remove assembly tool - T10134- .

t to the co
– Remove sealing lip support ring.

rrectness of i
l purpos
nform
mercia
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tion in
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te o
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Cop py
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48
by c lksw
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Rep. gr.13 - Crankshaft group
agen
Prote AG.
Polo 2010 ➤
– The sender wheel is exactly in the installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
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
– Place caliper gauge on crankshaft flange. , 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
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or c
thi
– Measure distance between crankshaft flange -A- and sender
te
sd
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wheel -B-.
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• Specification: dimension -a- = 0.5 mm
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t.
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– Re-press sender wheel ⇒ page 50 . t. C rig
gh ht
pyri by
If dimension -a- is attained:
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by c lksw
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Prote AG.
– Tighten bolts for sealing flange.

– Tighten bolts in 2 stages as follows:
Stag Bolts Specified torque
e
1) -1 … 6- Screw in by hand as far as stop
2) -1 … 6- In diagonal sequence and in stages;
final torque 15 Nm
– Install engine speed sender - G28- ⇒ page 287 .
– Install sump ⇒ page 121 .
– Install intermediate plate.
– Install flywheel with new bolts. Tighten securing bolts to 60 Nm
+ turn 90° further.

Polo 2010 ➤
2.3.8 f) Re-pressing sender wheel

– Secure assembly tool - T10134- to crankshaft flange with hex‐
agon socket head bolts -A-.
– Tighten the two hexagon socket head bolts hand-tight.
– Push assembly tool - T10134- against the sealing flange by
hand.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise n
– Screw hexagon nutth-E-or
onto threaded spindle by hand until it tee o
lies on assemblyss housing -C-.
au ra
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
– Tighten hexagon nut of assembly tool - T10134- with torque
l purpos
wrench - V.A.G 1331- and tool insert - V.A.G 1332/11- to 40

Nm.
nf
ercia
– Check the sender wheel installation position on crankshaft

rm
m
again ⇒ page 48 .
atio
om
n in
c
If dimension -a- is still too small:

or
thi
te
sd
a
– Tighten hexagon nut of assembly tool - T10134- to 45 Nm.

iv
o
r
rp
cu
o
– Check the sender wheel installation position on crankshaft

f
en
ng
t.
again ⇒ page 48 .
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

Polo 2010 ➤
3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 51
⇒ “3.2 Crankshaft dimensions”, page 52 n AG. Volkswagen AG do
lkswage es n
o ot g
⇒ “3.3 Measuring axial clearance of crankshaft”, d by V page 52 ua
ran
ir se tee
⇒ “3.4 Measuring radial clearance of crankshaft”,
autho
page 53 or
ac
ss
3.1 Assembly overview - crankshaft
ce
e
nl
pt
du
an
itte
y li
erm
ab
1 - Bearing shells 1, 2 and 4
ility
ot p
wit
❑ For bearing cap without
, is n
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oil groove.
hole
spec
❑ for cylinder block with oil
es, in part or in w
groove
t to the co
❑ Do not interchange
used bearing shells
rrectness of i
(mark).
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2 - Bolts
❑ Renew
nf
ercia
❑ 65 Nm +90°
orm
m
3 - Bearing cap
atio
om
n in
❑ Bearing cap 1: belt pul‐
or c
thi
ley end.
te
sd
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4 - Crankshaft
rp
cu
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f
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ng
❑ Measuring axial clear‐

t.
yi Co
ance ⇒ page 52 . Cop py
t. rig
gh
❑ Measuring radial clear‐
ht
pyri by
Vo
o
ance ⇒ page 53
c by lksw
cted agen
Prote AG.
❑ Crankshaft dimensions
⇒ page 52 .
5 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ for cylinder block with oil
groove
6 - Thrust washers
❑ For bearing 3
3. Crankshaft 51
Polo 2010 ➤
Installation position of thrust washers for bearing 3
3.2 Crankshaft dimensions

swa
gen AG
. Volkswagen AG
does
k not
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by
Honing di‐ Crankshaftrisbearing
ed Conrod bearing journal ara
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mension journaluthdiameter
o diameter eo
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ss mm mm
a c
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Basic dimen‐ 54.00 -0.022 47.80 -0.022

nl
pt
du
an
sion -0.042 -0.042
itte
y li
erm
ab
ility
3.3 Measuring axial clearance of crankshaft
ot p
wit
, is n
h re
hole
spec
♦ Universal dial gauge holder - VW 387-
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
te
sd
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♦ Dial gauge - VAS 6079-

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Cop py
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co lksw
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Prote AG.

Polo 2010 ➤
Procedure
– Screw dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder block as shown in the illustration.
– Position dial gauge against crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off measured
value.
Axial clearance:
• New: 0.07 to 0.17 mm
• Wear limit: 0.37 mm
3.4 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Note
♦ Mark used bearings for re-installation but not on bearing sur‐

face.
♦ Renew bearing shells worn down to base layer.
– Remove bearing cap.

– Remove bearing cap and clean bearing journal.
G. Volkswage nA n AG d
wage oe
– Place Plastigage corresponding Voto
lks the width of the bearing son
not
gu
by
the journal or into the bearing
ise
d shells. ara
n r tee
tho
• The Plastigage musts lie
au in the middle of the bearing shell.
or
ac
s
ce
– Fit bearing cap and tighten bolts to 65 Nm without turning fur‐

e
nl
pt
du
ther angle and without rotating crankshaft.

an
itte
y li
erm
ab
– Remove bearing cap again.

ility
ot p
wit
– Compare width of Plastigage with the measurement scale.

, is n
h re
hole
Radial clearance:
spec
es, in part or in w
• New: 0.03 to 0.08 mm

t to the co
• Wear limit: 0.17 mm.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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Cop py
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co lksw
by
cted agen
Prote AG.
3. Crankshaft 53
Polo 2010 ➤
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 54
⇒ “4.2 Removing and installing pistons”, page 56
⇒ “4.3 Measuring piston projection at TDC ”, page 57
⇒ “4.4 Checking pistons and cylinder bores”, page 58
⇒ “4.5 Separating new conrods”, page 60
⇒ “4.6 Measuring radial clearance of conrods”, page 60
Note
Oil spray jet and pressure relief valve ⇒ page 141 .
4.1 Assembly overview - pistons and conrods
1 - Retaining ring
❑ Renew
2 - Piston ring
❑ compression ring
❑ Offset gaps by 120°
AG. Volkswagen AG d
agen
❑ Use piston ring pliers to Volksw
oes
not
remove and install. d by gu
ara
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❑ Installation position utho eo
ra
marking: “TOP” or sside
sa c
with lettering towards
ce
le
un
pt
piston crown.
an
d
itte
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rm
ab
marking “dots or line”

pe
ility
ot
-arrows- towards piston

wit
, is n
crown.
h re
hole
spec
❑ Measuring ring gap

es, in part or in w
⇒ page 58
t to the co
❑ Measuring ring-to-
groove clearance
⇒ page 59
rrectness of i
3 - Piston ring
l purpos
❑ compression ring
❑ Offset gaps by 120°
nform
ercia
❑ Use piston ring pliers to

m
a
com
remove and install.

tion in
❑ Installation position
r
te o
thi
marking: “TOP” or side

s
iva
do
with lettering towards

r
rp
cum
piston crown.
fo
en
ng
t.
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Co
Cop py
marking “dots or line”
t. rig
gh ht
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-arrows- towards piston p by
co Vo
lksw
crown.
by
cted agen
Prote AG.
❑ Measuring ring gap
⇒ page 58
❑ Measuring ring-to-groove clearance ⇒ page 59
4 - Piston ring
❑ Oil scraper ring

Polo 2010 ➤
❑ Offset gap 120° relative to lower compression ring
❑ Use piston ring pliers to remove and install.
❑ Installation position marking: “TOP” or side with lettering towards piston crown.
❑ Installation position: marking “dots or line” -arrows- towards piston crown.
❑ Measuring ring gap ⇒ page 58
❑ Measuring ring-to-groove clearance ⇒ page 59
5 - Bolt
❑ Renew
❑ Oil threads and contact surface
❑ 30 Nm +90°
6 - Conrod bearing cap
❑ The conrod bearing cap only fits in one position and only on the appropriate conrod due to the breaking
procedure (cracking) separating the cap from the conrod.
❑ Mark cylinder allocation in colour -B-.
❑ Installation position: markings -A- face towards belt pulley end.
7 - Bearing bushes
❑ Fitting position ⇒ page 59
❑ Mark used bearing shells for re-installation but not on bearing surface.
❑ Renew bearing shells worn down to base layer.
❑ Note version: upper bearing shell (towards piston) made of a more wear-resistant material. Identification
on new bearing shells: black line on bearing surface in area of joint
❑ Ensure firm seating
8 - 27 Nm
❑ Bolt with pressure relief valve
9 - Oil spray jet (for cooling of pistons)
10 - Connecting rod
AG. Volkswagen AG d
❑ Renew as set only. agen oes
olksw not
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❑ With industrially cracked conrod bearinged b cap ara
nte
ris
❑ Separate new conrod ⇒ pagea60 ut
ho eo
ra
s c
❑ Mark cylinder allocation in colour
s -B-.
ce
e
nl
pt
❑ Installation position: markings -A- towards belt pulley end

du
an
itte
y li
❑ Axial clearance, wear limit: 0.37 mm

erm
ab
ility
❑ Measuring radial clearance ⇒ page 60

ot p
wit
, is n
11 - Retaining ring
h re
hole
spec
❑ Renew
es, in part or in w
t to the co
12 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C.
❑ Remove and install using drift - VW 222 A- .
rrectness of i
13 - Piston
l purpos
❑ With combustion chamber.

nf
ercia
❑ Mark installation position and cylinder number ⇒ page 59 .

orm
❑ Checking ⇒ page 59
m
atio
m
❑ Install using piston ring clamp.

o
n in
or c
thi
❑ Piston and cylinder dimensions ⇒ page 60 .

te
sd
iva
❑ Measuring cylinder bore ⇒ page 60

o
r
rp
cu
o
m
f
❑ Measuring piston projection at “TDC” ⇒ page 57

en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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o
by c lksw
cted agen
Prote AG.
4. Pistons and conrods 55

olkswagen AG
en AG. V
Polo 2010 ➤ ksw
ag does
not
Vol
3-cylinder common rail engineed(1.2 l, EA189) - Edition 06.2019 guara
by
ris nte
utho eo
ra
4.2 Removing and installing pistons ss
a c
ce
e
nl
pt
du
an
itte
y li
erm
♦ Pin - VW 222 A-
ab
ility
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♦ Piston ring clamp, commercially available
ion
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Removing
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• Securing engine to assembly stand ⇒ page 15 .

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caps to conrods as an aid for reinstalling ⇒ page 54 .
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– Unscrew conrod bearing cap.
Prote AG.
– Withdraw piston upwards together with conrod.
Note
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
– Remove retaining ring from piston pin eye.

– Drive out piston pin using drift - VW 222 A- .
Installing
Install in reverse order of removal, observing the following.
• Specified torques ⇒ page 54 .
Note
If a further tightening angle is specified for certain bolts, these

must be renewed.
– Oil running surfaces of bearing shells.

– Install piston with piston ring clamp.
Installation position:
• Piston ⇒ page 59
• Bearing shells in conrods ⇒ page 59 .
– Install conrod bearing cap in accordance with marking.
– Install cylinder head ⇒ page 68 .

Polo 2010 ➤
4.3 Measuring piston projection at “TDC”
Note
♦ Piston projection at “TDC” must be measured when installing

new pistons or a short engine.
♦ If you have measured the piston projection and it is not same
for all pistons, use the highest value to allocate the gasket.
♦ Install the appropriate cylinder head gasket depending on pis‐
ton projection, according to following table.

equipment required
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♦ Measuring bridge -VW 382/7- from measuring tool - VW 382-

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♦ Measuring plate -VW 385/17- from universal measuring tool -

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♦ Dial gauge - VAS 6079- C py
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Polo 2010 ➤
Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in the illustration.
– Measure the projection of each piston at the two points marked
with -arrows- (at the rear side and front side of the piston seen
in the longitudinal direction of the engine).
– Install the appropriate cylinder head gasket depending upon
piston projection, according to following table:
Piston projection over upper Identification
edge of cylinder block (No. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2
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⇒ “4.4.1 Checking piston”, page 58 C py
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⇒ “4.4.2 Cylinder bore ”, page 60
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⇒ “4.4.3 Piston and cylinder dimensions”, page 60
Prote AG.
4.4.1 Checking piston

Measuring piston ring gap
– Push piston ring at right angles to cylinder wall from above
down into cylinder bore to approx. 15 mm from bottom end of
cylinder.
– Push in using a piston without piston rings.
Piston ring New Wear limit
mm mm
1st compression ring 0.20 … 0.40 1.00
2nd compression ring 0.20 … 0.40 1.00
Oil scraper ring 0.25 … 0.50 1.00

Polo 2010 ➤
Measuring ring-to-groove clearance

– Clean annular groove of piston before check.
Piston ring New Wear limit
mm mm
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15
Checking piston
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
ton pin axis with a 75 to 100 mm external micrometer. en AG. V
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• Maximum deviation from nominal dimension: 0.04 mm.
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Nominal dimension ⇒ page 60 tho eo
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If piston skirt is cracked, renew piston.
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Installation position and allocation of piston to cylinder
spec
t to the co
• Arrow on piston crown points towards belt pulley end
-arrows-.
– Centre bearing shells on conrod and on conrod bearing cap.
rrectne
• Dimension -a- = 2.5 mm
ss
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
o
cial p
f
ton pin axis with a 75 to 100 mm external micrometer.
inform
mer
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Nominal dimension
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• Arrow on piston crown points towards belt pulley end
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• Dimension -a- = 2.5 mm

Polo 2010 ➤
4.4.2 Cylinder bore

Measuring
– Using cylinder gauge - VAS 6078- take measurements at 3
positions diagonally in lateral direction -A- and longitudinal di‐
rection -B-.
Nominal dimension
4.4.3 Piston and cylinder dimensions swagen AG. Volkswagen AG does

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erm
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4.5 Separating new conrods
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spec
On new conrods it is possible that the breaking point is not fully
t to the co
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
rrectne
– To avoid damage, gently clamp conrod in a vice with protection
jaws, as shown in illustration. ss
• Clamp conrod below dashed line.

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– Unscrew bolts -arrows- around 5 turns.

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– Using a plastic hammer, carefully knock against conrod bear‐

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ing cap -arrow- until it is loose.

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4.6 Measuring radial clearance of conrods

♦ Plastigage

Polo 2010 ➤
3-cylinder
l wage
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Vo otgu
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»Carry out the following work sequence« oris eo
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– Remove conrod bearing cap. Clean bearing cap and bearing ss
ce
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journal.
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– Place a Plastigage corresponding to the width of the bearing
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on the journal or into the bearing shells.
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– Fit conrod bearing cap and tighten to 30 Nm without turning
, is n
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further angle and without rotating crankshaft.
hole
spec
– Remove conrod bearing cap again.
es, in part or in w
t to the co
Radial clearance:
rrectness of i
• Wear limit: 0.08 mm
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– Renew conrod bolts.
nform
mercia
at
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ion
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do
priv
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Cop py
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rig ht
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Prote AG.

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Polo 2010
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15 – Cylinder head, valve gear
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⇒ “1.1 Assembly overview - cylinder head cover”, page 62
t to the co
⇒ “1.2 Removing and installing cylinder head cover”, page 63
rrectness of i
⇒ “1.3 Assembly overview - cylinder head”, page 66
l purpos
⇒ “1.4 Removing and installing cylinder head ”, page 68

⇒ “1.6 Checking compression”, page 81
nf
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1.1 Assembly overview - cylinder head cov‐
rm
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⇒ “1.2.3 Removing and installing injector seal in cylinder head

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2 - Heat shield p by
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3 - Crankcase breather hose Prote AG.
❑ To suction hose
⇒ page 235
4 - Rubber grommet
❑ For screw of clamp
❑ Renew
5 - Injector seal
❑ Renew
❑ Exchange without tools.
❑ Note installation posi‐
tion of lugs.
⇒ page 65
6 - Seal
❑ For screw of clamp
❑ Renew
7 - Bolt
❑ 10 Nm
8 - Cylinder head cover
⇒ page 64
62 Rep. gr.15 - Cylinder head, valve gear

Polo 2010 ➤
1.2 Removing and installing cylinder head

cover
⇒ “1.1 Assembly overview - cylinder head cover”, page 62
⇒ “1.2.2 Fitting the cylinder head cover”, page 64
1.2.1 Removing cylinder head cover

Observe the.
⇒ “2 Safety information”, page 2
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♦ Torque wrench - V.A.G 1331- horis tee
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– Remove engine cover panel ⇒ page 24
nf
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– Remove injectors ⇒ page 197 .
orm
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Caution
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Make sure that no wiring connections are damaged when dis‐

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connecting the connectors. Otherwise the whole wiring har‐

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ness will need to be renewed. Do not compress the pliers -

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3314- to firmly to separate the connectors, otherwise the C py
t. rig
support sleeve may be damaged.
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– Pull vacuum hose off cylinder head cover.
– Remove vacuum hoses with bracket from cylinder head cover.
1. Cylinder head 63
Polo 2010 ➤
– Remove upper timing belt guard by detaching clips -arrows-.
AG. Volkswagen AG d
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– Unscrew securing bolts of cylinder head cover in sequence
an
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erm
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– Remove cylinder head cover.
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1.2.2 Fitting the cylinder head cover

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Install in reverse order of removal. During this procedure, observe

the following:
⇒ “1 Injection system”, page 185
Note
Renew seal for bolts if damaged.
– Tighten cylinder head cover bolts hand-tight in the sequence

-1 … 6-.

Polo 2010 ➤
– Tighten bolts in the sequence -1 … 6- ⇒ Item 7 (page 62) .

After any work on the fuel system
Connect a ⇒ Vehicle diagnostic tester.
Perform the function “Fuel pump activation (filling/bleeding fuel
system)” in “Guided functions” ⇒ page 188 .
AG. Volkswagen AG d
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1.2.3 Removing and installing injector seal in uthorise nte
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⇒ “1 Injection system”, page 185
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♦ Lambda probe open ring spanner set - 3337-
t to the co
♦ Tool set - T10055-
♦ Assembly tool - T10208/2-
rrectness of i
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Removing
m
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– Engine cover panel ⇒ page 24 .
com
tion in
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– Remove noise insulation at injectors.

te o
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do
– Injectors (piezo injectors) where the injector seal is to be re‐
r
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newed ⇒ page 197
fo
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t.
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– Move affected return lines aside slightly. Cop py
t. rig
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Caution
by lksw
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Prote AG.
You must therefore proceed very carefully in order to avoid

unnecessary assembly work or further damage.
Maintain cleanliness. No dirt may get into the injector holes and
the cylinder head cover.
First remove leaked oil or fuel with workshop equipment.
Remove affected seal ⇒ Item 5 (page 62) .

– After removal, check whether the spring washer is still on the
old seal.
If this is not the case, make sure that spring washer does not
remain behind.
1. Cylinder head 65
Polo 2010 ➤
Installing
Caution

Remember that the cylinder head cover is made of plastic.
A plastic cylinder head cover is damaged easily during repairs.
Check cylinder head cover for damage.
– Insert new seal by hand ⇒ Item 5 (page 62) .

Note installation position of seal lugs.
Further assembly is carried out in the reverse order of removal.
1.3 Assembly overview - cylinder head
Note
♦ The plastic packing pieces for protecting the open valves must
AG. Volkswagen
not be removed until immediately before fitting
lksw
agen cylinder head.
AG do
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♦ If cylinder head has to be renewed,
ris
ed the coolant must be com‐
b ran
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pletely renewed as well. tho or
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mercia
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c
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or
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ate
do
priv
cum
for
en
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Cop py
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rig ht
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by lksw
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Prote AG.

Polo 2010 ➤
1 - 25 Nm
2 - Lifting eye
3 - Seal
❑ Renew
4 - Vacuum pump
5 - 10 Nm
6 - 10 Nm
7 - G 62
❑ Radiator outlet coolant
8 - Coolant hose connection
9 - O-ring
❑ Renew
10 - Clip
11 - 25 Nm
12 - Bracket
13 - Cylinder head gasket
AG. Volkswagen AG d
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⇒ page uth o 68 . eo
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❑ Afterss renewing, renew c
ce
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entire coolant
un
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d
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14 - Cylinder head
y li
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ab
pe

ility
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⇒ page 68 .
wit
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❑ After renewing, renew

hole
spec
entire coolant
es, in part or in w
t to the co
15 - Glow pin plug, 18 Nm

16 - Cylinder head bolt
rrectness of i
❑ Observe sequence when loosening and tightening ⇒ page 68 .

❑ Before installing, insert washers into cylinder head.
l purpos
17 - Oil pressure switch - F1- , 22 Nm

nform
ercia
❑ Identification: green
m
❑ 0.5 bar
a
com
tion in
❑ If seal is leaking, nip open and renew.

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Checking cylinder head for distortion
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Prote AG.
1. Cylinder head 67
Polo 2010 ➤

♦ Straight edge 500 mm - VAS 6075-
♦ Feeler gauge
Max. permissible distortion: 0.1 mm
Note
Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification

1- Part number
2- Holes
3- Ignore
Note
♦ Different thicknesses of cylinder head gasket are fitted de‐

pending on the piston projection. When renewing gasket,
install new gasket with same identification.
♦ Piston projection at TDC must be determined when installing
new pistons or a short engine ⇒ page 57 .
1.4 Removing and installing cylinder head
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.

AG. Volkswagen AG d
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eo Polo 2010 ➤
aut 3-cylinder common rail engine (1.2 l, EA189) ra - Edition 06.2019
ss c
ce
le
un
pt
an
d
itte
equipment required
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erm
ab
ility
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spec
t to the co
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cial p
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mer
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te
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Cop py
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rig ht
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Prote AG.
♦ Guide pin - 3070-

♦ Diesel injection pump locking pin - 3359-
♦ Crankshaft stop - T10050-
♦ Counter-hold tool - T10051-
♦ Puller - T10052-
♦ Socket XZN 10 - T10385-
1. Cylinder head 69
Polo 2010 ➤
AG. Volkswagen AG d
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
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ion
c
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or
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do
priv
c
um
for
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t.
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Cop py
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♦ Tool set - T100395-
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Prote
♦ Used oil collection and extraction unit - V.A.G 1782-
AG.

Polo 2010 ➤
Note
♦ The battery earth must be disconnected for the remaining pro‐

cedure. For this reason, check whether a coded radio is fitted.
Then obtain anti-theft coding first if necessary.
♦ All cable ties which are opened or cut through when cylinder
head is removed must be fastened in the same position when
cylinder head is installed. agen
AG. Volkswagen AG d
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♦ All connectors which are separated during
ed
by disassembly must
V ua
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be reconnected in the original position
ho
ris when installing. tee
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WARNING
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♦ When performing any repair work, especially in the engine
ility
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compartment, pay attention to the following due to the
wit
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h re
hole
spec
♦ Route all the various lines and electrical wiring so that they
es, in part or in w
are in their original positions.
t to the co
♦ e.g. for fuel, hydraulics, activated charcoal filter system,
coolant and refrigerant, brake fluid, vacuum.
rrectness of i
♦ Ensure that there is sufficient clearance to all moving or
l purpos
hot components.
nform
ercia
1.4.1 Removing
m
at
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» Please carry out the following work sequence«
n
c
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or
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– Engine cover panel ⇒ page 24 .

at
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priv
c
– With ignition switched off, disconnect battery earth strap. ⇒
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for
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t.
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ing batteries. ht. Cop py
rig
rig ht
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐ py by
co Vo
screen wiper system; Removing and installing wiper arms .
by lksw
cted agen
Prote AG.
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
– Remove vacuum hoses with bracket -1- from air filter.
valve - N75- -3-.
bracket -2-.
– Place charge pressure control solenoid valve - N75- with vac‐
uum lines on engine.
– Remove charge air pipe »hot« side ⇒ page 180 .
1. Cylinder head 71
Polo 2010 ➤
– Detach vacuum line -arrow- on brake servo.
Pre-heater line -arrow 2- is not necessarily installed.

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– Unscrew bolts -arrows- and remove pulsation
ss damper -2-.
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ility
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spec
t to the co
rrectness
– Separate electrical connector -1- on oil pressure switch - F1- .

o
cial p
f inform
mer
atio
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n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
– Pull off vacuum hose -2-, unscrew vacuum hose connection

-arrow-.
– Disconnect electrical connector -4- at coolant temperature

sender - G62- .
– Remove coolant hoses from connections, loosen hose nclips

AG. Volkswagen AG d
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– Disconnect connectors -1…4-. db ara
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es, in part or in w
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♦ -4- lambda probe - G39-

nform
mercia
a
com
tion in
r
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thi
s
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cum
fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 73
Polo 2010 ➤
– Disconnect electrical connector -2- at pressure differential

sender - G505- .
– Unscrew bolt -3- from pressure differential sender - G505-
bracket.
– Lay pressure differential sender - G505- with lines down to
rear.
– Remove fuel supply line and return line -arrows- at high-pres‐

sure pump.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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– Unscrew coolant return line bolts -arrows-, lay coolant return
ce
le
un
line aside.
pt
an
d
itte
y li
– Remove cylinder head cover ⇒ page 63 .
rm
ab
pe
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Detach high-pressure line -2- between fuel rail and high-pres‐

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

Polo 2010 ➤
– Unclip engine pre-wiring harness from bracket -arrow-.

– Separate all remaining connectors to engine.
– Lay engine pre-wiring harness to one side.
– Unscrew bolt from oil dipstick connection -arrow-.
Caution
Ensure that flexible joint of connecting pipe is not bent and

stretched. There is a danger of cracking.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ss
ce
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Loosen particulate filter.

un
pt
an
d
itte
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1) Remove securing clamp between particulate filter and

erm
ab
turbocharger
ility
ot p
wit
2) Unscrew bolts and nuts -2 … 3-

is n
h re
ole,
spec
3) Loosen bolt -4-

t to the co
4) Unscrew nuts -5-

– Secure particulate filter to plenum chamber bulkhead.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
– Remove connecting pipes -A- for exhaust gas recirculation.

um
r
fo
en
ng
t.
yi
– Install oil supply line and turbocharger support ⇒ page 139 .
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 75
Polo 2010 ➤
– Separate connector for Hall sender - G40- -arrow-.

– Removing toothed belt from camshaft and high-pressure
pump ⇒ page 83 .
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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aut ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
– Remove vacuum hoses complete with bracket -1- upwards is n
h re
from air filter.
ole,
spec
t to the co
valve - N75- -3-.
bracket -2-.
rrectne
– Place charge pressure control solenoid valve - N75- with vac‐
s
uum lines on engine.
s o
cial p
f i
nform
mer
atio
om
n
c
i
or
n
– Counterhold hub with counterhold - T10051- , loosen hub se‐
thi
te
sd
a
curing bolt -1-.

iv
o
pr
cum
r
fo
– Unscrew hub securing bolt approx. 2 turns.
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.
– Position puller - T10052- and align with holes in hub.

– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
Hold puller with a spanner 30 mm whilst doing this.
– Remove hub from taper of camshaft.

Polo 2010 ➤
– Unscrew securing bolt -arrow- from toothed belt guard.
– Unscrew nut -1- for tensioning roller.

– Unscrew cylinder head bolts.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Maintain sequence when loosening cylinder head bolts.
hole
spec
es, in part or in w
t to the co
Note
♦ A second mechanic is required to remove the cylinder head.
rrectness of i
♦ The toothed belt tensioning roller is pulled off the stud when
l purpos
the cylinder head is lifted out.

nf
ercia
– First raise cylinder head on gearbox side and thread out of

orm
toothed belt guard. Make sure that toothed belt tensioner does
m
atio
m
not fall down.

o
n in
or c
thi
te
sd
1.4.2 Installing
iva
o
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rp
cu
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f

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.
1. Cylinder head 77
Polo 2010 ➤
Note
♦ Do not use sandpaper, grinding wheels, abrasive or scour

pads or any other sanding or abrasive media.
♦ 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.
– Only remove sealant residue from cylinder head and cylinder

block using scraper - VAS 852 005- or a commercially availa‐
ble ceramic glass scraper.
• The sealing surfaces must not be damaged.
• There must be no oil or coolant in the bolt pockets.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• If a new cylinder head is installed, contact surfaces between
roller rocker fingers and running surface of cam must be oiled.
• Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
• Turn the crankshaft carefully at least 2 rotations to ensure that
none of the valves make scontact
wage
n AGwhen the
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agen AG
doeis
s
operated.
k not
Vol g
• When the cylinderedhead
by or cylinder head gasket is renewed,
ua
ra
ris and the engine oil must be changed. ntee
the entire coolant
o
th o
au ra
– Remove any
ss loose remains using a lint-free cloth. c
ce
e
nl
pt
– Before fitting cylinder head, remove crankshaft stop -

du
an
itte
T10050- , and turn crankshaft in opposite direction of engine

y li
erm
ab
rotation until all pistons are nearly uniformly below TDC.

ility
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wit
, is n
– Note cylinder head gasket identification:

h re
hole
spec
1- Part number
es, in part or in w
t to the co
2- Holes
3- Ignore
rrectness of i
– Cylinder head gasket must lie with identification facing up‐

l purpos
wards.
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.

Polo 2010 ➤
– To centre, screw guide pins -3070/9- into outer threaded holes

on intake side.
Note
♦ Tensioning roller must be pushed onto studs when fitting cyl‐

inder head.
♦ If the cylinder head gasket or cylinder head have been re‐
placed, select a new cylinder head gasket according to the
number of holes on the old cylinder head gasket.
♦ If parts of the crankshaft assembly have been renewed, the
new cylinder head gasket must be selected by measuring the
piston projection at “TDC” ⇒ page 57 .
– Fit cylinder head.

– Insert 8 cylinder head bolts and screw in by hand until contact
is made.
– Unscrew guide pins -3070/9- through bolt holes in cylinder
head and screw remaining cylinder head bolts by hand until
contact is made.
olkswagen AG
en AG. V
– Tighten cylinder head in 4 stages inolksequence
swa
g
shown as fol‐does no
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lows: ed
by V
ara
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1- tho wrench:
Tighten initially with torque eo
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c
ss
Stage I = 30 Nm
ce
le
un
pt
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Step II = 50 Nm
itte
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2- Turn further with rigid spanner:
pe
ility
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Stage III = turn 90° further.

h re
hole
Stage IV = turn 90° further.

spec
es, in part or in w
t to the co
– Secure rear toothed belt guard on cylinder head.

– Install hub and camshaft sprocket.
rrectness of i
– Lock camshaft and high-pressure pump with diesel injection

pump locking pin - 3359- .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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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.
1. Cylinder head 79
Polo 2010 ➤
– Turn crankshaft in direction of engine rotation to TDC of No. 1

cylinder, and lock crankshaft using crankshaft stop - T10050- .
Continue installation in reverse order of removal. During this pro‐
cedure, observe the following:
– Install toothed belt again ⇒ page 92 .
– Install cylinder head cover ⇒ page 63 .
– Install oil supply line and turbocharger support ⇒ page 139 .
– Top up engine oil ⇒ page 125 .
After any work on the fuel system
Connect vehicle diagnostic tester.
Perform function “Fuel pump actuation (Filling/bleeding fuel sys‐
tem)” in “Guided Functions” ⇒ page 188 .
– Carry out road test and read all event memories
⇒ page 241 .
1.5 Removing and installing vacuum pump
DANGER! AG. Volkswagen AG d

agen oes
olksw not
y V gu
The vacuum pump may, under no circumstances, be disman‐
ise
d b ara
nte
tled as the vacuum part could otherwise malfunction.
uthor
This eo
would result in failure of the brake servo. a ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Removing
wit
, is n
h re
– Remove air filter housing with air mass meter and connecting
hole
pipe ⇒ page 235 .
spec
es, in part or in w
– Pull vacuum line -1- off vacuum pump -2-.
t to the co
– Unscrew securing bolts of the charge-air pipe
⇒ Item 11 (page 179) , then push charge-air pipe down slightly
to gain access to rear threaded connection of vacuum pump. 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.

Polo 2010 ➤
– Unscrew vacuum pump securing bolts -arrows-.

– Remove vacuum pump -2- from cylinder head.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
♦ Ensure that vacuum pump coupling seats properly in the cam‐

shaft.
♦ Renew vacuum pump seal.
– Install vacuum pump and tighten securing bolts to 10 Nm.

– Connect brake servo vacuum line to vacuum pump -1-.
1.6 Checking compression

♦ T-bar and socket, 10 mm - 3220-
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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nl
pt
du
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itte
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erm
ab
♦ Compression tester - V.A.G 1763- with adapter - V.A.G

ility
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1763/8-
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
Prerequisites for check

ion
c
in t
or
• Engine oil temperature min. 80°C

his
ate
do
riv
• Battery voltage at least 12.5 V.

p
cum
for
en
g
Test sequence
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 81
Polo 2010 ➤
– Detach electrical connector from fuel pressure regulating

valve - N 276- -arrow- at fuel rail.
– Start engine briefly to reduce fuel pressure in fuel rail.
– Remove all glow pin plugs using jointed spanner - 3220-

⇒ page 281 .
– Screw in adapter - V.A.G 1763/8- in each place where glow
plugs were and connect compression tester - V.A.G 1763- .
Note
AG. Volkswagen AG d
agen oes
ksw
Using compression tester ⇒ operating instructions . by V ol not
gu
ara
d
rise nte
ho eo
– Have a 2nd mechanic operate starter untils atester shows no
ut ra
c
further pressure increase. s
ce
le
un
pt
an
Compression pressures bar
d
itte
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erm
ab
New 25.0 … 31.0
ility
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Wear limit 19.0
wit
is n
h re
ole,
Maximum difference between cylinders 5.0
spec
Installation is carried out in the reverse order; note the following:
t to the co
– Install glow plugs ⇒ page 281 .
– Entries are stored in the event memory of the engine control
rrectne
unit because electrical connectors were disconnected and the
engine was started: Read event memory in vehicle self-
diagnosis ⇒ . 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.

Polo 2010 ➤
2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt drive”, page 83
⇒ “2.2 Removing, installing and tensioning toothed belts”,
page 88
2.1 Assembly overview - toothed belt drive
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
❑ Removing, installing
and tensioning
⇒ page 88 .
swage es n
2 - 120 Nm + 90° further yV
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ua
d b ran
❑ Renew o
ir se tee
th or
❑ Use counterhold - 3415 ss
au ac
- to loosen and tighten.
ce
le
un
pt
❑ Do not additionally oil or
an
d
itte
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grease the threads and
rm
ab
shoulder
pe
ility
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wit
3 - Crankshaft pulley
, is n
h re
hole
4 - 20 Nm
spec
es, in part or in w
5 - Lower idler roller
t to the co
Note
rrectness of i
Renew stud for idler pulley only if
l purpos
damaged. Specified torque for stud:

15 Nm.
nform
ercia
6 - 20 Nm + 45° further
m
a
com
tio
7 - Tensioning pulley
n in
r
te o
thi
❑ Remove engine bracket
s
iva
to remove and install do

r
rp
⇒ page 85 .
um
fo
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ng
t.
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op
Note C py
t. rig
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pyri by
Renew stud for tensioning roller only
co Vo
by lksw
cted agen
if damaged. Specified torque for Prote AG.
stud: 15 Nm.
8 - 25 Nm
9 - Camshaft sprocket
10 - 15 Nm
11 - 100 Nm
12 - Hub
❑ Use counterhold - T10051- to loosen and tighten.
❑ To remove, use puller - T10052- .
2. Toothed belt drive 83

Polo 2010 ➤
13 - Rear toothed belt guard

14 - 20 Nm + 90° further
15 - 10 Nm agen
AG. Volkswagen AG d
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❑ Renew d by V gu
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16 - Upper idler
utho roller eo
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s
17 - 50 Nm + 90° further
ce
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nl
pt
du
an
18 - Hub
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
19 - 95 Nm
es, in part or in w
t to the co
20 - Toothed belt pulley on high-pressure pump
21 - 20 Nm
rrectness of i
22 - Coolant pump
l purpos

23 - 15 Nm
nf
ercia
orm
24 - Toothed belt guard upper part
m
atio
om
n in
25 - Toothed belt guard lower part
or c
thi
te
26 - 10 Nm
sd
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cu
❑ Renew
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t.
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27 - 10 Nm + 90° further
Co
Cop py
t. rig
❑ Renew opyri
gh by
Vo
ht
c lksw
28 - Belt pulley and vibration damper
by
cted agen
Prote AG.
❑ Can only be installed in one position, holes are offset.
29 - 5 Nm
30 - Protective plate
31 - 40 Nm + 180° further
❑ Renew
❑ Observe tightening sequence ⇒ page 88
32 - Engine support

Polo 2010 ➤
Lower toothed belt guard

– Tighten bolts -arrows- to 9 Nm.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
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ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
2.1.1 Removing and installing engine bracket
rrectne
s
equipment required
s 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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222 A-

Polo 2010 ➤
♦ Adapter - 10 - 222 A /8-

♦ Hook - 10-222 A/10-
♦ Shackle - 10-222 A/12-
♦ Adapter - 10-222 A/18-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
At a later point, support bracket - 10-222 A- will be fitted onto
ole,
spec
longitudinal members with adapters - 10 - 222 A /8- .
t to the co
To prevent damage to edges of wings, cover lower areas of both
adapters - 10 - 222 A /8- with duct tape -arrow- ⇒ Electronic parts
catalogue (ETKA, chemical substances) .
rrectne
Removing
ss o
cial p
f inform
mer
Note
atio
om
n
c
Do not open fuel lines or coolant lines. Coolant expansion tank
i
or
n thi
remains closed.
te
sd
iva
o
pr
cum
r
fo

en
ng
t.
yi Co
op
– Remove noise insulation ⇒ General body repairs, exterior; C py
ht. rig
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐ rig ht
py by
tion .
co Vo
by lksw
cted agen
Prote AG.
– Remove upper and lower brackets for particulate filter.

1) Unscrew bolts - 2 + 3 -
2) Remove upper particulate filter bracket
3) Unscrew bolts + nuts - 4 + 5-

4) Remove lower particulate filter bracket
– Removing and installing charge air pipe »cold« side
⇒ page 181 .
– Unclip hoses from coolant expansion tank.
– Pull connector off coolant expansion tank.

Polo 2010 ➤
– Pull connector off pressure differential sender - G505 - -1-.

– Loosen coolant expansion tank.
– Lay coolant expansion tank, pressure differential sender -
G505- and fuel filter with lines aside.
– Fit support bracket - 10 - 222 A- with the necessary adapters

as shown and take up weight of engine in installation position.
Note
. Volkswagen AG
gen AG does
swa
♦ The engine's assembly mounting may only be removed if the yV
olk not
gu
engine is supported with support bracket 10-222A! rised b ara
nte
ho eo
♦ ut
The engine bracket must be loosened only when thes aassembly ra
c
mounting has been removed. s
ce
e
nl
pt
du
an
itte
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erm
ab
Caution
ility
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wit
, is n
Nut -2- must not be loosened.
h re
hole
spec
es, in part or in w
t to the co
– Unscrew securing bolts -arrows-.
– Remove entire engine mounting upwards.
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2010 ➤
– Unscrew securing bolts of engine bracket in sequence

-3…1-.
– Remove engine bracket out upwards.
Installing
Prescribed torque and tightening sequence for assembly mount‐
ing ⇒ page 20
lowing:
Caution
The tightening sequence and specified torques for the engine

bracket securing bolts must always be followed. Otherwise the
engine bracket can be stressed, causing it to break.
– Insert engine bracket from above.

– First, tighten new securing bolts hand-tight in sequence
-1 … 3-. AG. Volkswagen AG d
agen oes
olksw not
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d b ara
Tightening sequence for engine bracket horise nte
eo
ut ra
a
– Tighten securing bolts in the specified sequence
ss to the pre‐ c
scribed torque.
ce
le
un
pt
an
d
itte
– Then use the spindle to bring the engine bracket to rest on the
y li
rm
ab
engine carrier.
pe
ility
ot
Further assembly is performed in the reverse order of removal.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.2 Removing, installing and tensioning toothed belts
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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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.

Polo 2010 ➤

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
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 thi
te
sd
iva
o
pr
cum
r
fo
en
ng
♦ 2x diesel injection pump locking pin - 3359-

t.
yi Co
Cop py
t. rig
♦ Crankshaft stop - T10050- opyri
gh by
Vo
ht
c
by lksw
cted agen
Prote AG.
♦ Angled screwdriver - T10264-
♦ Locking tool - T10265-
♦ Socket XZN 10 - T10385-
Not illustrated:
2.2.1 Removing
Note
Adjustment work on toothed belts must be performed only on cold

engines, as the indicator position on the tensioning element varies
depending on the engine temperature.

Polo 2010 ➤
– Engine cover panel ⇒ page 24

– With ignition switched off, disconnect battery. ⇒ Electrical
system; Rep. gr. 27 ; Disconnecting and reconnecting batter‐
ies.
– Poly V-belt ⇒ page 25 .
– Remove upper timing belt guard by detaching clips -arrows-.
– Remove front right wheel housing liner.
– Unscrew bolts -arrows-.

– Press coolant lines aside slightly. agen
AG. Volkswagen AG d
oes
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– Remove vibration damper ⇒ page 33 . ed byV gu
ara
ris nte
ho eo
aut ra
ss c
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
– Remove lower toothed belt guard.
rrectne
Note ss o
cial p
♦ Engine bracket must be removed to exchange belt tensioner.

f inform
mer
♦ The engine bracket must be loosened only when the assembly

atio
mounting has been removed.

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♦ The assembly mounting may only be removed if the engine is

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supported with support bracket - 10-222A- !

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♦ Remove engine bracket ⇒ page 20 .

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Polo 2010 ➤
– Turn engine to TDC and lock crankshaft pulley in position with

crankshaft stop - T10050- . Fit the crankshaft stop in the teeth
from the face side of the toothed belt pulley.
• The mark -2- on the toothed pulley and the arrow -1- on the
crankshaft stop - T10050- must align -arrow-. When doing this,
the pin of the crankshaft stop must engage in the drilling of
sealing flange.
The arrow on the camshaft pulley must be at almost »12 o'clock«.

– Mark direction of rotation of toothed belt.
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– Loosen bolts -arrows- approx. 90° for camshaft toothed belt
es, in part or in w
pulley.
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– Loosen bolts -1- approx. 90° for high-pressure pump toothed

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belt pulley using bit XZN 10 - T10385- .

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Polo 2010 ➤
– Loosen securing nut of tensioning roller -1- and turn tensioning

roller eccentric using socket - T10264- counter-clockwise
-arrow- until tensioning roller can be locked with locking pin -
T10265- .
– Turn eccentric of tensioning roller clockwise -arrow- to stop.

Tighten securing nut -1- hand-tight.
Caution AG. Volkswagen AG d

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Risk of irreparable damage if direction of rotation is reversed ised b ara
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♦ Before removing toothed belt, mark direction of rotation
ss
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with chalk or felt tipped pen for installation purposes.

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– Remove toothed belt first from idler pulley and then from re‐
ot p
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maining toothed belt pulleys.
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2.2.2 Installing (adjusting valve timing)
es, in part or in w
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Note
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♦ The toothed belt may only be adjusted on cold engines, as the
l purpos
indicator position on the tensioning element varies depending

on the engine temperature.
nf
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♦ If the tensioning roller is to be renewed, the engine bracket
rm
m
must be removed ⇒ page 20 .
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♦ Renew securing bolts for camshaft pulley and high-pressure

or
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pump pulley.
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Polo 2010 ➤
• Tensioning roller must be locked with locking tool - T10265-

and secured to right stop.
• Crankshaft is locked using crankshaft stop - T10050- .
Note
Turn camshaft hub with counterhold - T10172- and adapters -

T10172/4- until camshaft can be locked in position. To do this,
hand-tighten at least one securing bolt -1-.
– Lock the camshaft hub with locking pin - 3359- . To do this,

insert locking pin through outer free elongated hole into hole
in cylinder head.
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– Loosen the hand-tightened bolt again.
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Bolts -arrows- screwed in loosely.
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It should just be possible to turn camshaft toothed belt pulley t to the co

without axial movement. rrectness of i
Note
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If necessary, turn hub of high-pressure pump at bolt heads with

screwdriver until it can be locked in position.
nform
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Positioning hub of high-pressure pump

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Polo 2010 ➤
– Lock the camshaft hub with locking pin - 3359- . To do this,

push locking pin into adjustment hole outside toothed belt pul‐
ley.
Loosely tightened bolts -1-.
It should just be possible to turn high-pressure pump toothed belt
pulley without axial movement.
– Turn camshaft sprocket and toothed belt sprocket of high-
pressure pump in their elongated holes clockwise to stop.
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– Fit toothed belt in sequence described:
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1- Crankshaft pulley s
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2- Tensioning pulley
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3- Camshaft toothed belt pulley
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4- Coolant pump toothed belt pulley
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5- High-pressure pump toothed belt pulley
spec
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6- Idler roller
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– Loosen belt tensioner securing nuts and pull out locking tool -
T10265- .
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Note
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Ensure that belt tensioner seats correctly in rear toothed belt Cop py
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guard -arrow-.
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– Carefully turn eccentric of tensioning roller clockwise using

angle driver - T10264- . Indicator -2- must be roughly past the
centre of the gap in the base plate (corrects itself during pre‐
tensioning).
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position. Tighten tensioning roller
securing nuts as follows: 20 Nm and turn 45° further.

Polo 2010 ➤
– Fit counterhold - T10172- as shown. Press counterhold -

T10172- in direction of arrow and keep camshaft sprocket in
pretensioning position. olkswage es n
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– In this position, first
ris tighten securing bolts -1- of camshaft pul‐
ed ran
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ley and of toothed
utho belt pulley for high-pressure pump by hand, or
and then tighten
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– Remove locking pins - 3359- and crankshaft stop - T10050- .
pt
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– Turn crankshaft at least two rotations in engine direction of
rm
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rotation and set to just before TDC No. 1 cylinder.
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– Place crankshaft stop - T10050- on the crankshaft's toothed
h re
belt pulley again.
hole
spec
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t to the co
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin -arrow- engages in sealing flange whilst turning.
rrectness of i
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During the following checking procedure, only the camshaft and cted agen
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crankshaft must be secured in position. It is very difficult to find
the securing position of the high-pressure pump hub again. A mi‐
nor deviation -arrow-, though, does not influence engine opera‐
tion.
– Check whether:
♦ Camshaft hub can be locked with locking pin - 3359- .
♦ Tensioning roller indicator is centred or maximum 5 mm to
right of base plate notch.
If camshaft hub cannot be locked:
– Pull crankshaft stop - T10050- back until pin uncovers hole.
– Turn crankshaft out slightly past TDC by turning it in the op‐
posite direction of engine rotation.
– Now turn crankshaft slowly in direction of engine rotation until
camshaft hub can be secured in position.
– After locking, loosen securing nuts of camshaft pulley.
If pin of crankshaft stop - T10050- is standing on left next to hole:

Polo 2010 ➤ gen AG
. Volkswagen AG
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3-cylinder common rail engine (1.2 l, EA189) - Editiony06.2019
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– Turn crankshaft in engine direction of rotation until crankshaft
au
tho e or
ac
stop pin engages in sealing flange whilst turning. ss
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– First, tighten securing bolts of camshaft toothed belt pulley
pt
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hand-tight, then tighten them to 20 Nm.
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If pin of crankshaft stop - T10050- is standing on right next to hole:
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– Turn crankshaft slightly counter to engine direction of rotation
h re
hole
again.
spec
es, in part or in w
– Turn crankshaft in engine direction of rotation until crankshaft
t to the co
stop pin arrow engages in sealing flange whilst turning.
– First, tighten securing bolts of camshaft toothed belt pulley
rrectness of i
hand-tight, then tighten them to 20 Nm.
l purpos
Continuation
– Remove locking pin - 3359- and crankshaft stop - T10050- .
nform
ercia
– Turn crankshaft at least two rotations in engine direction of

m
at
rotation and set to just before TDC No. 1 cylinder.
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– Repeat check.
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– If camshaft hub can be secured in position, tighten securing

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♦ Camshaft sprocket: 45° further. Counterhold with counterhold
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- T10172- and adapters - T10172/4- .
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– Install middle and lower toothed belt guards.
agen
Prote AG.
– Install vibration damper/belt pulley. Tighten to specified torque

10 Nm and then turn a further 90°.
– Install upper toothed belt guard.
Further assembly is basically a reverse of the dismantling se‐
quence. During this procedure, observe the following:
♦ Ensure fuel hoses are seated correctly.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line white).
– Install wheel housing liner.

Polo 2010 ➤
3 Valve gear
Note
If there are slight cracks, max. 0.5 mm wide, re-use cylinder heads
with cracks between the valve seats.
⇒ “3.1 Assembly overview - valve gear”, page 97 .

⇒ “3.2 Measuring axial clearance w
ofagcamshaft”,
en AG. V
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agen A98
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⇒ “3.3 Measuring radial clearance
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⇒ “3.4 Inlet and exhaust
au valves”, page 100 .
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⇒ “3.5 Removing and installing camshafts”, page 109 .
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⇒ “3.6 Checking hydraulic compensation elements”, page 115

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⇒ “3.7 Removing and installing camshaft oil seal”, page 116 .
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3.1 Assembly overview - valve gear
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hole
spec
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t to the co
1 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
rrectness of i
ing lip.
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❑ Before installing, re‐

move residual oil from
camshaft journal using a
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clean cloth.
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❑ To install, mask off

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com
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groove on camshaft tap‐

n in
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er (e.g. using Sellotape)

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⇒ page 116
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❑ 10 Nm Prote
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4 - Bearing frame
❑ Observe sequence for
loosing and tightening
⇒ page 109
❑ Seal with sealant as per
⇒ ETKA (Electronic
Parts Catalogue)
5 - Exhaust camshaft
6 - Inlet camshaft
7 - Roller rocker fingers
❑ Mark installation posi‐
tion
❑ Check roller bearing for
ease of movement.
❑ Oil cam contact surface
before installing.
3. Valve gear 97
Polo 2010 ➤
8 - Hydraulic compensation element

❑ Mark installation position
❑ Lubricate contact surfaces before installing.
9 - Cylinder head
❑ See note ⇒ page 66 .
10 - Hall sender - G40- connector
11 - Valve
❑ Do not rework. Only lapping in is permitted.
❑ Mark installation position for re-installation.
❑ Valve dimensions ⇒ page 100
❑ Checking valve guides ⇒ page 100
12 - Stud
13 - Valve stem seal
14 - Valve springs
15 - Valve spring plate
16 - Valve cotter
17 - Cap
❑ Renew
Retaining frame - specified torques andoinstallation

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– Unscrew retaining frameVol securing bolts in sequence o-20…1-.
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– Tighten bolts in
ut
ho2 stages in the sequence shown:
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Stage Bolts Specified torque
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1) -1 … 20- Screw in by hand as far as stop

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• The retaining frame must make

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contact with the cylinder head over

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the entire contact surface.

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2) -1 … 20- 10 Nm
spec
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3.2 Measuring axial clearance of camshaft

rrectness of i

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at
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ion
c
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do
priv
cum
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Prote AG.

Polo 2010 ➤
♦ Dial gauge - VAS 6079-
Procedure
– Remove retaining frame.
– Fasten dial gauge - VAS 6079- to retaining frame using uni‐
versal dial gauge bracket - VW 387- as shown in the illustra‐
tion.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
• Specification: 0.048 to 0.118 mm.
• Wear limit: 0.17 mm.
3.3 Measuring radial clearance of cam‐

shafts
Special tools and workshop equipment Arequired
G. Volkswagen A n G do
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♦ Plastigage Volks ot g
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Procedure oris tee
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– Remove roller rocker finger.
s
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nl
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– Remove bearing cap and clean crankshaft journal.

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itte
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ab
– Place a length of Plastigage corresponding to the width of the

ility
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bearing on the journal to be measured or into the bearings.

wit
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• Plastigage must lie in the middle of the bearing.

hole
spec
– Fit retaining frame and tighten to 10 Nm ⇒ page 98 without

es, in part or in w
twisting crankshafts.
t to the co

rrectness of i

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• Radial clearance: 0.035 to 0.085 mm.

nform
mercia
at
om
ion
c
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or
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ate
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for
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t.
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Cop py
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Prote AG.
3. Valve gear 99
Polo 2010 ➤
3.4 Inlet and exhaust valves

⇒ “3.4.1 Valve dimensions”, page 100
⇒ “3.4.2 Reworking valve seats”, page 100
⇒ “3.4.3 Checking valve guides”, page 100
⇒ “3.4.4 Renewing valve stem seals”, page 101
⇒ “3.4.1 Valve dimensions”, page 100
⇒ “3.4.2 Reworking valve seats”, page 100
⇒ “3.4.3 Checking valve guides”, page 100
wage
⇒ “3.4.4 Renewing valve stem seals”, page 101 olks es n
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⇒ “3.4.5 Renewing valve stem seals withhor cylinder head removed”,
is tee
page 105 aut or
ac
ss
⇒ “3.4.6 Checking valves”, page 108
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3.4.1 Valve dimensions
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Note
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Do not rework valves. Only lapping-in is permitted.
t to the co
Dimension Inlet valve Outlet valve
rrectness of i
∅a mm 26.50 … 26.70 24.4 … 24.60
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∅b mm 5.968 … 5.982 5.958 … 5.972

c mm 99.30 99.10
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α ∠° 45 45
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tion in
3.4.2 Reworking valve seats
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Do not rework valve seats due to the very small tolerances.
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3.4.3 Checking valve guides
Prote AG.


Polo 2010 ➤
♦ Dial gauge
– 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 rock. Wear limit: max. 1.3 mm
– Cylinder head must be renewed if rock exceeds wear limit.
3.4.4 Renewing valve stem seals
AG. Volkswagen AG d
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c
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3. Valve gear 101

Polo 2010 ➤

equipment required
lkswage es n
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spec
es, in part or in w
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rrectness of i
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♦ 10 mm jointed spanner - 3220-

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♦ Valve stem seal puller - 3364-
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♦ Valve stem seal fitting tool - 3365-
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Prote AG.
♦ Removal and installation device for valve cotters - VAS 5161-
with guide plate - VAS 5161/23- and knurled spacer ring - VAS
5161/23-1-
Removing
– Remove all glow plugs using jointed spanner - 3220- .
⇒ page 281
– Remove camshafts ⇒ page 109 .
– Remove roller rocker fingers, note installation position of roller
rocker fingers ⇒ Item 7 (page 97) .
– Place guide plate - VAS 5161/23- onto cylinder head.

Polo 2010 ➤
– Secure guide plate on intake manifold side using knurled

screw - VAS 5161/12- and M6 bolts -1-.
– Screw sealing bolt - VAS 5161/10- into the guide plate.

– Screw adapter - VAS 5161/11- into the respective glow plug
thread hand-tight.
AG. Volkswagen AG d
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– Insert punch - VAS 5161/3- into guide plate and rise use a plastic nte
ho eo
hammer to knock loose the firmly seated valve
s aut
cotters. ra
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– Screw attachment fork - VAS 5161/5- with ratchet piece - rrectness of i
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VAS 5161/6- into guide plate .

– Push knurled spacer ring - VAS 5161/23-1- onto the assembly
nform
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cartridge - VAS 5161/8- .

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at
– Connect adapter - VAS 5161/11- to compressed air using a

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commercially available intermediate piece. Leave constantly

n
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or
under pressure.
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• Minimum pressure: 6 bar.

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– Attach pressure fork - VAS 5161/2- to ratchet piece , press

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assembly cartridge down. C py
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– At the same time, turn knurled screw of assembly cartridge
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clockwise until tips engage in valve cotters. Prote
cted AG.
agen
– Move knurled screw back and forth slightly to press apart valve
cotters and capture them in the assembly cartridge.
– Release pressure fork.
– Remove assembly cartridge with knurled spacer ring, valve
plate and valve spring.
3. Valve gear 103

Polo 2010 ➤
– Pull off valve stem seals using valve stem seal puller - 3364- .
Installing
– Lightly oil sealing lip of valve stem oil seal and valve stem.
– Carefully push valve stem oil seal on valve stem -A-.
. Volkswagen AG
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– Carefully press valve stem oil seal onto valve Vguide
olks using
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valve stem seal fitting tool - 3365- . ed
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– If necessary, use a plastic head hammer au
th and tap lightly on ra
fitting tool until valve stem seal is fitted
ss to stop. c
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nl
pt
– Insert valve spring and valve plate into cylinder head.
du
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ility
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– If valve cotters have been removed from assembly cartridge ,
spec
they need to be put into insertion device - VAS 5161/18- first.
es, in part or in w
t to the co
Note
rrectness of i
Larger diameter of valve cotters faces upwards.
l purpos
– Press assembly cartridge onto insertion device from above

nf
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and pick up valve cotters. orm

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Prote AG.

Polo 2010 ➤
– Insert installation cartridge - VAS 5161/8- into guide plate

again.
Volkswagen AG
– Push down pressure fork, and pull knurled screw upwards agen
AG. does
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while turning to left and right - this will insert the
by
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– Reduce pressure on pressure fork whilstthopulling
ri on knurled eo
screw. ss au ra
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Further installation is carried out in the reverse order of removal;
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note the following:
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– Install camshafts ⇒ page 109 .
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– Installing ceramic glow pin plugs ⇒ page 281 .
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Engine is not to be rotated for approx. 30 minutes after instal‐
ling camshafts. The hydraulic compensation elements must
rrectness of i
settle (otherwise valves will strike pistons).
l purpos
♦ After working on the valve gear, turn the engine carefully at

least 2 rotations to ensure that none of the valves make con‐
nf
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tact when the starter is operated.
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3.4.5 Renewing valve stem seals with cylinder head removed

or
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3. Valve gear 105

Polo 2010 ➤

equipment required
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♦ Valve stem seal puller - 3364-

spec
♦ Valve stem seal fitting tool - 3365-

t to the co
♦ Removal and installation device for valve cotters - VAS 5161-

with guide plate -VAS 5161/23- and sleeve -VAS 5161/23-1-
rrectne
♦ Engine and gearbox support - VAS 6095-

s
♦ Cylinder head tensioning device - VAS 6419-

s o
cial p
f i
♦ Bolt M6×30 (qty. 2)

nform
mer
Procedure
atio
om
n
c
– Removing glow plugs ⇒ page 281

i
or
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te
sd
a
– Remove camshafts ⇒ page 109 .

iv
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pr
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fo
– Mark allocation of roller rocker fingers and hydraulic compen‐

en
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t.
sation elements for reinstallation.
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– Remove roller rocker fingers together with hydraulic compen‐ gh ht
yri by
sation elements and place down on a clean surface. cop Vo
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Prote AG.

Polo 2010 ➤
– Insert cylinder head tensioning device - VAS 6419- into engine

and gearbox support - VAS 6095- .
– Tension cylinder head on cylinder head tensioning device as
shown in the operating instructions.
Operating instructions for the cylinder head tensioning device -
VAS 6419- are enclosed with unit.
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.
– Place guide plate -VAS 5161/23- onto cylinder head.

– Tighten guide plate on intake manifold side by hand using
knurled screw -VAS 5161/12- and 2 M6x30 bolts until it makes
contact.
– Insert drift -VAS 5161/3- into guide plate and use a plastic AG. Volkswagen AG d
hammer to knock loose the firmly seated valve cotters. agen oes
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– Screw toothed piece -VAS 5161/6- with hooking fork -
VAS 5161/5- into guide plate.
– Push sleeve -VAS 5161/23-1- onto assembly cartridge - rrectness of i
l purpos
VAS 5161/8- .
– Attach pressure fork -VAS 5161/2- to toothed piece and press
nform
ercia
assembly cartridge down.

m
– At the same time, turn knurled screw of assembly cartridge

at
om
io
clockwise until tips engage in valve cotters.

n
c
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– Move knurled screw back and forth to press apart valve cotters
at
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and capture them in assembly cartridge.

p
cum
for
en
– Release pressure fork.

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op py
– Remove assembly cartridge with knurled spacer ring. t. C rig
gh ht
pyri by
– Remove valve spring and valve spring plate.
co Vo
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cted agen
Prote AG.
3. Valve gear 107

Polo 2010 ➤
– Pull off valve stem seal using valve stem seal puller - 3364- .
. Volkswag
en AG
– Lightly oil sealing lip of valve stem oil
ksw
seal
agenand valve stem.
AG does
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– Carefully push valve stem oiliseseal
d b on valve stem -A-. ua
ran
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– Carefully press valve stems au oil seal onto valve guide using
or
ac
valve stem seal fitting tool
s - 3365- .
ce
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ab
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spec
t to the co
If the valve cotters have been removed from the assembly car‐
tridge, they must first be inserted into the valve insertion device -
VAS 5161/18- .
rrectne
• Larger diameter of valve cotters faces upwards.
ss
– Insert valve spring and valve spring plate.
o
cial p
f inform
– Press assembly cartridge onto valve insertion device from

mer
above and pick up valve cotters.

atio
om
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c
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or
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– Insert assembly cartridge into guide plate -VAS 5161/23- Cop py
t. rig
again. opyri
gh by
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ht
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– Press pressure fork downwards and pull knurled screw up‐
lksw
cted agen
Prote
wards, turning it clockwise and anticlockwise. This inserts the
AG.
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Assembling
Installation is carried out in the reverse order; note the following:
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensation
elements.
– Install camshafts ⇒ page 109 .
3.4.6 Checking valves

– Check for scoring on valve stems and valve seat surfaces.
– Exchange valve if significant scoring can be seen.

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3-cylinder gen AG
wacommon rail enginedo(1.2
es n l, EA189) - Edition 06.2019
olks o
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3.5 Removing and installing camshafts aut
ho eo
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nl
pt
du
an
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equipment required
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ab
ility
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spec
es, in part or in w
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♦ Diesel injection pump locking pin - 3359-

♦ Puller - T10052-
♦ Camshaft fitting tool - T40094-
♦ Camshaft clamping tool - T40095-
♦ Camshaft fitting tool - T40096-
3. Valve gear 109

Polo 2010 ➤
♦ Torque wrench - V.A.G 1331/- AG. Volkswagen AG d

agen oes
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t to the co
♦ Torque wrench - V.A.G 1332/-
rrectness o
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f inform
mer
atio
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♦ Sealant as per ⇒ ETKA (Electronic Parts Catalogue) opyri
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3.5.1 Removing
by
cted agen
Prote AG.

– Removed toothed belt from camshaft and high-pressure pump
⇒ page 88 .
– Unscrew camshaft sprocket securing bolts -1-.
– Remove camshaft sprocket from hub.

Polo 2010 ➤
– Counterhold hub with counterhold - T10051- and loosen hub

securing bolt -1-.
– Unscrew hub securing bolt approx. 2 turns.
AG. Volkswagen AG d
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or eo
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nl
pt
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– Position puller - T10052- and align with hub holes.
ab
ility
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– Tighten securing bolts -1-.
wit
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h re
– Apply tension to hub by evenly tightening puller -2- until hub
hole
spec
separates from taper of camshaft.
es, in part or in w
t to the co
Note
rrectness of i
Hold puller with a »30 mm« spanner whilst doing this.
l purpos
– Remove hub from camshaft taper.
nform
ercia
– Remove vacuum pump ⇒ Item 4 (page 67) .

m
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ion
– Unscrew retaining frame securing bolts in sequence -20…1-.
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– Carefully remove camshafts.

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3.5.2 Installing
Note
Seal parting surface between retaining frame and cylinder head

using sealant as per ⇒ ETKA (Electronic Parts Catalogue) .
Caution
The camshafts may be installed only with the camshaft fitting

tool - T40094- as described below. Otherwise the axial bear‐
ings in the retaining frame will be destroyed and the cylinder
head must be replaced.
– Remove sealant residue from cylinder block and retaining

frame using, for example, a plastic rotary brush.
3. Valve gear 111

Polo 2010 ➤
Caution
Make sure that no sealant residue gets into the cylinder head
or the bearings.
– Clean sealing surfaces. They must be oil and grease free.

– Oil running surfaces of camshafts.
Set up camshaft fitting tool - T40094- for camshafts as follows:
AG. Volkswagen AG d
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nl
pt
du
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– Remove supports -T40094/3- , -T40094/4- and -T40094/5-
erm
ab
from base plate. Threaded connection is accessible from be‐
ility
ot p
low.
wit
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hole
spec
Note
es, in part or in w
t to the co
If the supports of the camshaft fitting tool - T40094- are not yet
marked, mark the removed supports, e.g. with number stamps,
rrectness of i
so they can be fitted in the original positions later.
l purpos
nf
ercia
orm
m
– Instead, position supports -T40094/9- and -T40094/12- on

atio
m
outer positions which have become free.

o
n in
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thi
– Place support -T40094/2- in position “A”. Place support -

te
sd
a
T40094/1- in position “D”.

iv
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– First insert inlet camshaft as shown. Ensure that indentation

en
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t.
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-arrow- for cylinder head bolt faces »outwards«.
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Prote AG.
– Fit 0.50 mm feeler gauge. Push support -T40094/8- into inlet

camshaft groove.

Polo 2010 ➤
– Insert exhaust camshaft, lock via its groove -arrow- with

-cover T40094/11-.
– Position clamping tool - T40096/1- on exhaust camshaft
sprockets.
Caution
Ensure that the clamping jaw marked with an arrow is seated

on the wider gear.
– Tighten clamping tool - T40096/1- using knurled wheel so that

faces of gear teeth are in alignment. Use a 13 mm open-end
spanner to assist if necessary.
– Slide exhaust camshaft towards inlet camshaft until teeth en‐
gage.
n AG. gen AG Volkswa
– Position retaining wage
olksframe on camshafts.
does
not
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• All camshaft
or
ise bearings must be seated on the camshafts.
ran
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au ra
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pt
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ab
ility
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– Position camshaft fitting tool - T40095- as shown, thereby

wit
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locking camshafts in retaining frame.

h re
hole
spec
– Remove cover - T40094/11- .

es, in part or in w
t to the co
– Pull support - T40094/8- out of inlet camshaft groove.

rrectness of i
l purpos
nform
mercia
at
om
ion
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ate
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– Cut off nozzle on tube at front marking (∅ of nozzle approx.
by lksw
cted agen
Prote
2 mm).
AG.
– Apply sealant beads (approx. 2 … 3 mm wide) -arrows- as

shown in illustration on clean sealing surfaces of cylinder
head.
3. Valve gear 113

Polo 2010 ➤
Note
The sealant beads (working time 5 minutes) must not be thicker

than specified, otherwise excess sealant could enter the camshaft
bearings.
– Install new cap ⇒ Item 17 (page 98) flush on cylinder head.

– Take camshafts out of camshaft fitting tool - T40095- together
with retaining frame and camshaft fitting tool - T40094- .
– Carefully insert camshafts and retaining frame into cylinder
head.
wage e
– First, tighten securing bolts ofy Vretaining
olks frame hand-tight ins not gu
sequence -1…20-. ise
d b ara
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t ho
• The retaining frame sshould
au make contact with the cylinder or
ac
head over the complete
s surface.
ce
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un
pt
– Tighten retaining frame bolts to final torque in the sequence
an
d
itte
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-1 … 24-. Specified torque: 10 Nm.
erm
ab
ility
ot p
– Remove camshaft fitting tool - T40095- and clamping tool - wit

is n
T40096/1- . h re
ole,
– Renew camshaft seal ⇒ page 116 .

spec
t to the co
Perform further installation in reverse order, paying attention to

the following:
rrectne
Note
ss
♦ After installing camshafts wait for approx. 30 minutes before

o
cial p
f i
starting engine. The hydraulic compensation elements must

nform
settle (otherwise valves will strike pistons).

mer
atio
m
♦ After working on valve gear, carefully crank engine at least 2

o
n
c
revolutions by hand to ensure that no valves make contact on

or
n thi
e
starting.
t
sd
iva
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pr
cum
r
fo
– Place hub back onto camshaft.

en
ng
t.
yi Co
Cop py
t. rig
– Tighten hub securing bolt -1- to 100 Nm. Use counter-hold tool
gh ht
yri by
- T10051- to do this.
cop Vo
by lksw
cted agen
Prote AG.

Polo 2010 ➤
– Push camshaft sprocket onto hub.
Note
olkswagen AG
en AG. V
The arrow on the camshaft pulley must be at almost »12 o'clock«.
Vol
ksw
ag does
not
by gu
ara
ed nte
ris
– Hand tighten securing bolts -1- to camshaft sprocket
tho so that eo
there is no play. au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
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– Lock hub with locking pin - 3359- .
h re
hole
spec
– Install toothed belt, adjust valve timing ⇒ page 88 .
es, in part or in w
t to the co
– Install vacuum pump.
rrectness of i
– Install fuel filter ⇒ Fuel supply; Rep. gr. 20 .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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3.6 Checking hydraulic compensation ele‐

t
sd
iva
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ments
rp
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f
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t.
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Cop py
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Note rig ht
py by
co Vo
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♦ The hydraulic compensation elements cannot be repaired.
Prote AG.
♦ Irregular valve noise during starting is normal.

♦ Plastic wedge
♦ Feeler gauge
Procedure
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2500 rpm for 2 minutes; per‐
form road test if necessary.
Note
If the irregular valve noises stop but recur repeatedly during short
journeys, the oil filter bracket ⇒ page 131 with integrated oil re‐
tention valve must be renewed.
– If the hydraulic compensation elements are still noisy, find out

which is the defective compensation element as follows:
– Turn crankshaft by the bolt for the toothed belt wheel until cam
of supporting element to be tested is facing upwards.
3. Valve gear 115

Polo 2010 ➤
– Press roller rocker finger downwards -arrow- with a plastic

wedge to check clearance between cam and roller rocker fin‐
ger.
– If a 0.20 mm feeler gauge can be inserted between cam and
roller rocker finger, replace hydraulic compensation element
⇒ page 109 .
Concluding measures
3.7 Removing and installing camshaft oil seal

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
♦ Fitting tool - V.A.G 10-203-

p
cum
for
en
g
♦ Seal puller - 3240-

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
♦ Use bolt M12 x 1.5 x 75 -10203- .

Polo 2010 ➤

Removing
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 88 .
– Remove camshaft sprocket and hub ⇒ page 109 .
– Insert thrust piece -3240/1- into camshaft.
– Unscrew inner part of oil seal extractor - 3240/1- 2 turns (ap‐
prox. 3 mm) from the outer part and lock in position with the
knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Installing
AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
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Do not be additionally oil or grease the oiluseal
thor
sealing lip. eo
a ra
ss c
– Remove oil residues from camshaft journal using a clean cloth.
ce
e
nl
pt
du
an
itte
y li
– Fit guide sleeve -10-203- onto camshaft as shown in illustra‐
erm
ab
ility
tion.
ot p
wit
, is n
– Carefully slide oil seal -1- over guide sleeve onto camshaft. h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Press seal in using thrust piece of fitting tool - 10 - 203- .

om
ion
c
in t
– Install camshaft sprocket and hub ⇒ page 109 .

or
his
ate
– Install toothed belt and adjust the valve timing ⇒ page 88 .

do
priv
cum
for
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 117

Polo 2010 ➤
17 – Lubrication
1 Sump agen
AG. Volkswagen AG d
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Caution horis nte
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If large quantities of metal chips and abraded material are
ce
le
un
found during engine repair, this may indicate that the crank‐
pt
an
d
shaft bearings or conrod bearings are damaged. To avoid any

itte
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rm
subsequent damage, the following work must be carried out
ab
pe
ility
following the repair:
ot
wit
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Thoroughly clean oil channels.
h re
hole
spec
Renew engine oil cooler.
es, in part or in w
t to the co
Renew oil filter element.
rrectness of i
⇒ “1.1 Assembly overview - sump”, page 118
l purpos
⇒ “1.3 Removing and installing sump”, page 121

⇒ “1.2 Removing and installing oil level and oil temperature send‐
nform
ercia
er G266 ”, page 120

m
a
com
t
⇒ “1.4 Engine oil:”, page 125
ion in
r
te o
1.1 Assembly overview - sump

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rig ht
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co Vo
by lksw
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Prote AG.
118 Rep. gr.17 - Lubrication

Polo 2010 ➤
1 - Cylinder block
2 - Seal
❑ Renew
❑ Must not be oiled.
❑ Fit into lugs on oil filter
bracket.
3 - Oil filter bracket with engine
oil cooler
❑ Assembly overview
⇒ page 131 .
4 - 14 Nm + 90° (1/4 turn) fur‐
ther
❑ Renew
5 - Oil dipstick
❑ The oil level must not be
above the max. mark
6 - 9 Nm
7 - Noise insulation
8 - 9 Nm lkswage es n
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9 - 8 Nm ir se
d ran
tee
tho
or
10 - Charge air pipe au ac
ss
ce
le
11 - Sump
un
pt
an
d

itte
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erm
⇒ page 121
ab
ility
ot p
12 - Bracket for coolant pipes
wit
is n
h re
ole,
13 - Bolt
spec
❑ 10 Nm
t to the co
14 - Oil level and oil tempera‐
ture sender - G266-
rrectne
❑ Checking ⇒ Vehicle diagnostic tester
15 - O-ring
ss o
❑ Renew
cial p
f inform
16 - 15 Nm
mer
atio
m
17 - Oil drain plug, 30 Nm

o
n
c
i
or
❑ With captive seal

thi
te
sd
a
❑ Renew
iv
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18 - 5 Nm
en
ng
t.
yi Co
op
19 - Cover C py
t. rig
gh ht
yri
❑ Balancer shaft module p by
co Vo
by lksw
❑ Clean if soiled.
cted agen
Prote AG.
20 - Balancer shaft module with oil pump

❑ Renew only as complete unit
21 - 15 Nm
22 - Sealing flange at belt pulley end
❑ Renew
❑ Must seat on dowel sleeves.
1. Sump 119
Polo 2010 ➤
Sump - specified torque and tightening sequence
Note
– Tighten bolts in 3 stages:

1) -1 … 20- In diagonal sequence to 5 Nm
2) -Arrows- 40 Nm
3) -1 … 20- Diagonally in stages; final torque
15 Nm
AG. Volkswagen AG d
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olksw not
1.2 Removing and installing oil level and oil rised byV gu
ara
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temperature sender - G266- aut
ho eo
ra
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an
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Removing
itte
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erm
ab
– Drain engine oil ⇒ Maintenance ; Booklet 24.1 .
ility
ot p
wit
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– Disconnect connector -3-.
h re
ole,
spec
– Unscrew bolts -1- and remove oil level and oil temperature
sender - G266- -item 4-.
t to the co
Installing
• Specified torque ⇒ Item 13 (page 119)
rrectne
ss o
cial p
f in
Note
form
mer
atio
m
Renew seal -2- and self-locking bolts -1-.

o
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2010 ➤
1.3 Removing and installing sump

equipment required
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
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ 10 mm jointed spanner - VAS 3185-

♦ Multi-point bit - T10058-
nform
ercia
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-

m
at
om
io

n
c
in t
or
his
ate
♦ Sealant as per ⇒ ETKA (Electronic Parts Catalogue)

do
priv
cum
or
♦ Hand drill with plastic brush attachment

f
en
ng
t.
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op
♦ Safety glasses C py
t. rig
gh ht
yri by
♦ Scraper cop Vo
by lksw
cted agen
Prote
AG.
Removing
tion .
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine. Drain engine oil.
1. Sump 121
Polo 2010 ➤
Note
Please observe disposal instructions!
– Disconnect electrical connector -arrow- on oil level and oil

temperature sender - G266- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Remove noise insulation -2- for
ut
h oil sump. To do this:
o eo
ra
s a c
- Undo bolts -1-. s
ce
le
- Remove 2-section clips -arrows-.

un
pt
an
d
- Detach pipe fastenings at noise insulation element.

itte
y li
erm
ab
– Loosen bolt -3-.
ility
ot p
wit
is n
– Move coolant lines aside slightly.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
– Unscrew bolts -arrows- of oil dipstick connections.

t
sd
iva
o
pr
cum
– Remove oil dipstick upwards.

r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2010 ➤
ageengine
3-cylinder common
olkswrail (1.2 l, EA189)
es n- Edition 06.2019
o
V t gu
by ara
ed nte
– Unscrew connecting bolts -arrows- for sump/gearbox.
ho
ris
eo
aut ra
– Unscrew sump securing bolts diagonallyssusing Allen key, long c
ce
e
reach 5 mm - T10058- .
nl
pt
du
an
itte
– Release sump carefully from adhesive.
y li
erm
ab
ility
– Loosen sump with light blows of a rubber headed hammer if
ot p
wit
necessary.
, is n
h re
hole
– Remove sealant residues from crankcase.
spec
es, in part or in w
t to the co
rrectness of i
– Remove sealant residue and rubber gasket from sealing
l purpos
flange on belt pulley side -arrows-.
nf
ercia
Caution
orm
m
atio
m
Danger of soiling lubrication system and bearings.

o
n in
or c
thi
e
♦ Cover open parts of engine.

t
sd
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o
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rp
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f
en
ng
t.
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op
WARNING
C py
t. rig
gh ht
pyri by
Vo
co
Wear protective goggles.
by lksw
cted agen
Prote AG.
– Remove sealant residues on sump with a rotating brush, e.g.

a hand drill with a plastic brush insert.
– Clean sealing surfaces. They must be oil and grease free.
Installing
Note
Note expiration date of sealant as per ⇒ ETKA (Electronic Parts

Catalogue) .
1. Sump 123
Polo 2010 ➤
wage
e ks s no
Vol t gu
by ara
– Cut off tube nozzle at front marking (∅ of nozzlerisapprox.
ed
nte
3 mm). tho eo
au ra
c
ss
– Apply sealant as per ⇒ ETKA (Electronic Parts Catalogue) on
ce
e
nl
clean sealing surface of sump as shown in illustration. Sealant
pt
du
an
bead must be:
itte
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erm
ab
♦ Run bead along inner side of bolt holes -arrows-.
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w
t to the co
Danger of blocking lubrication system with excess sealant.
♦ Do not apply sealant bead thicker than specified.
rrectness of i
♦ Ensure adequate quantity of sealant in area of sealing
flange on belt pulley side (better too much than too little)
l purpos
nform
mercia
Note
at
om
ion
c
in t
r
The sealing surfaces of the sealing flange on the belt pulley side
o
his
te
facing the cylinder block have an offset of approx. 1 mm, which

a
do
riv
has to be compensated by means of more sealant being applied

p
cum
or
to the oil sump.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Thickness of sealant bead on sump: p by
o Vo
by c lksw
cted agen
♦ In area of sealing surface of sealing flange on pulley side Prote AG.
-arrows pointing upwards-: 3 … 4 mm
♦ In area of sealing surface of cylinder block and sealing flange
on gearbox side -arrows pointing downwards-: 2 … 3 mm
• Sealant bead in area of sealing flange on belt pulley side must
be able to substitute the no longer existent rubber gasket of
sealing flange on belt pulley side in terms of height and width.
Note
Oil sump must be installed within 5 minutes after applying sealant.
– Mount oil sump.
Note
♦ The oil sump must be flush with the gearbox flange at the in‐
termediate plate.
♦ When installing sump with engine out of the vehicle, ensure
that sump is flush with cylinder block at flywheel end.

Polo 2010 ➤
– Tighten bolts of oil sump in 3 stages as follows:

1 -1 … 16- In diagonal sequence to 5 Nm
2 -Arrows- 40 Nm
3 -1 … 16- in diagonal sequence and in stages to
15 Nm
Further assembly is carried out in the reverse order, note the fol‐
lowing:
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
1.4 Engine oil:
Note
The oil level must not be above the max. marking on the dipstick
- danger of damage to the catalytic converter! Markings
Draining engine oil ⇒ Maintenance ; Booklet 24.1

Engine oil specification ⇒ Maintenance ; Booklet 24.1
⇒ “1.4.1 Oil capacities”, page 125 agen
AG. Volkswagen AG d
oes
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⇒ “1.4.2 Checking engine oil level”, page by V 125 gu
ara
ed
ris nte
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1.4.1 Oil capacities
h
aut ra
ss c ce
le
With oil filter change: 4.3 l

un
pt
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d
itte
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Without oil filter change: 4.0 l
erm
ab
ility
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1.4.2 Checking engine oil level

wit
is n
h re
ole,
spec
Note
t to the co
The oil level may be in area -d- due to the infiltration of fuel in the
engine oil as a result of unfavourable driving conditions after fill‐
rrectne
ing. As this is a normal self-regulating phenomenon, it is not

necessary to drain engine oil.
ss o
cial p
1 - Min. mark
inform
mer
2 - Max. marking
atio
m
a - Oil level in area of min. marking: replenish engine oil.

o
n
c
i
or
n thi
e
b - Oil level in middle range: can be topped-up with engine oil.

t
sd
iva
o
pr
c - Oil level in area of max. marking: do not replenish engine oil.

um
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fo
en
ng
t.
yi
d - The oil level may be in this area as a result of particular driving
Co
op py
conditions.
. C rig
ht ht
rig by
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Prote AG.
1. Sump 125
Polo 2010 ➤
2 Engine oil cooler

⇒ “2.1 Removing and installing engine oil cooler”, page 126
⇒ “2.2 Checking engine oil cooler for leaks”, page 128
2.1 Removing and installing engine oil cool‐

er
A n AG d G. Volkswage
agen
♦ Used oil collection and extraction
Volksw unit - V.A.G 1782- es not
o
g y ua
db ran
rise tee
tho or
au ac
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
o
♦ Spring-type clip pliers - VAS 6362- by c lksw
cted agen
Prote AG.

Removing
– Remove cowling ⇒ page 167 .
– Connection hose

Polo 2010 ➤
– Remove oil filter element.
– Remove coolant hoses. To do this, loosen hose clips -1-.
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
– Remove engine oil cooler from housing.

erm
ab
ility
ot p
Installing
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Renew gaskets, seals and O-rings.

♦ Hose unions and air intake pipes and hoses must be free of
rrectness of i
oil and grease before installation.

l purpos
♦ Secure all hose connections with hose clips corresponding to

the series equipment ⇒ Electronic Parts Catalogue .
nform
mercia
Install in reverse order.

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
127
by c lksw
cted
2. Engine oil cooler
agen
Prote AG.
Polo 2010 ➤
– Insert new seals into oil free lugs -1- on oil filter bracket.
– Carefully slide engine oil cooler onto centring pins.
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
– Press oil cooler on until it is flush -1- with end of centring pins.
erm
ab
ility
ot p
– Start new bolts, and screw them in until heads make contact.
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
– Tighten bolts -arrows- diagonally in 3 stages.
m
atio
om
n in
c

or
thi
te
sd
1 -Arrows- Screw in hand tight in diagonal se‐
iva
o
r
quence
rp
cu
o
m
f
en
ng
2 -Arrows- in diagonal sequence to 5 Nm

t.
yi Co
op py
3 -Arrows- tighten in diagonal sequence to 11 Nm t. C rig
gh ht
pyri by
Vo
o
– Install oil filter element, replenish engine oil and check oil level
c by lksw
cted agen
⇒ page 125 .
Prote AG.
– Replenish coolant in cooling system, change coolant if engine

oil cooler has been renewed ⇒ page 150 .
2.2 Checking engine oil cooler for leaks

Polo 2010 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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
♦ Refractometer - T10007-
um
r
fo
en
ng
t.
yi
♦ Hose clamps up to 25 mm - 3094-
Co
Cop py
ht. rig
♦ Cooling system tester - V.A.G 1274-
rig ht
py by
co Vo
by lksw
♦ Adapter for cooling system tester - V.A.G 1274/8-
cted agen
Prote AG.
♦ Pliers for spring-type clips - VAS 5024 A-

♦ Drip tray - V.A.G 1306- or drip tray - VAS 6208-
2. Engine oil cooler 129

AG. Volkswagen AG d
agen oes
olksw not
Polo 2010 ➤ d byV gu
ara
e
horis - Edition 06.2019 nte
eo
aut ra
ss c
ce
e
nl
pt
du
an
Without illustration:
itte
y li
erm
ab
♦ Expansion tank - 1K0 121 407 A- or expansion tank - 1J0 121
ility
ot p
407 B-
wit
, is n
h re
♦ Sealing plugs - 191 211 343-
hole
spec
♦ Cap - 1J0 121 324-
es, in part or in w
t to the co
♦ Coolant hose - 251 265 056-
Condition:
rrectness of i
• Engine cold
l purpos
Test sequence
nf
ercia
– Remove noise insulation ⇒ Rep. gr. 50 .
orm
m
atio
om
n in
c
– Loosen hose clip on engine oil cooler with spring-type clip pli‐
or
thi
e
ers - VAS 5024- .

t
sd
iva
o
r
rp
cu
– Remove engine oil cooler with housing ⇒ page 131 .
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
♦ Collect escaping coolant with drip tray - V.A.G 1306- or drip Prote AG.
tray - VAS 6208- .

♦ Collect leaking engine oil with a cleaning cloth, if necessary.
Checking when removed

– Clamp housing with old seal on a suitable, level and clean
surface.
– Attach plug -2- to venting connection of expansion tank -1-.
– Secure coolant hose -3- on engine oil cooler and expansion
tank.
– Fill expansion tank up to “max.” mark.
– Fit cooling system tester - V.A.G 1274- with adapter for cooling
system tester - V.A.G 1274/8- on expansion tank.
– Generate about 1.6 bar pressure using hand pump of tester.
– Observe pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If the pressure drops:
– Renew engine oil cooler ⇒ page 131 .
note the following:
– Renew seal for housing.
– Check coolant level and, if necessary, replenish
⇒ page 150 .
– Check engine oil level, replenish engine oil if necessary
⇒ page 125 .

Polo 2010 ➤
3 Oil filter, oil pressure switch

⇒ “3.1 Assembly overview - oil filter bracket and engine oil cooler”,
page 131 .
⇒ “3.2 Removing and installing oil filter bracket with engine oil
cooler”, page 132
⇒ “3.3 Checking oil pressure and oil pressure switch”,
page 135
⇒ “3.4 Removing and installing oil pressure switch F1 ”,
page 137
3.1 Assembly overview - oil filter bracket and engine oil cooler
1 - Cap, 25 Nm
2 - O-ring
❑ Renew
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - Oil filter element
❑ See note.
❑ Observe change inter‐
vals.
6 - Engine oil cooler olkswage es n
ot g
yV
❑ Ensure clearance db to ad‐ ua
ran
ir se
jacent components
tho
tee
or
au ac
❑ Checking
ss engine oil
cooler for leaks
ce
le
un
pt
⇒ page 132
an
d
itte
y li
erm
ab
7 - 11 Nm
ility
ot p
8 - Rubber seals
wit
is n
h re
❑ Renew
ole,
spec
❑ Fit into lugs on oil filter

t to the co
bracket.
❑ May not be lubricated
with oil
rrectne
9 - Bolt
s
❑ Renew
s o
cial p

inform
tightening sequence
mer
⇒ page 132
atio
om
10 - Oil filter bracket

c
i
or
n thi
e
❑ Ensure clearance to adjacent components

t
sd
iva
o
pr
11 - Rubber seals
um
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fo
en
ng
❑ Renew
t.
yi Co
Cop py
❑ Fit into lugs on oil filter bracket.
t. rig
gh ht
yri by
❑ May not be lubricated with oil cop Vo
by lksw
cted agen
Prote AG.
3. Oil filter, oil pressure switch 131

Polo 2010 ➤
Oil filter bracket - specified torques and sequence
Note
Renew bolts of oil filter bracket.
– First tighten upper left and lower right bolts.

– Tighten bolts in 2 stages:
Stage Bolts Specified torque/turning further angle
1) -Arrows- In diagonal sequence to 14 Nm
2) -Arrows- turn 90° further diagonally
Oil pressure switch - F1-

♦ With seal agen
AG. Volkswagen AG d
oes
olksw not
♦ Switch pressure 0.3 to 0.6 bar d by V gu
ara
rise nte
o
♦ Removing and installing ⇒ page 137 auth eo
ra
ss c
♦ Checking ⇒ page 135
ce
le
un
pt
an
d
♦ 20 Nm
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
3.2 Removing and installing oil filter bracket
t to the co
with engine oil cooler
rrectne
♦ Release lever - 80 - 200-
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.

Polo 2010 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
♦ Drip tray for workshop
s au hoist - VAS 6208- ra
c
s
ce
le
un
pt
an
d
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
♦ Spring-type clip pliers - VAS 6362-
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.

Removing
– Remove cowling ⇒ page 167 .
– Remove 4/2-way valve ⇒ page 158

Polo 2010 ➤
– Remove oil filter element.

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
– Unscrew bolts of oil dipstick connections -arrows-.
y li
rm
ab
pe
– Remove oil dipstick upwards.
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
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Remove coolant hoses. To do this, loosen hose clips -1-.
C py
t. rig
gh ht
yri by
– Place used oil collection and extraction unit - V.A.G 1782- un‐
cop Vo
by lksw
cted
der engine.
agen
Prote AG.

Polo 2010 ➤
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b
♦ Renew gaskets,
rise
d seals and O-rings. ara
nte
tho eo
♦ Hosesunions
sa
u
and air intake pipes and hoses must be free r a of
c
oil and grease before installation.
ce
e
nl
pt
du
♦ Secure all hose connections with hose clips corresponding to
an
itte
y li
the series equipment ⇒ Electronic parts catalogue .
erm
ab
ility
ot p
wit
– Install oil filter element, replenish engine oil and check oil level
, is n
h re
⇒ page 125 .
hole
spec
– Replenish coolant in cooling system, change coolant if engine
es, in part or in w
t to the co
oil cooler has been renewed ⇒ page 150 .
3.3 Checking oil pressure and oil pressure switch
rrectness of i
l purpos

equipment required
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.

Polo 2010 ➤
♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527 B-
♦ Adapter set - V.A.G 1594 C-
3.3.1 Checking oil pressure switch

Test conditions
• Oil level OK, checking ⇒ page 125
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
Note
Functional check and repair of theagoptical

n AG. Voand
lkswaacoustic
gen AG oil pres‐
w e does
sure warning: ⇒ Current flow Vdiagrams,
olks Electrical fault finding
not and
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Fitting locations ise
d by ara
n r tee
ho
aut or
ac
– Remove oil switch - F1- ⇒ Item 17 (page 67) pressure
ss »green
insulation« and screw into tester.
ce
e
nl
pt
du
an
itte
– Screw tester into cylinder head in place of oil pressure switch.
y li
erm
ab
ility
– Connect brown wire of tester to earth (-).
ot p
wit
, is n
– Connect voltage tester -V.A.G 1527 B- using auxiliary cables

h re
hole
from -V.A.G 1594 C- to battery positive (+) and oil pressure

switch. LED must not light up. spec
es, in part or in w
t to the co
– Start engine and increase revolutions slowly. At 0.3…0.6 bar,
the LED must light up, otherwise the oil pressure switch must
be renewed.
rrectness of i
l purpos
3.3.2 Checking oil pressure

nf
ercia

orm
m
atio
♦ Oil pressure tester - V.A.G 1342-

om
n in
or c
thi
te
sd
iva
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rp
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o
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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.
Procedure
• Oil level OK.
• Engine oil temperature approx. 80 °C.
– Remove oil pressure switch - F1- ⇒ page 137 .
– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch - F1- .
– Screw an old oil pressure switch into hole on oil pressure tester
- V.A.G 1342- to seal hole.
– Start engine.

AG. Volkswagen AG d Polo 2010 ➤
agen oes
Volksw 3-cylinder notcommon rail
gu
engine (1.2 l, EA189) - Edition 06.2019
by ara
d
rise nte
• Minimumutho oil pressure at idling speed: 0.8 bar. eo
ra
s a c
• Increase engine speed further. At 2000 rpm and an oil tem‐
s
ce
le
perature of 80°C, the oil pressure should be at least 1.5 bar.

un
pt
an
d
itte
y li
At higher engine speeds, the oil pressure must not exceed 5.0
rm
ab
bar. If oil pressure exceeds 5.0 bar:
pe
ility
ot
wit
, is n
– Renew oil pump ⇒ page 143 .
h re
hole
spec
3.4 Removing and installing oil pressure
es, in part or in w
t to the co
switch - F1-
rrectness of i
Removing
l purpos

– Detach hose for crankcase breather -3- from cylinder head
nform
ercia
cover and swing to one side.

m
a
com
t
– Pull vacuum hose -2- together with bracket off suction hose
ion in
-1-.
r
te o
thi
s
iva
– Pull suction hose -1- off air mass meter.
do
r
rp
cum
fo
– Unscrew bolt -4- completely (captive), swing suction hose en

ng
t.
yi
-1- together with inlet union to rear and pull off from turbo‐
Co
op py
charger. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew bolts -2 and 3-, remove engine lifting eye -1-.

– Separate electrical connector -arrow-.
– Remove oil pressure switch - F1- .
Installing
Note
Renew seal.
– Install vacuum line to exhaust gas recirculation cooler.

– Install suction hose.

Polo 2010 ➤
4 Oil circuit
⇒ “4.1 Removing and installing oil supply line and oil return (tur‐
bocharger support) ”, page 138 .
⇒ “4.2 Oil spray jet”, page 141
4.1 Removing and installing oil supply line

and oil return (turbocharger support)
4.1.1 Assembly overview - oil supply line and oil return (turbocharger support)
1 - Oil return line

2 - Seal
❑ Renew
3 - Bolt
❑ 20 Nm
4 - O-ring
❑ Renew
5 - Bolt
❑ 20 Nm
6 - Oil return (turbocharger
support)
7 - Bolt
❑ 10 Nm
8 - O-ring
❑ Various diameters. n AG. Volkswagen AG do
swage es n
❑ Renew together with yV
olk ot g
ua
banjo bolt. ir se
d b ran
tee
tho
or
9 - Banjo bolt au ac
ss
❑ 60 Nm
ce
le
un
pt
an
❑ Renew together with O-

d
itte
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rings.
erm
ab
ility
ot p
10 - Oil seals
wit
is n
h re
❑ Renew together with

ole,
banjo bolt.
spec
11 - Banjo bolt
t to the co
❑ 30 Nm
❑ Renew together with
rrectne
seals.
12 - Seal
ss o
cial p
❑ Renew
f inform
mer
13 - Connection pipe to exhaust gas recirculation cooler

atio
m
❑ With flexible joint; do not bend flexible joint - risk of cracking

o
n
c
i
or
❑ Renew seals or gaskets.

thi
te
sd
va
14 - Nuts
i
o
pr
cum
r
fo
❑ 22 Nm
en
ng
t.
yi Co
❑ Renew Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
15 - Bolts
❑ 9 Nm
16 - Seal
❑ Renew
17 - Union nut for oil supply line
❑ 22 Nm
4.1.2 Removing and installing oil supply line

and oil return (turbocharger support)
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
c

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 AG.

Removing
4. Oil circuit 139

Polo 2010 ➤
– Remove drive shaft shield.
– Remove connection pipe -2- leading to cooler for exhaust gas

recirculation.
Collect escaping oil using used oil collection and extraction unit -
V.A.G 1782- .
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
– Undo union nut -1- with open box end wrench, width across
erm
ab
flats 17 mm -A-.
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
– Loosen banjo bolts -6 + 7-.

m
atio
om
n in
or c
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
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
– Unscrew bolts -1, 4 + 5-.

Remove turbocharger support and oil supply line.
Installing
Specified torques ⇒ page 138 .
Note
Renew gaskets, seals, O-rings and self-locking nuts ⇒ Electronic

Parts Catalogue
• The procedure must be adhered to, in order to ensure that the

oil supply line and oil return (turbocharger support) are instal‐
led stress-free.
• Furthermore this ensures that the turbocharger support is in‐
stalled stress-free between crankcase and turbocharger.
– First bolt oil return line and oil return (turbocharger support) to
crankcase and turbocharger by hand.
– Position oil supply line on crankcase and turbocharger.
– Then tighten oil return line and oil return (turbocharger sup‐
port) in several steps up to the specified torque, alternating
between the crankcase and turbocharger.
– Then tighten the banjo bolt for oil supply line on crankcase and
union nut on turbocharger in several steps up to the specified
torque, alternating between the crankcase and turbocharger.
– Finally tighten bolt on oil supply line/turbocharger support
clamp to specified torque.
– Further assembly in reverse order of removal.
4.2 Oil spraylksjet

wage
es n
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yV ua
Oil spray jet and ipressure
se
db relief valve ran
r tee
tho
1- Bolt with
sa
u pressure relief valve, 27 Nm or
ac
s
ce
2- Oil spray jet (for cooling of pistons)

e
nl
pt
du
an
itte
• Installation position: align leading edge of oil spray jet arrow

y li
erm
ab
with machined surface of cylinder block.

ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
♦ Do not bend oil spray jets.

♦ Renew bent oil spray jets.
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 agen
Prote AG.
4. Oil circuit 141

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Polo 2010 r➤ ised
nte
o eo
3-cylinder
aut common rail engine (1.2 l, EA189) - Edition 06.2019
h
ra
ss c
ce
e
nl
pt
du
5 Balancer shaft module
an
itte
y li
erm
ab
⇒ “5.1 Assembly overview - balancer shaft module”, page 142
ility
ot p
wit
, is n
⇒ “5.2 Removing and installing balance shaft module”,
h re
hole
page 143 .
spec
es, in part or in w
5.1 Assembly overview - balancer shaft module
t to the co
1 - Cover
rrectness of i
❑ Clean if soiled.
l purpos
2 - 8 Nm
nf
ercia
3 - 14 Nm + 180° further
orm
m
❑ Tighten in several
atio
m
stages.
o
n in
or c
❑ Tighten diagonally from
thi
te
sd
a
inside to outside.
iv
o
r
rp
cu
o
m
4 - 14 Nm + 180° further
f
en
ng
t.
yi Co
op
5 - Balancer shaft with oil pump C py
ht. rig
rig ht
❑ Before installing, check py by
co Vo
that the dowel sleeves
by lksw
cted agen
Prote
for centring oil pump on
AG.
cylinder block are fitted

and the O-ring is fitted in
the retaining frame
⇒ page 143
6 - O-ring
❑ Renew
❑ Check firm seating, in‐
serted into retaining
frame.
❑ Lightly coat with oil be‐
fore installing
7 - Cylinder block
8 - Dowel sleeve
9 - Chain tensioner with ten‐
sioning rail
❑ To remove, lock with
locking pin - T40011-
⇒ page 143
10 - 8 Nm + turn 90° further
❑ Renew
11 - Assembly aid
❑ Locking pin - T40011-
12 - Chain
❑ Observe installation position ⇒ page 143 , Removing and installing balance shaft
13 - 23 Nm
14 - Chain sprocket/guide roller

Polo 2010 ➤
5.2 Removing and installing balance shaft module

equipment required
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
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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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.
♦ Locking pin - T40011-

♦ Torque wrench - V.A.G 1331- (5 - 50 Nm)
♦ Torque wrench - V.A.G 1332- (40 - 200 Nm)
Removing
– Toothed belt ⇒ page 88 .
– Oil sump ⇒ page 121 .
– Sealing flange at belt pulley end ⇒ page 36 .
– Balancer shaft module cover ⇒ Item 1 (page 142) .
5. Balancer shaft module 143

Polo 2010 ➤
– Lock chain tensioner using locking pin - T40011- -arrow-.

– Unscrew bolt from idler sprocket -1- and remove idler sprock‐
et.
– Unscrew bolts -2- from chain tensioner and remove chain ten‐
sioner.
– Remove chain from sprockets and lay chain on a clean sur‐
face.
– Unbolt balance shaft module from cylinder block, and place it
on a clean surface.
Installing
Specified torque ⇒ page 142
– Check chain drive components for wear.
Note
Ensure when installing the retaining frame that the fitted sleeve
is fitted in the cylinder block and the O-ring is fitted in the retaining
frame.
– Screw balance shaft module onto cylinder block hand-tight.
– Align the balance shaft module so that the belt pulley end is
flush with the outer edge of the cylinder block.
Caution
The balance shaft module may never be fitted as shown in the

illustration section with -arrow 1 and 2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Check that marking -arrow- on crankshaft sprocket is posi‐

t to the co
tioned almost at top.

– Clean chain with a lint-free cloth.
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.

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
Polo 2010 ➤
d
orise 3-cylinder common rail engine
nte (1.2
eo
l, EA189) - Edition 06.2019
th
au ra
s c
– Fit chain onto chain sprockets of crankshaft, oil pump and bal‐ s
ce
e
ance shaft as shown in illustration.
nl
pt
du
an
itte
y li
• Marking on crankshaft sprocket must align with single colour
erm
ab
marking on chain link -top arrow- in this case.
ility
ot p
wit
, is n
• Marking on balance shaft sprocket must be located between
h re
2 colour markings on chain links -bottom arrow-.
hole
spec
es, in part or in w
• The colour markings are only on the outer plates of the chain.
t to the co
They must be on the outside. This also guarantees the original
direction of rotation of the chain.
– Insert guide sprocket into chain, and bolt to balance shaft
rrectness of i
module at 23 Nm.
l purpos
– Install chain tensioner.
nf
ercia
o
– Replace bolts -2- and tighten as follows.
rm
m
atio
m
1) Centre bolt 8 Nm
o
n in
or c
2) Bolt on oil pump 8 Nm
thi
te
sd
iva
3) Bolt on guide rail 8 Nm
o
r
rp
cu
o
m
f
4) Centre bolt Turn 90° (1/4 turn)
en
ng
t.
yi Co
further
Cop py
t. rig
gh ht
5) yri
Bolt on oil pump Turn 90° (1/4 turn)
p by
co Vo
by lksw
cted further
agen
Prote AG.
6) Bolt on guide rail Turn 90° (1/4 turn)
further
– Remove locking pin - T40011- from chain tensioner.
– Check whether markings on sprocket/crankshaft and sprock‐

et/balance shaft are still positioned correctly to colour mark‐
ings on chain links -arrows-.
– Install sealing flange on belt pulley end ⇒ page 36 .
– Install balance shaft cover.
Note
When installing, make sure that cover engages in balance shaft

module.
– Install sump ⇒ page 121 .

– Install toothed belt ⇒ page 88 .
5. Balancer shaft module 145

Polo 2010 ➤
19 – Cooling
lkswage es n
1 Cooling system/coolant
o ot g
byV ua
d ran
ir se tee
ho
⇒ “1.1 Coolant hose connection diagram”,
aut page 146 . or
ac
ss
⇒ “1.2 Checking cooling system for leaks”, page 147
ce
le
un
pt
an
d
itte
⇒ “1.3 Draining and adding coolant”, page 149
y li
erm
ab
⇒ “1.4 Cooling system - fitting locations”, page 153
ility
ot p
wit
is n
1.1 Coolant hose connection diagram
h re
ole,
spec
Coolant hose schematic diagram
t to the co
1 - Expansion tank
rrectne
2 - Coolant circulation pump 2
- V178-
ss o
3 - Radiator/cooler
cial p
f in
❑ For exhaust gas recircu‐
form
mer
lation
atio
m
❑ Checking exhaust gas

o
n
c
i
or
n
recirculation cooler for
thi
e
leaks ⇒ page 271

t
sd
iva
o
pr
cum
4 - Heat exchanger for heater
r
fo
en
ng
t.
yi
❑ With quick-release cou‐
Co
op py
pling t. C rig
gh ht
pyri by
5 - Cylinder head/cylinder
co Vo
by lksw
cted
block
agen
Prote AG.
6 - Engine oil cooler

7 - Upper coolant hose
8 - Radiator/cooler
⇒ page 165
❑ Renew coolant after re‐
placing.
9 - Lower coolant hose
10 - 4/2-way valve with ther‐
mostat
⇒ page 158
11 - Coolant pump
⇒ page 162
❑ Renew coolant after re‐
newing ⇒ page 150 .
146 Rep. gr.19 - Cooling

Polo 2010 ➤
1.2 Checking cooling system for leaks

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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
o
by c lksw
cted agen
Prote AG.

♦ Cooling system tester - V.A.G 1274 B-
Note
To perform the leakage test correctly, first run a self-test on the

cooling system tester - V.A.G 1274 B- .
1. Cooling system/coolant 147

lkswage es n
o ot g
byV ua
d ran
ir se
Polo 2010 ➤ tho tee
or
u
3-cylinder common rail engine (1.2 l, EA189) - Edition
ss
a
06.2019 ac
ce
e
nl
pt
du
Self-test of cooling system tester - V.A.G 1274 B-
an
itte
y li
erm
ab
– Operate cooling system tester - V.A.G 1274 B- several times.
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
ercia
– Build up a pressure of 3.0 bar on cooling system tester .
m
at
– Observe pressure on pressure gauge of cooling system tester om
ion
for 30 seconds.
c
in t
or
his
te
If no pressure builds up or if the pressure drops again:

a
do
priv
cum
or
The cooling system tester - V.A.G 1274 B- is leaking and should

f
en
g
not be used.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Checking cooling system for leaks

• Coolant temperature at least 40 °C
WARNING

Skin and other parts of the body may be scalded.
♦ Wear protective gloves.
♦ Wear protective goggles.
♦ Reduce excess pressure by covering cap of coolant ex‐
pansion tank with cloths and opening it carefully.
– Open cap -1- on coolant expansion tank.

Polo 2010 ➤
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- to coolant expansion tank.
– Build up pressure of approx. 1.5 bar using hand pump of cool‐
ing system tester.
• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops by more than 0.2 bar, locate and rectify
leaks.
Note
The pressure drop of 0.2 bar within 10wminutes

agen
AG. Vdepends on
olkswagen AG dthe
o
how far the coolant can cool down. o ks colder the engine, thees not
The
l
y V gu
lower the pressure drop. ise
db ara
nt r ee
ho
aut or
ac
ss
WARNING
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
Skin and other parts of the body may be scalded.
ot
wit
, is n
h re
• Release pressure by pressing pressure relief valve on
hole
spec
cooling system tester until the gauge shows a pressure of
es, in part or in w
0.
t to the co
rrectness of i
Check pressure relief valve in cap.
l purpos
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/9- onto coolant filler cap.
nform
ercia
– Using hand pump of cooling system tester, build up pressure

and check the opening pressure of the filler cap.
m
a
com
tion in
Colour of filler cap Opening pressure

r
te o
thi
s
iva
blue 1.4 … 1.6 bar

do
r
rp
cum
black 1.6 … 1.8 bar

fo
en
ng
t.
yi Co
op
– Renew filler cap, if pressure relief valve does not open as de‐ C py
t. rig
scribed. gh ht
pyri by
Vo
co lksw
by
cted agen
1.3 Draining and adding coolant
Prote AG.
⇒ “1.3.1 Draining”, page 149

⇒ “1.3.2 Filling with coolant”, page 150 .
1.3.1 Draining
WARNING

Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.

Polo 2010 ➤
– Open filler cap on coolant expansion tank.

– Remove connecting hose »hot side« to charge air pipe
⇒ page 178 .
Note
To prevent ingress of coolant, seal connection on charge air cool‐

er using a clean plug from engine bung set - VAS 6122- .
– Place drip tray - VAS 6208- beneath engine.
– Pull off coolant hoses -arrows-.
– Remove lower coolant hose from radiator.
wage
Note yV
olks es n
ot g
d b ua
ran
ir se tee
Please observeuth disposal instructions!
o
or
a ac
ss
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
1.3.2 Filling with coolant

t to the co
⇒ “1.3.3 Filling: Using cooling system charge unit VAS 6096 only”,
page 151
rrectness of i
⇒ “1.3.4 Topping up”, page 153

l purpos
Caution
nf
ercia
orm
If large components (e.g. engine, radiator etc.) are to be re‐

m
atio
m
moved/installed, it is absolutely necessary to drain the cooling

o
n in
c
system.
or
thi
te
sd
a
If coolant has been drained, cooling system must be filled using

iv
o
r
rp
cu
cooling system charge unit - VAS 6096- ⇒ page 151 .

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
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 region to region, Volkswagen has
decided to define the quality of the water to be used in the
coolant system. Distilled water fulfils all requirements.
♦ 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. agen
AG. Volkswagen AG d
o
w es n
olks o
♦ Frost protection
ed
by
V
must be guaranteed down to
t gu
about
ara -25 °C (in
countries
ho
ris with Arctic climates, down to about -35nte°C).
e
t or
au
♦ Do
ss not reduce the coolant concentration by adding water
c even a
in warmer seasons and in warmer countries. The coolant ad‐
ce
le
un
pt
ditive concentration must be at least 40%.

an
d
itte
y li
rm
♦ If a stronger anti-freeze mixture is necessary due to harsher

ab
pe
ility
weather conditions, the coolant additive content can be in‐

ot
wit
creased. However, this is only permitted to 60% (antifreeze

, is n
h re
protection to about -40 °C). Otherwise, the antifreeze protec‐

hole
spec
tion will be reduced again and the cooling effect will be im‐
es, in part or in w
paired.
t to the co
♦ If radiator, heat exchanger, cylinder head or cylinder head

gasket is renewed, do not reuse old coolant.
rrectness of i
♦ The refractometer - T10007A- is recommended for determin‐

l purpos
ing the current anti-freeze density.
Recommended mixture ratios:

nform
ercia
• Coolant additive (40 %) and distilled water (60 %) for frost

m
a
com
ti
protection to -25 °C
on in
r
te o
thi
• Coolant additive (50%) and distilled water (50%) for frost pro‐
s
iva
tection to -35°C
do
r
rp
cum
fo
• Coolant additive (60 %) and distilled water (40 %) for frost

en
ng
t.
yi
protection to -40 °C
Co
Cop py
ht. rig
1.3.3 Filling: Using cooling system charge unit

rig ht
py by
co Vo
by lksw
- VAS 6096- only
cted agen
Prote AG.
• Cooling system is leak tight

. Volkswagen AG
Polo 2010 ➤ wage
n AG does
olks not
db
y V gu
ara
e nte
ris
ho eo
– Fill coolant expansion tank of -VAS 6096- with at leasts a8u litres
t ra
c
of pre-mixed coolant in correct mixture ratio: s
ce
le
un
pt
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
an
d
itte
y li
coolant expansion tank.
erm
ab
ility
ot p
– Attach cooling system charge unit - VAS 6096- to adapter -
wit
is n
V.A.G 1274/8- .
h re
ole,
– Feed vent hose -1- into a small container -2-.
spec
t to the co
Note
rrectne
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
ss o
cial p
f
– Close valves -A- and -B- (turn lever transverse to direction of
inform
flow to do this).
mer
atio
m
– Connect hose -3- to compressed air.

o
n
c
i
or
n
• Pressure: 6 to 10 bar.
thi
te
sd
iva
o
pr
cum
r
– Open valve -B-; turn lever in direction of flow to do this.

fo
en
ng
t.
yi Co
• In cooling system, vacuum is generated by suction jet pump; Cop py
needle of gauge must move into green area. ht. rig
rig ht
py by
co Vo
– Also briefly open valve -A- (turn lever in direction of flow to do
by lksw
cted agen
this) so that hose on -VAS 6096- coolant reservoir fills with
Prote AG.
coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• Vacuum continues to be generated in the cooling system by
the suction jet pump; the needle of gauge must remain in green
range.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ If vacuum drops, cooling system must be checked for leaks.
– Pull off compressed air hose.

– Open valve -A-.
• Vacuum in cooling system causes coolant to be extracted from
-VAS 6096- coolant reservoir and coolant system to be filled.
– Remove cooling system charge unit - VAS 6096- from coolant
expansion tank.

Polo 2010 ➤
– Fill coolant up to “max.” mark.

– Fit expansion tank cap.
– Start the engine. Keep engine speed at approx. 2000 rpm for
approx. 3 minutes.
– Then run engine at idling speed until radiator fan cuts in.
– Check coolant level and top up as needed. When engine is at
normal operating temperature, the coolant level must be at the
upper mark; when engine is cold, in the middle of the shaded
field.
1.3.4 Topping up lksw

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• Cooling system is leak tight ised ara
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– Slowly fill coolant in up to upper marking of hatched field on
e
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pt
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expansion tank.
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1.4 Cooling system - fitting locations
nform
ercia
⇒ “1.4.1 Assembly overview - parts of cooling system, body side”,

m
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page 153 ion

c
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⇒ “1.4.2 Parts of cooling system - engine side”, page 155

his
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1.4.1 Assembly overview - parts of cooling system, body side

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AG. Volkswagen AG d
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Polo 2010 ➤ Vol
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3-cylinder common rail engine (1.2risl,e EA189) - Edition 06.2019
d ara
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au ra
1 - Clip ss c
ce
le
❑ Renew if damaged
un
pt
an
d
itte
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2 - Upper coolant hose
rm
ab
pe
ility
❑ Connection diagram for
ot
wit
coolant hoses
, is n
h re
⇒ page 146
hole
spec
3 - Expansion tank
es, in part or in w
t to the co
❑ Check cooling system
for leaks with cooling
system tester -
rrectness of i
V.A.G 1274- and adapt‐
er - V.A.G 1274/8-
l purpos
⇒ page 147
4 - Cap
nform
ercia
❑ Check using cooling

m
a
system tester - V.A.G
com
tio
1274- and adapter for
n in
r
te o
cooling system tester -
thi
s
iva
V.A.G 1274/9- .
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❑ Test pressure: 1.4 to
fo
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1.6 bar
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5 - 5 Nm
t. rig
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6 - Connector
c by lksw
cted agen
Prote AG.
7 - Coolant hose
8 - Radiator mounting
9 - 5 Nm
10 - Clip
11 - Radiator/cooler
⇒ page 165
❑ Renew coolant after renewing ⇒ page 150 .
12 - Cowling with radiator fan - V7-
13 - Lower coolant hose
14 - Charge air cooler
❑ Can only be removed and installed with radiator ⇒ page 165 .
15 - Lower mounting
❑ black
16 - Clip
17 - Connector
18 - Radiator fan thermal switch - F18- , 35 Nm
❑ For radiator fan.
❑ Switching temperatures:
• 1st stage on: 92 … 97 °C, off: 84 … 91 °C
• 2nd stage on: 99 … 105 °C, off: 91 … 98 °C
19 - Seal
Renew

Polo 2010 ➤
20 - Condenser
❑ Removing and installing ⇒ Rep. gr. 87 agen
AG. Volkswagen AG d
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1.4.2 Parts of cooling system - engine side ss au ra
c
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nl
pt
du
an
itte
1 - Coolant hose
y li
erm
ab
❑ From expansion tank
ility
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wit
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2 - Coolant hose
h re
hole
❑ To expansion tank
spec
es, in part or in w
3 - Bolt
t to the co
❑ 8 Nm
4 - Coolant return line
rrectness of i
5 - Coolant return hose
l purpos
6 - 4/2-way bypass valve
nform
ercia
7 - Coolant hose
m
at
❑ From heat exchanger
om
io
for heater unit
n
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8 - Coolant hose
at
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❑ To heat exchanger for
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9 - Bolt
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❑ 15 Nm
p by
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10 - Bolt
Prote AG.
❑ 10 Nm
11 - -G62-
❑ Radiator outlet coolant
12 - O-ring
❑ Renew
13 -
14 - Coolant hose connection
15 - O-ring
❑ Renew
16 - Connection hose
❑ Coolant circulation pump
17 - Coolant circulation pump -V178-
18 - Bolt
❑ 8 Nm
19 - Spacer
20 - Bolt
❑ 8 Nm
21 - Washer
❑ Exhaust gas recirculation cooler
23 - Exhaust gas recirculation cooler

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Polo 2010 ➤ olks
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3-cylinder common
ised b rail engine (1.2 l, EA189) - Edition ar06.2019
an
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24 - Coolant lines ss a ac
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❑ With bracket for coolant circulation pump.
nl
pt
du
an
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ab
❑ Exhaust gas recirculation cooler
ility
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26 - -G83-
h re
hole
❑ Radiator outlet coolant temperature sender
spec
es, in part or in w
t to the co
27 - Bolt
❑ 10 Nm
rrectness of i
❑ Coolant lines for exhaust gas recirculation cooler
l purpos
29 - Coolant hoses
nf
ercia
❑ Supply and return/radiator.
orm
m
30 - Bolts
atio
om
n in
❑ 15 Nm
or c
thi
te
sd
31 - 4/2-way valve with thermostat
iva
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32 - O-ring
Co
Cop py
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❑ Renew
gh ht
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cted agen
Prote AG.

Polo 2010 ➤
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump and 4/2-way valve with
thermostat”, page 157
⇒ “2.2 Removing and installing 4/2-way valve with thermostat”,
page 158
⇒ “2.3 Removing and installing coolant pump”, page 162
2.1 Assembly overview - coolant pump and 4/2-way valve with thermostat
1 - Bolt
❑ 15 Nm
2 - Coolant pump
⇒ page 162
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - Thermostat
❑ Checking 4/2-way valve
with thermostat ⇒ Vehi‐
cle diagnostic tester
“Function and compo‐
nent selection”
♦ -A-: Line from heater return AG. Volkswagen AG d
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lksw not
♦ -B-: Bypass line to radiator d byV
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supply line orise nte
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♦ -C-: To expansion tank ss a c
ce
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nl
♦ -D-: Radiator return line
pt
du
an
itte
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6 - Bolt
erm
ab
ility
❑ 15Nm
ot p
wit
, is n
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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
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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.
2. Coolant pump, regulation of cooling system 157

Polo 2010 ➤
2.2 Removing and installing 4/2-way valve with thermostat

equipment required
AG. Volkswagen AG d
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olksw not
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un
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ab
ility
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♦ 10 mm jointed spanner - 3185-

spec
t to the co

rrectne

ss o
♦ Hose clamp pliers - VAS 6340-

cial p
f inform

mer
atio
m
Removing
o
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c
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or
n thi

te
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Rep. gr. 50 ; Body - front; Assembly overview - noise insulation

iv
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C py
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– Removing cowling with radiator fan - V7- ⇒ page 167 . cop Vo
by lksw
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Prote AG.

AG. Volkswagen AG d
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olksw not
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oris Polo 2010
nte ➤
eo
th
3-cylinder common
s au rail engine (1.2 l, EA189) - Edition 06.2019 ra
c
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le
un
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an
d
itte
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Note
erm
ab
ility
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Renew gaskets and seals.
wit
is n
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ole,
spec
– Remove the generator ⇒ Electrical system; Rep. gr. 27 .
t to the co
– Guide alternator with extreme caution past radiator to prevent
damaging it.
rrectness o
cial p
f inform
mer
atio
om
n
c
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te
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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.
– Pull connector -5- off throttle valve module - J338- .

AG. Volkswagen AG d
agen oes
olksw not
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Polo 2010 ➤ autho eo
ra
3-cylinder common rail engine (1.2 l, EA189) - Edition 06.2019 ss c
ce
e
nl
pt
du
an
– Remove throttle valve module - J338- .
itte
y li
erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
o
– Separate connector of Hall sender - G40- -1-.
rm
m
atio
m
– Disconnect connector of knock sensor - G61- -2-.

o
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or c
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pyri by
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Prote AG.
– Loosen Hall sender - G40- bracket -arrow-.

– Remove coolant hose -arrow-.

Polo 2010 ➤
– Remove coolant hoses -B, C and D-.
lkswage es n
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byV ua
ed ran
– Loosen securing bolts -3- of 4/2-way valve -2-
or using T-bar and
is tee
h
socket, 10 mm - 3185- and unscrew withauAllen key, long reach
t or
ac
5 mm - T10058- . ss
ce
e
nl
pt
du
– Turn thermostat -2- with O-ring -1- 90° anticlockwise and re‐
an
itte
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move from union.
erm
ab
ility
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Installing
wit
, is n
– Moisten new O-ring -1- with coolant.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Thread hose -A- behind oil filter module.
l purpos
The next 2 steps require sparing use of force. Make sure that no
damage occurs.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
– Thread 4/2-way valve in past ancillary bracket in direction of
agen
Prote AG.
oil filter module.

Polo 2010 ➤
– Insert connection -2- of 4/2-way valve with O-ring -1- into cyl‐
inder block with slight rotary motions.
Remaining installation is carried out in the reverse order. When
installing, note the following:
– Tighten securing bolts -3- using T-bar and socket, 10 mm -

3185- . Specified torque: 15 Nm
Specified torque for throttle valve module - J338- ⇒ page 237 .
– Install throttle valve module - J338- ⇒ page 237 .
– Install alternator ⇒ Starter, current supply, CCS; Rep. gr. 27 ;
Removing and installing alternator .
– Installing charge air pipe ⇒ page 178 .
2.3 Removing and installingAcoolant pump

G. Volkswagen A
agen G do
es n
ksw
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ua
b
ed ran
oris tee
th or
au ac
ss
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
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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤

equipment required
lkswage es n
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byV ua
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ir se tee
tho
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a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
♦ Drip tray - V.A.G 1306-
rrectne
♦ Pliers for spring-type clips - VAS 6362-
ss o

cial p
f inform
Removing
mer
atio
om
n
c
i
or
Note
thi
te
sd
iva
o
pr
Renew gaskets and seals.

um
r
fo
en
ng
t.
yi Co
op
– Drain coolant ⇒ page 146 . C py
t. rig
gh ht
yri by
– Remove poly V-belt ⇒ page 25 . cop Vo
by lksw
cted agen
Prote
AG.

Polo 2010 ➤
– Unscrew securing bolts -1- of coolant pump -2- and carefully

remove coolant pump.
Installing
note the following:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Coat new O-ring -3- with coolant.
ce
le
un
pt
an
d
– Insert coolant pump -2- into cylinder block and tighten securing
itte
y li
bolts -1-.
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
The coolant pump plug faces downwards.
t to the co
– Install toothed belt ⇒ page 88 .
rrectne
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
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
3 Radiator, radiator fan

. Volkswagen AG
does gen AG
⇒ “3.1 RemovingVand
olks installing radiator ”, page
wa no165
t y gu
db a
⇒ “3.2 Assembly
or
ise overview - with radiator fan V7 ”, page
ran
te 167
h eo
ut r
⇒ “3.3 sRemoving
sa and installing cowling with radiator fan V7
ac ”,
page 167 .
ce
e
nl
pt
du
an
3.1 Removing and installing radiator
itte
y li
erm
ab
ility
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wit
, is n
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equipment required
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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Drip tray for V.A.G 1202 - V.A.G 1306/-
♦ Pliers for spring-type clips - VAS 6362-
♦ Guide pins - 3411-
3. Radiator, radiator fan 165

Polo 2010 ➤
Removing
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Extract refrigerant from air conditioner ⇒ Heating, air condi‐
tioning; Rep. gr. 87 .
– Unscrew refrigerant lines -arrow- from lock carrier.
Continued for all vehicles:
– Remove connecting hoses to charge air cooler ⇒ page 178 . . Volkswagen AG
gen AG wa does
olks not
– Drain coolant ⇒ page 146 . byV gu
ara
ed nte
ris
– Pull coolant hoses off radiator. tho eo
au ra
c
ss
– Pull off connector for radiator fan.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Unscrew securing bolts for front radiator -arrow-. Remove ra‐
hole
spec
diator upwards together with charge air cooler.
es, in part or in w
t to the co
Disconnecting charge air cooler from radiator
rrectness of i
Caution
l purpos
In order to avoid damage to charge air cooler, 2 mechanics

should be used to disconnect charge air cooler from radiator.
nform
mercia
at
om
ion
c
in t
or
his
ate
– Push a wide screwdriver into the latch on the left. Turn the do
priv
screwdriver in order to carefully open the latch of the charge

um
for
en
g
air cooler -1- at radiator.

n
t.
yi Co
op py
– Then, pull the charge air cooler on left downwards a little bit.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Push charge air cooler -1- towards the right out of the locking
latch of the radiator -2-.
Installing
note the following:
– Vehicles with air conditioner. Charge air conditioning system
with refrigerant ⇒ Heating, air conditioning; Rep. gr. 87 .

Polo 2010 ➤
kswage es n
3.2 Assembly overview - with radiator fan - V7- ol ot g
byV ua
d ran
ir se tee
tho
u or
a ac
1 - 5 Nm ss
ce
e
nl
pt
du
2 - Support sleeves
an
itte
y li
erm
ab
3 - Cowling
ility
ot p
4 - Radiator fan
wit
, is n
h re
hole
5 - Fan ring
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
co lksw
by
cted agen
Prote AG.
3.3 Removing and installing cowling with ra‐

diator fan - V7-
Removing
– Undo bolts -arrows- for air intake -1-. Remove connecting
hose -2- from air filter.
tion .
– Remove connecting hoses to charge air cooler ⇒ page 178 .
– Disconnect connector for radiator fan ⇒ Item 17 (page 154) .
3. Radiator, radiator fan 167

Polo 2010 ➤
– Disengage cowling with radiator fan - V7- from locking hook

using a suitable tool.
– Push cowling together with radiator fan - V7- upwards out of
the mountings and remove downwards.
Detach radiator fan from fan shroud
– Remove connector for radiator fan from retainer.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
– Push pins out of spreader
auth rivets -arrows- ⇒ page 167 . or
ac
ss
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
– Carefully lift up fan ring on back of cowling using a suitable

tool. nform
ercia
– Remove fan ring.

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
co lksw
by
cted agen
Prote AG.
– Unscrew nuts, remove radiator fan.
Installing
– Carefully insert fan shroud together with radiator fan - V7- from
below and then push into all 4 mountings on radiator from
above.
• The fan frame must engage audibly on the right and left at the
top.
– Check that it has engaged securely by pulling on it.

Polo 2010 ➤
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Assembly overview - turbocharger with attachments”, page
169
⇒ “1.2 Removing and installing turbocharger ”, page 171
1.1 Assembly overview - turbocharger with

attachments
Note
♦ All hose connections are secured.

♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before installing, fill oil supply port with a »splash« of engine
oil at union. “To prevent dry running during the first few sec‐
onds”.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
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
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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om
n in
or c
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te
sd
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f
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Turbocharger 169
Polo 2010 ➤
1 - Intake connecting pipe

2 - Bolt
❑ 9 Nm
❑ Attached in inlet con‐
nection to prevent loss.
3 - O-ring
❑ Renew
4 - Bolt
❑ 10 Nm
5 - Bracket
❑ For electrical cables
6 - Heat shield
7 - Seal
❑ Renew
8 - Turbocharger
❑ Can only be renewed
complete with exhaust
manifold and vacuum
unit.
⇒ page 171
9 - Nut
❑ 24 Nm
10 - Exhaust gas temperature
sender 1 - G235-
❑ Tightening exhaust tem‐ n AG. Volkswagen AG do
perature sender 1 - lkswage es n
o ot g
G235- ⇒ page 176 byV ua
d ran
ir se tee
o
11 - Union auth or
ac
ss
❑ For oil supply line.
ce
le
un
pt
❑ Must not be loosened

an
d
itte
y li
rm
12 - Nut
ab
pe
ility
❑ 24 Nm
ot
wit
, is n
h re
13 - Heat shield
hole
spec
14 - Retaining ring
es, in part or in w
t to the co
❑ Installation possible in one position only.

15 - Seal
rrectness of i
❑ Renew
l purpos
16 - Bolt
❑ 9 Nm
nform
ercia
17 - Pulsation damper
m
a
com
tion in
r
te o
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
cted agen
Prote AG.
170 Rep. gr.21 - Turbocharging/supercharging

Polo 2010 ➤
Installation position of exhaust gas temperature sender with an‐

gled cable guide
Note
. Volkswage
When installing the exhaust temperature sender
ksw
agenwith angled ca‐
AG n AG d
oes
ble guide, adhere to dimension -a- of 3by…
V 5 mm from the turbo‐
ol not
gu
ara
charger support threaded connection.
orise
d
nte
th eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
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ility
1.2 Removing and installing turbocharger
ot p
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♦ Tool insert, AF 17 mm - T10395-
es, in part or in w
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♦ Used oil collection and extraction unit , e.g. -V.A.G 1782-
1. Turbocharger 171
Polo 2010 ➤
Caution
If a mechanical fault is found on the turbocharger, e.g. a de‐

stroyed compressor impeller, just renewing the turbocharger is
not enough. To avoid subsequent damage, the following work
must be carried out:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.

Removing
ing batteries. AG. Volkswagen AG d
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– Remove engine cover panel ⇒ page 24 . by
Vol
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– Pull connector -1- off position sender for charge pressure po‐hor eo
ut
sitioner - G581- on turbocharger. ss a ra
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– Remove connecting hose -2-.

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– Unscrew bolt -3- (attached) and screw intake hose clockwise
erm
ab
out of its bracket.
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pipe ⇒ page 235 .
hole
spec
– Remove plenum chamber bulkhead ⇒ General body repairs;
es, in part or in w
t to the co
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Pull off vacuum hose on turbocharger.
rrectness of i
– Loosen upper charge air pipe.
l purpos
– Loosen clamp -1- on connecting hose to pulsation damper.

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Polo 2010 ➤
– Remove pulsation damper together with connecting hose.

Loosen particulate filter.
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or
– Remove
au securing clamp -1- between particulate filter aand
c tur‐
ss
bocharger.
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– Loosen bolt -2- and remove clamp.
an
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ility
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spec
t to the co
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– Disconnect connector -3-.

ss o
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– Unscrew bolt -2-, remove pressure differential sender - G505- ,

inform
free hoses -1-.

mer
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– Remove connecting pipes -A-.
1. Turbocharger 173
Polo 2010 ➤
– On flexible joint in front exhaust pipe, fasten the transport lock

- T10403- -arrow-.
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– Unscrew bolts -1- and nuts -2-, remove brackets afor particulate
ut ra
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filter. s
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es, in part or in w
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– Pull particulate filter from mountings -arrows-.

– Remove oil supply line and oil return line (turbocharger sup‐
nf
ercia
port) ⇒ page 139 .
orm
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– Loosen securing bolts -arrows- of clamping sleeve, then push

down backwards from front exhaust pipe.
– Move particulate filter to side and fix using suitable means.
Caution
Exhaust temperature sender 1 - G235- conceals upper threa‐

ded connection of turbocharger support.
It must not be bent.
It must therefore be removed.

Polo 2010 ➤
– Remove exhaust temperature sender 1 - G235- -1-.
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– Unscrew bolts -arrows- and remove heat shield.
h re
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spec
t to the co
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mer
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– Unscrew nuts -arrows- and pull turbocharger with exhaust
te
sd
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manifold off cylinder head.

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1. Turbocharger 175
Polo 2010 ➤
– Carefully remove turbocharger from above in direction of gear‐

box.
Installing
Caution
Before installing, check whether flexible joint of oil return line

is bent and thus stretched. If this is the case, micro-fractures
may have been caused and this will cause leaks. If necessary,
renew oil return line before installing turbocharger.
– Install in reverse order. During this procedure, observe the

following:
Specified torques: Turbocharger ⇒ page 169 .
Specified torques: Oil supply line and oil return line (turbocharger
support) ⇒ page 138 .
Specified torques: Connecting pipes ⇒ page 266 . agen
AG. Volkswagen AG d
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♦ Position connecting hose of charge air pipe before boltingd bonyV gu
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♦ Note installation position of exhaust temperature sender
ss 1- c
G235- .
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Installation position of exhaust gas temperature sender with an‐
erm
ab
gled cable guide
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Note
spec
es, in part or in w
t to the co
When installing the exhaust temperature sender with angled ca‐
ble guide, adhere to dimension -a- of 3 … 5 mm from the turbo‐
charger support threaded connection.
rrectness of i
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nf
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m
1.2.1 Tightening exhaust gas temperature

atio
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n in
sender 1 - G235-
or c
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WARNING
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The torque wrench - V.A.G 1331- must be set to 28 Nm in this
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case. rig ht
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Extending the torque wrench - V.A.G 1331- with the spanner cted agen
Prote AG.
from tool set - T10395/7- allows the correct torque of 45 Nm to
be achieved.
Lubricate thread of sender using high-temperature paste - G 052

112 A3- .

Polo 2010 ➤
– Screw exhaust temperature sender 1 - G235- in by hand.

– Then apply tightening torque using torque wrench - V.A.G
1331- together with wrench from tool set - T10395/7- .
AG. Volkswagen AG d
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pe
ility
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spec
es, in part or in w
t to the co
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mercia
a
com
tion in
r
te o
thi
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1. Turbocharger 177
Polo 2010 ➤
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 178
⇒ “2.2 Removing and installing charge air cooler”, page 179
⇒ “2.3 Fitting charge air system hose connections”, page 180
⇒ “2.4 Checking charge air system for leaks”, page 182
2.1 Assembly overview - charge air system
Note
♦ All hose connections of charge air system are secured by hose

clips ⇒ page 180 .
♦ The charge air system must be free of leaks.
♦ Checking charge air system for leaks ⇒ page 182 .
Charge air path, 1.2 l common rail engine in Polo

Assembly overview - charge air path
AG. Volkswagen AG d
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spec
t to the co
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cial p
f inform
mer
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c
i
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AG. Volkswagen AG d
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rised
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o e
aut
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3-cylinder common rail engineor(1.2 ac l, EA189) - Edition 06.2019
ss
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1 - Charge air cooler
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❑ Can only be removed to‐
y li
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ab
gether with radiator
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⇒ page 165 .
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2 - Connection hose
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spec
❑ »Cold« side, bottom
es, in part or in w
t to the co
3 - Screw-type clips
❑ 5.5 Nm
rrectness of i
4 - 5 Nm
l purpos
5 - Intake air temperature

sender - G42-
nf
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6 - Bolts
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❑ 8 Nm
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7 - Charge air pipe

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❑ »Cold« side
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❑ »Cold« side, top Prote
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agen
❑ »Hot« side, top
11 - Charge air pipe
❑ »Hot« side
❑ »Hot« side, bottom
2.2 Removing and installing charge air cool‐

er
Charge air cooler is located beneath radiator.
Charge air cooler can only be removed together with radiator
⇒ page 165 .
2. Charge air system 179

Polo 2010 ➤
2.3 Fitting charge air system hose connec‐

tions
n AG. Volkswagen A
⇒ “2.3.1 Installing hose connections
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⇒ “2.3.2 Removing
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page 180 ss
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⇒ “2.3.3 Removing and installing charge air pipe cold side”, page
pt
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181
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2.3.1 Installing hose connections with corru‐
ility
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Caution
t to the co
The screw-type clips -A- on the charge air lines must always
be tightened to 5.5 Nm. If the torque is too low or too high, the
rrectness of i
charge air hose may slip off the corrugated pipe connection or
l purpos
the charge air pipe when the vehicle is used.
nform
mercia
a
com
tio
2.3.2 Removing and installing charge air pipe n in
r
te o
»hot« side
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Removing
Co
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ing batteries.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
pipe ⇒ page 235 .
– Remove connecting hose »hot« side; loosen clips -arrows- to
do this.

Polo 2010 ➤
– Release clip -1- from connecting hose to pulsation damper.

Unscrew securing bolts -arrows- from charge air pipe.
– Unclip top coolant hose on charge air pipe -arrow-.
– Unclip wiring harness on charge air pipe -arrows-.

– Take out charge air pipe. AG. Volkswagen AG d
agen oes
olksw not
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Installing d by ara
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– Install in reverse order.
s auWhen
t
doing this, observe the follow‐ ra
c
ing: s
ce
le
un
pt
– First start off all charge air pipe securing bolts. Then tighten.
an
d
itte
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Specified torque: ⇒ page 178 .

erm
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ility
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Renew any damaged cable ties and clips.

wit
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spec
t to the co
2.3.3 Removing and installing charge air pipe

»cold« side
rrectne

Removing
ss o
cial p

inform
mer
– Pull connector from intake air temperature sender - G42- -3-.

atio
om

n
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or

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Prote AG.

Polo 2010 ➤
– Remove connecting hose -arrows-.
– Open clamp -2-.

– Unscrew securing bolts -arrows- from charge air pipe.
– Take out charge air pipe.
Installing
– Install in reverse order. When doing this, observe the follow‐
ing:
Renew any damaged cable ties and clips.
2.4 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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ility
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spec
es, in part or in w
♦ Adapter - V.A.G 1687/10-

t to the co
rrectness of i
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nf
ercia
orm
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by
cted agen
Prote AG.

Polo 2010 ➤
– Remove intake hose -1- from air filter.

– Insert adapter - 1687/10- -1- into intake hose and secure with
a clip.
Prepare charge air system tester - V.A.G 1687- as follows:
– Unscrew pressure control valve -2- completely and close

valves -3- and -4-.
Note AG. Volkswagen AG d

agen oes
olksw not
Pressure control valve -2- can only be turned when knob is pulled
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upwards. horis nte
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nl
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du
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ab
ility
ot p
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– Connect charge air system tester - V.A.G 1687- to adapter -
h re
1687/10- as shown.
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
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cum
for
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ng
t.
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t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

Polo 2010 ➤
– Connect compressed air hose -1- (compressed air supply) to

charge air system tester - V.A.G 1687- .
Note
If water is in inspection glass, drain via drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure control valve -2-.
Caution
The pressure must remain at or below 0.5 bar! If the pressure

is too high this can cause damage to the engine.
– Open valve -4- and wait until test circuit is full. If necessary,
regulate pressure to 0.5 bar.
– Check charge air system for leaks by listening, touching, with
leak detector spray or using ultrasonic tester - V.A.G 1842- .
Note
♦ Slight leaks on the intakesw

side
agenof turbocharger are
doepermissible,
AG. V gen AG olkswa
s
as the intake hosesbyare V not designed for high-pressure.
olk not
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♦ A small amount hor of air escapes through the valves and enterseo
ut
the engine.ss Therefore a holding pressure test is not possible.r ac
a
ce
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♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions

nl
pt
du
an
itte
♦ If a leak has been located, observe notes for charge air system
y li
erm
ab
⇒ page 178 when carrying out any repair work.

ility
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wit
♦ Depressurise test circuit by detaching coupling from adapter -

, is n
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1687/10- before removing adapter.

hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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Prote AG.

Polo 2010 ➤
23 – Mixture preparation - injection

1 Injection system
The diesel direct injection system control unit is equipped with an
event memory. Read this before and after repairs and adjust‐
ments.
⇒ “1.1 Instructions for working on fuel system”, page 185
⇒ “1.2 Schematic overview - fuel system”, page 186
⇒ “1.3 Filling/bleeding fuel system ”, page 188 agen
AG. Volkswagen AG d
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⇒ “1.4 Checking for leaks in the fuel system”,
ed by page 189 ara
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1.1 Instructions for working on fuel system
h
aut ra
ss c
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le
To prevent the high-pressure fuel pump from running while it is

un
pt
an
d
empty and to ensure that the engine starts quickly after parts have
itte
y li
been renewed, it is important to observe the following:
erm
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ility
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♦ If fuel system components between fuel tank and fuel high-
wit
is n
pressure pump are removed or renewed, initial fuel filling must
h re
ole,
be carried out.
spec
♦ If a fuel pump, fuel line (between fuel tank and fuel high-pres‐
t to the co
sure pump) or fuel filter is removed or renewed
♦ Fuel system must be bled before starting engine for first time.
rrectne
♦ If the high-pressure fuel pump is removed or renewed, the fuel
system must be bled before engine is started for the first time.
ss o
♦ Initial fuel filling procedure ⇒ page 188 .
cial p
f inform
• Clean tools and workbench etc. before working on injection
mer
atio
system.
om
n
c
i
• Thoroughly clean all unions and adjacent areas before dis‐
or
n thi
e
connecting.
t
sd
iva
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pr
• When removing components, seal all open connections im‐

um
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fo
en
ng
mediately with suitable, clean protective caps.

t.
yi Co
Cop py
• Do not remove sealing caps from components until immedi‐
t. rig
gh ht
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ately prior to installation. Removed components should be p by
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by c lksw
kept in new, sealable plastic bags (use the original new part Prote
cted agen
packaging if possible).
AG.
• Before installation, check injectors and their fitting location

visually; they must be undamaged and free of lint. Ensure that
the injector bore is clean. If necessary, clean the injector shaft
using a clean cloth.
• Do not damage it (no sharp-edged tools!)
• If high-pressure lines are not renewed, they must be labelled
on removal. High-pressure fuel lines must always be re-instal‐
led in their original positions (i.e. on the same cylinder).
• Whenever injectors are removed and installed, always renew
the following components and seals/O-rings: “bolt for clamping
piece”, “copper seal”, “O-ring for injector bore”.
• The following components must also be renewed when an in‐
jector is replaced: “bolt for clamping piece”
• Always fit new copper seals for the injectors. Check all new O-
rings for damage before installing. Lubricate O-rings lightly
with assembly oil or clean engine oil before installing.
1. Injection system 185

Polo 2010 ➤
• Take care not to damage the injectors when removing the old
copper seals.
• Align high-pressure lines stress-free. First tighten all unions
hand-tight and then tighten to torque.
• Never attempt to reshape high-pressure fuel lines.
• When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
• Disassembling individual common rail components is not per‐
mitted.
• The components should be replaced as complete units if faul‐
ty. AG. Volkswagen AG d
agen oes
lksw not
• Never attempt to bleed the common rail system by looseningby V o gu
ara
high-pressure components after starting the engine. rised
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• No assembly work may be carried out on the CR system
ss a while ra
c
the engine is running. In particular, do not open/loosen the
ce
le
un
high-pressure lines.
pt
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d
itte
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• Loosened cable ties must be secured in the same position on
erm
ab
installation.
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• Cut cable ties must be renewed and secured in the same po‐
h re
ole,
sition on installation.
spec
• When the fuel system is open: Do not work with compressed
t to the co
air. Do not move vehicle unless absolutely necessary.
• Also ensure that no diesel fuel comes into contact with the
rrectne
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
ss
1.2 Schematic overview - fuel system
o
cial p
f inform
mer
WARNING
atio
om
n
c
i
or
n
♦ First read through the rules for cleanliness and the in‐
thi
te
sd
structions for working on the fuel system ⇒ page 185 .
iva
o
pr
cum
r
♦ Always follow these rules for cleanliness and instructions

fo
en
ng
before starting work and while working on the fuel system.

t.
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♦ If components of the fuel system between the tank and the rig ht
py by
high-pressure fuel pump are removed or renewed, the fuel co Vo
by lksw
system must be filled to be bled ⇒ page 188 . (It is im‐
cted agen
Prote AG.
portant not to allow the high-pressure pump to run while
still empty.)
To prevent the high-pressure fuel pump from running while it is

empty and to ensure that the engine starts quickly after parts have
been renewed, it is important to observe the following:
♦ If fuel system components between fuel tank and fuel high-
pressure pump are removed or renewed;
♦ If a fuel pump, fuel line or fuel filter is removed or replaced.
♦ If the fuel high-pressure pump is removed or replaced
– Connect vehicle diagnostic tester .
– Perform the function “Fuel pump activation (Filling/bleeding
fuel system)” in “Guided Functions” ⇒ page 188 .
186 Rep. gr.23 - Mixture preparation - injection

Polo 2010 ➤
1 - Fuel metering valve - N290-

❑ Do not open.
2 - High-pressure pump
❑ After renewing, a first
fuel filling “must” be per‐
formed (never allow
pump to run while dry)
⇒ page 188 .
⇒ page 214
3 - Fuel pressure sender -
G247-
❑ Installing and removing
⇒ page 228
4 - High-pressure accumulator AG. Volkswagen
(rail) wage
n AG do
es n
Volks ot g
❑ Removing and ed installing
by ua
ran
⇒ page 208
thoris tee
o
au ra
5 - Fuel pressure
ss regulating c
ce
e
valve - N276-
nl
pt
du
an
❑ Renew
itte
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erm
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ility
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wit
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⇒ page 224
hole
spec
❑ 80 Nm
es, in part or in w
t to the co
6 - Injectors
❑ Injector for cylinder 1 -
N30-
rrectness of i

l purpos
N31-
nform
ercia
N32-
❑ Installing and removing
m
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⇒ page 197
ion
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7 - Fuel return lines

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ate
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❑ The fuel return lines must not be dismantled.

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8 - Fuel
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❑ With fuel delivery unit - G6- .
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❑ If fitted: supplementary fuel filter and integrated pressure control valve py by
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❑ Removing and installing ⇒ fuel supply system; Rep. gr. 20 .
agen
Prote AG.
9 - Fuel supply and return line separating points

❑ On bottom right of fuel tank.
10 - Fuel filter
❑ Assembly overview - fuel filter ⇒ fuel supply system; Rep. gr. 20 .
❑ Removing and installing ⇒ fuel supply system; Rep. gr. 20 .

Polo 2010 ➤
1.3 Filling/bleeding fuel system
Caution
Risk of irreparable damage to high-pressure pump if allowed

to run dry.
♦ After the high-pressure pump has been installed, it must
be filled with fuel before engine is started
Note
♦ When installing the high-pressure pump, it is essential to en‐

sure that no dirt enters the fuel system.en AG. Volkswagen AG
ag does
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♦ Only remove sealing plugs immediately prior to installation of ot gua n
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fuel lines. ris
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♦ The bleeding procedure
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fuel supply system. (fuel pump, fuel lines, fuel filter)
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• Vehicle must have fuel.
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• Fuel system temperature ≥ 15 °C
wit
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These requirements must be met in order to ensure proper bleed‐
ole,
ing/filling of fuel system.
spec
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♦ Vehicle diagnostic tester
rrectne
Proceed as follows to fill high-pressure pump / fuel system with
fuel:
ss

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– Start function “Fuel pump activation (filling/bleeding fuel sys‐

form
mer
tem)” in Guided functions.

atio
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Note
t
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There could still be air bubbles in the fuel system after the bleed‐
en
ng
t.
ing procedure.
yi Co
Cop py
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– Start engine and visually check fuel system for leaks.
py by
co Vo
by lksw
cted agen
Prote AG.
Caution
Do not carry out starting attempts for longer than 15 seconds.

If engine does not start, repeat bleeding process.
– After filling fuel system and successfully starting engine, allow

it to run for a few minutes at a moderate speed. Switch off
engine.
– Check fuel system for leaks.
– Therefore, read the event memory and erase event entries if
necessary.
– Then, road-test the vehicle for more than 20 km with full throttle
acceleration at least once. Then check high-pressure part of
fuel system again for leakage.

Polo 2010 ➤
Note
If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Switch off engine and
erase event memory entries. Continue road test.
– Read event memory entries.
1.4 Checking for leaks in the fuel system

Procedure
n AG. Volkswagen A
– Allow engine to run atwaaverage
olks
ge revs for aGfew
doesminutes.
no
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– Switch off ignition.
ris
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– Checksthe
s a entire fuel system for leaks.
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– If leaks are found although the connections have been tight‐

un
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renewed.
erm
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ility
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– Then road test the vehicle, accelerating to full throttle at least
wit
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once.
h re
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– Finally, check the high-pressure area for leaks again.
t to the co
rrectness o
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mer
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by
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Prote AG.

Polo 2010 ➤
2 Vacuum system
AG. Volkswagen AG d
⇒ “2.1 Vacuum hose connection diagram”, page 190lkswagen oes
not
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⇒ “2.2 Checking vacuum system”, page 191 rised b ara
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2.1 Vacuum hose connection diagram ss au ra
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Caution
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Do not kink, twist or crush the vacuum lines when routing vac‐
wit
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uum lines. This may cause breakdowns.
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Blue = vacuum control line for exhaust gas recirculation.
l purpos
♦ Grey = breather line from air filter housing.

♦ Green = vacuum control line for turbocharger.
nf
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♦ Red = vacuum supply line for vacuum pump.
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1 - Vacuum actuator
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❑ On turbocharger.
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❑ With position sender for
yi Co
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charge pressure posi‐
C py
t. rig
gh
tioner - G581-
ht
pyri by
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cted
2 - Vacuum line
agen
Prote AG.
❑ To brake servo
3 - Suction hose
❑ With connecting piece
for ventilation line
4 - Charge pressure control
solenoid valve - N75-
❑ Remove ⇒ page 191
5 - Vacuum pump
6 - Breather line to air filter
housing
7 - Exhaust gas recirculation
cooler changeover valve -
N345-
❑ Checking changeover
⇒ page 270 .
8 - Vacuum line
❑ To cylinder head cover/
vacuum tank
9 - Vacuum line
❑ To vacuum unit at ex‐
haust gas recirculation
cooler
10 - Vacuum actuator
❑ On exhaust gas recircu‐
lation cooler

Polo 2010 ➤
11 - Vacuum line
❑ To vacuum unit at exhaust turbocharger
12 - Vacuum connection
❑ At cylinder head cover/vacuum reservoir
Removing charge pressure control solenoid valve - N75-

– Pull off connector -arrow-.
– Unscrew nuts -1 and 2-.
– Remove vacuum hoses with bracket -1- from air filter com‐
pletely.
AG. Volkswagen AG d
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2.2 Checking vacuum system

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♦ Hand vacuum pump - VAS 6213-

h re
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
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Procedure
do
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– Check all vacuum lines throughout entire vacuum system for:

en
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♦ Cracks C py
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♦ Marten bites cop Vo
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♦ Crushing
AG.
♦ Porous areas and other leaks

– Check vacuum line to solenoid valve and from solenoid valve
to relevant component.
2. Vacuum system 191

Polo 2010 ➤
– If event is entered in memory, check vacuum lines to specified

component, but also additionally the other vacuum lines to
other components.
AG. Volkswagen
– If pressure cannot be builtlksup using
wagen hand vacuum pump
AG do
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6213- or pressure immediately
d by
Vo
drops again, check handot g
uvac‐
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uum pump and connecting
orise hoses for leaks. nte
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spec
es, in part or in w
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mercia
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tion in
r
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s
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do
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cum
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en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
3 Injectors, wfuel
agen rail
AG . Volkswagen AG
does
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Note s au ra
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If performance is subject of complaint, cause may be inadequate
pt
an
d
fuel low-pressure. Faults in the high-pressure section may also

itte
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rm
be caused by inadequate fuel pressure in the low-pressure sec‐
ab
pe
ility
tion. Fuel pressure in the high-pressure section is read from the
ot
wit
engine control unit. Fuel low-pressure is measured using pres‐
, is n
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sure tester - VAS 6551- ⇒ Fuel supply system; Rep. gr. 20 .
hole
spec
es, in part or in w
⇒ “3.1 Assembly overview - injectors”, page 193
t to the co
⇒ “3.2 Adapting correction values for injectors ”, page 195
rrectness of i
⇒ “3.3 Checking return flow rate of injectors with engine running”,
page 195
l purpos
⇒ “3.4 Removing and installing injectors”, page 197
nform
ercia
⇒ “3.5 Removing and installing high-pressure lines”, page 202

m
a
⇒ “3.6 Assembly overview - fuel rail”, page 206
com
tion in
⇒ “3.7 Removing and installing fuel rail”, page 208
r
te o
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3.1 Assembly overview - injectors
r
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Caution C py
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py by
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Prote AG.

3. Injectors, fuel rail 193

Polo 2010 ➤
1 - Injector
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 197 lkswage es n
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byV ua
❑ When removing and in‐ ir se
d ran
tee
stalling, always renew utho
or
the following compo‐ ss
a ac
nents and seals/O-
ce
le
un
pt
rings: “copper seal”, “O-
an
d
itte
ring for injector bore”,
y li
rm
ab
“bolt for clamping
pe
ility
piece”. ot
wit
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❑ The following compo‐
h re
hole
nents and seals or O-
spec
rings must always be
es, in part or in w
t to the co
renewed when an injec‐
tor is renewed: “copper
seal”, “O-ring for injector
rrectness of i
bore”, “bolt for clamping
piece”.
l purpos
❑ Before reusing the

“high-pressure line”,
nform
ercia
taper seals must be vis‐

ually checked:
m
a
com
t
❑ Always renew if dam‐
ion in
aged, e.g. transverse
r
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thi
scores, corrosion.
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❑ Before installing, clean

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injector bore using
en
ng
t.
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cleaning set - VAS
Co
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❑ If they are to be re-in‐ cop Vo
by lksw
stalled, injectors, high- cted agen
Prote AG.
pressure fuel lines and
clamping pieces must
always be re-fitted in
their original positions
(i.e. on the same cylin‐
der).
2 - O-ring
❑ O-rings are only to be renewed if necessary.
3 - Fuel return lines
❑ To high-pressure pump
❑ The fuel return line must be free of kinks, damage and blockages.
❑ Do not dismantle the fuel return lines.
4 - Seal in connector
❑ Renew
5 - Connector
❑ If connector is removed:
❑ Renew connector seal.
6 - Copper washer
❑ Renew
7 - O-ring
❑ Renew
8 - Clamping piece
9 - Bolt for clamp
❑ Renew

Polo 2010 ➤
❑ 8 Nm + 270°
10 - Injector union
Removing
Proceed with extreme caution. Avoid damage to fuel return line.
– Lever old O-ring very carefully off fuel return line.
Do not work with a sharp-edged tool.
Installing
Note
The O-rings must be free of twists in their seats in fuel return line.
Proceed with extreme caution. Avoid damage to the O-ring and

fuel return line.
– Clean seating surfaces for O-rings on fuel return line very
carefully.
When renewing O-ring, do not use any solvent, etc., to remove
graphite coating.
– Carefully push O-ring -1- on its seat -2-.
3.2 Adapting correction values for injectors

AG. Volkswagen A
agen G do
es n
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db ran
Note orise tee
th or
au ac
ss
♦ After renewing the injectors “adapt the correction values”
ce
le
⇒ Vehicle diagnostic tester.

un
pt
an
d
itte
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♦ “Reading / adapting” correction values.

rm
ab
pe
ility
ot
wit
3.3 Checking return flow rate of injectors

, is n
h re
hole
with engine running

spec
es, in part or in w
t to the co

♦ Return flow meter - VAS 6684- and adapter C5
rrectness of i
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nform
mercia
a
com
tion in
r
te o
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s
iva
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rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
Procedure yri
p by
co Vo
by lksw
cted
agen
Prote AG.
– Clean all return line connections (e.g. with standard commer‐

cially available cold cleaning solvent) before opening them.
– Dry all cleaned parts.

Polo 2010 ➤
– Release catch -1- and pull return line connections off all injec‐
tors in -direction of arrow-.
Note
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high compared to the
other injectors, that injector is probably defective.
Caution
Avoid impairing function through contamination or soiling.

♦ ⇒ “3.1 Rules for cleanliness”, page 6
Note
Maintain cleanliness. No dirt must be allowed to get into the dis‐

connected fuel return lines or the open connections on the injec‐
tors.
– Fit adapter C5 from return flow meter - VAS 6684- firmly onto
return line connections of all 3 injectors.
AG. Volkswagen AG d
– Connect hoses of return flow meter -VAS 6684-lkto
swadapters.
agen oes
not
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– Start engine, and allow it to idle for several ris
edminutes. ara
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Caution
ce
le
un
pt
an
d
itte
Avoid damage to injectors after return lines have been pulled y li

rm
off. ab
pe
ility
ot
♦ Do not accelerate the engine during the test. Engine must

wit
, is n
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be idling all the time.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
iva
do
r
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cum
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.

Polo 2010 ➤
– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 3 return lines must not differ by
more than a small amount.
♦ 1) Injector units OK. Return flow rate of all injector units ap‐
proximately equal.
♦ 2) Injector of cylinder no. 3 is not OK. The return flow rate is
more than three times the lowest measured return flow rate.
Note
There is a mechanical fault in the injector unit if the return flow

rate is more than three times the lowest measured return flow
rate. This injector unit must be renewed.
– If one injector has a significantly higher return flow rate than

the others (example -2-), it must be renewed ⇒ page 197 .
Installing fuel return lines
– Carefully press connections of return lines onto injectors. You
should hear them click into place. Then, carefully press the
release pin downwards.
– Checking fuel system for leaks ⇒ page 189 .
– Fit engine cover panel ⇒ page 24 .
3.4 Removing and installing injectors
Caution

torque after installing the high-pressure lines ⇒ pagewa193 . . Volkswagen AG does
gen AG
Clamping jaws are only secured »hand-tight« fory Vsettingolks
the not
gu
injectors while installing high-pressure lines. rNon-observance
ise
d b ara
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of these notes may lead to damage to engine. utho eo
r a ac
ss
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e
nl
pt
du
an
itte
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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
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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co lksw
by
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Prote AG.

Polo 2010 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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aut ra
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nl
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du
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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
nform
mercia
at
om
ion
c
in t
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♦ Puller - T10055-
o
his
ate
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♦ Assembly sleeve - T10377-

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en
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♦ Socket - T40055-
n
t.
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rig by
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♦ Ratchet wrench - V.A.G 1331/1- by c lksw
cted agen
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♦ Support sleeve - T10411-

Polo 2010 ➤
AG. Volkswagen AG d
agen oes
♦ Injector remover - T10426- olksw not
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3.4.1 Removing ris nte
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»Carry out the following work sequence« s
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e
nl
pt
du
an
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ab
– Pull charge pressure positioner connector -1- off turbocharger.
ility
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– Remove breather line between cylinder head cover -2- and
, is n
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intake hose. Press plug-in connectors together to do this.
hole
spec
es, in part or in w
t to the co
Caution
Observe rules of cleanliness. No dirt must be allowed to get
rrectness of i
into the disconnected return lines or the connections on the
injectors (solenoid valve injectors) under any circumstances.
l purpos
Protect open fuel connections from dirt entrainment using suit‐

able methods under all circumstances.
nf
ercia
orm
m
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om
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c
– Open return line connection. Release catch -1- to do this.

or
thi
te
sd
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– Pull fuel return line connection off injector in direction of arrow.

iv
o
r
rp
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.

Polo 2010 ➤
– Pull connector -1- off at the injectors to be removed.

Renew connector seal of connector -1- ⇒ Item 5 (page 194) ⇒
ETKA (Electronic Parts Catalogue) .

sure pump.
– Removing high-pressure lines between fuel rail and injectors.
– Unscrew securing bolt of clamping piece for injector to be re‐

AG. Volkswagen AG d
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ris
Caution tho
tee
or
au ac
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un
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an
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erm
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ility
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wit
is n
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ole,
spec
t to the co
– Position puller - T10055- with injector puller - T10426- as

shown.
rrectne
– Using tapping movements, always pull injectors out upwards

together with clamping piece.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
3.4.2 Installing
Important instructions for installing injectors
• Clean empty injector bores and sealing surfaces in cylinder
head using cleaning set - VAS 6811- before fitting injectors ⇒
Instructions
• When removing and installing, always renew the following
components and seals/O-rings: “bolt for clamping piece”, “cop‐
per seal”, “O-ring for injector bore”.
• Used injectors may only be re-installed on the same cylinder.
n AG. Volkswagen A
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swa es
• High-pressureby
Vol lines may only be re-installed
k not
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ua the same cyl‐
inder. rised ran
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• Check
ss
au injectors and installation area for cleanliness before
ra
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stalling.
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le
un
pt
an
• The injectors must be completely undamaged.
d
itte
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erm
ab
• Lubricate all O-rings with engine oil or assembly oil before in‐
ility
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stalling.
wit
is n
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If a used injector is being re-installed:
ole,
spec
– Spray tip of injector with a rust removal spray. Wait approx.
t to the co
5 minutes, then wipe off soot and oil particles with a cloth.
– To remove the old copper seal from the injector, carefully
clamp the copper seal in a pair of pliers so the copper seal is rrectne
just prevented from spinning. Then carefully pull and twist the
injector out of the copper seal by hand.
ss o
– Use a plastic socket to mount the new copper seal.

cial p
f inform
Use a cloth soaked in engine oil or rust remover to remove soot

mer
particles on sealing surface of injectors and sealing surface in

atio
m
cylinder head.
o
n
c
i
or
n thi
e
– Clean injector bore using a cloth soaked in engine oil or rust

t
sd
va
remover. Do not damage sealing surface.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Polo 2010 ➤
– Renew seal for injector bore using assembly sleeve -

T10377- .
• Ensure that the injector bore is clean before fitting.
– Push the clamping piece onto the injector.
– Carefully insert injectors together with the clamping piece into
injector bores in cylinder head.
Caution
lkswage es n
o ot g
yV ua
Proceed very carefully ir se to avoid unnecessary assembly work ante
d b r
and prevent furtheruthdamage.
o eo
ra
sa c
Avoid damage to the injectors and prevent them coming into
s
ce
le
contact with the cylinder head.

un
pt
an
d
itte
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rm
ab
pe
ility
– Initially tighten securing bolts only to 1 - 2 Nm.
ot
wit
, is n
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It should be possible to align the injectors while fitting the high-
hole
pressure lines by hand.
spec
es, in part or in w
– Install high-pressure lines ⇒ page 202 .
t to the co
– Tightening injectors ⇒ Item 9 (page 194)
rrectness of i
Further assembly in reverse order of removal.
l purpos
After renewing one or more injectors:

♦ Write adapted correction values for new injectors into engine nform
ercia
control unit ⇒ page 195 .

m
♦ Reset learnt values of fuel pressure regulating valve - N276- .

com
tion in
♦ 01 - Engine electronics
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do
♦ 01 - Engine electronics functions

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♦ 01 - Reset adaptation values of engine ctrl. mod-

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♦ Selection: Reset learnt values of dosing unit and
p by
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pressure regulating valve Prote AG.
3.5 Removing and installing high-pressure

lines

Polo 2010 ➤
♦ Ratchet wrench - V.A.G 1331/1-

lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
♦ Socket - T40055-
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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♦ Support sleeve - T10411-
t. C rig
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pyri by
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co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
♦ Engine plug set - VAS 6122-
Caution
To position injection lines more easily and free of stress, loosen

fuel rail and injectors, and shift them slightly. The lines must
never be bent or tensioned. Tension would otherwise cause
the respective line to break in the long-term.
Note
AG. Volkswagen A
♦ The use of tools to align the fuel rail of the
lkswinjectors is not per‐
agen G do
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mitted. o
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♦ Observe cylinder-specific markings
ut
ho if reusing high-pressure eo
ra
lines. ss
a c
ce
le
♦ Seal off fuel rail opening immediately with a suitable plug to

un
pt
an
d
prevent dirt from entering.

itte
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rm
ab
♦ The high-pressure lines may be re-used after the following

pe
ility
ot
checks:
wit
, is n
h re
♦ Check taper seal of respective high-pressure line for defor‐

hole
spec
mation and cracks.

es, in part or in w
t to the co
♦ The inside of the line must be free of deformations, constric‐

tions and damage.
rrectness of i
♦ Corroded lines should no longer be used.

l purpos
– Use a vacuum-type cleaner to remove dirt from taper seat on

fuel rail (fuel rail).
nform
ercia
– Clean fuel line and head of line using cold cleaning solvent
m
and dry using compressed air.

a
com
tion in
– Moisten union nut thread with fuel.

r
te o
thi
s
iva
– Fit injection lines from fuel rail to injector by hand first; tighten
do
r
rp
union nuts hand-tight only.

um
fo
en
ng
t.
yi
– Then, fit high-pressure line from high-pressure pump to fuel
Co
op py
rail. t. C rig
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pyri by
– Tighten union nuts of high-pressure line from high-pressure
o Vo
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cted agen
pump to fuel rail hand-tight only. Prote AG.
The further final assembly follows the sequence described.

Polo 2010 ➤
Sequence
– Tighten high-pressure lines on fuel rail and injectors to speci‐
fied torque ⇒ Item 1 (page 207) .
en AG wrench n . Volkswage
– To tighten injection lines, use
ksw
agtorque - AV.A.G
G do 1331-
es n
l
with ratchet - V.A.G 1331/1-
by Vo and socket - T40055- . ot gua
d ran
ise
– Tighten fuel railutto
ho specified torque.
r tee
or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
– To install high-pressure line between high-pressure pump and
es, in part or in w
t to the co
fuel rail, slide support sleeve -T10411- onto fuel pressure
sender - G247- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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te
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t.
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Note
Co
Cop py
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♦ The bracket (for engine mounting) must be movable to screw cop Vo
by lksw
union nut on high-pressure pump; loosen bolts -4- for this. cted agen
Prote AG.
♦ Support sleeve -T10411- specifies the correct distance be‐

tween fuel pressure sender - G247- and high-pressure line.

Polo 2010 ➤
– Tighten high-pressure line -2- between high-pressure pump

and fuel rail first at high-pressure pump -5- and then at fuel rail
-1-.
– Tighten bolt -3- for retainer for high-pressure line.
♦ Specified torques: assembly overview - fuel rail ⇒ page 206 .
♦ Tighten bolts for engine mounting bracket. Assembly overview
- Specified torques ⇒ page 34
– Remove support sleeve - T10411- .
– Reconnect connector to fuel pressure sender - G247- .
– Carefully press return line connections into injectors. (First
check seal for damage). You should hear them click into place.
– Filling fuel system ⇒ page 188 .
. Volkswagen AG
gen AG does
– Start engine and run at idling speed for a few Vol
kminutes,
swa then not
switch off again. ed by gu
ara
ris nte
– Switch off ignition. utho eo
ra
a c
ss
– Check the complete fuel system and return line connections
ce
le
un
pt
for leaks.
an
d
itte
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Renew the affected component if leakage still occurs after tight‐
erm
ab
ility
ening to the correct torque.
ot p
wit
is n
– Then test drive the vehicle, accelerating to full throttle at least
h re
ole,
once.
spec
– Then check high-pressure part of fuel system again for leak‐
t to the co
age.
rrectne
Note
ss
If there is still air in the fuel system, the engine can change to
o
cial p
f
emergency running mode during road test. Switch off engine and
erase event memory entries ⇒ Vehicle diagnostic tester. Then inform
mer
continue with a road test.

atio
om
n
c
i
or
n thi
te
3.6 Assembly overview - fuel rail

sd
iva
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pr
cum
r
fo
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ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
1 - High-pressure lines
❑ 28 Nm
❑ Between fuel rail and in‐
jectors
❑ Install so that compo‐
nent is not under tension
Note
♦ Observe cylinder-specific mark‐

ings if reusing high-pressure
lines.
♦ The high-pressure lines may be
re-used after the following
checks:
♦ Check taper seal of respective
high-pressure linesfor
wagdeforma‐
en AG. V
olkswagen AG
does
tion and cracks.
by
Volk not
gu
d ara
se
♦ The inside
tho of the line must be
ri nte
e or
free of
s a deformations, constric‐
u ac
tionss and damage.
ce
e
nl
pt
du
♦ Corroded lines should no longer
an
itte
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be used.
erm
ab
ility
ot p
2 - High-pressure accumulator
wit
, is n
h re
(rail)
hole
spec
es, in part or in w
⇒ page 208
t to the co
3 - Clamps
rrectness of i
4 - Connecting cable
❑ In fuel return.
l purpos
5 - Fuel pressure regulating

valve - N276-
nform
ercia
❑ Cannot be re-installed.
m
at
om

on
c
in t
or
❑ 80 Nm
his
ate
do
riv
6 - O-ring
p
cum
for
❑ Renew together with fuel pressure regulating valve - N276- .

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t.
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7 - Bolt
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rig ht
❑ 9 Nm
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8 - Fuel return line
Prote AG.
❑ To fuel supply.
9 - Bolt
❑ 20 Nm + 180° further
❑ Renew
10 - High-pressure line
❑ 28 Nm
❑ Between high-pressure pump and fuel rail.
❑ Install so that component is not under tension

Polo 2010 ➤
Note
♦ The high-pressure line may be

checks:
♦ Check taper seal of high-pres‐
sure line for deformation and
cracks.
♦ The inside of the line must be
free of deformations, constric‐
tions and damage. AG. Volkswagen AG d
agen oes
ksw not
♦ Corroded lines should no Vlonger
ol
by gu
ara
be used. orise
d
nte
th eo
au ra
c
11 - Fuel pressure senders - G247-
s
ce
le
un
pt
an
d
itte
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❑ 100 Nm
rm
ab
pe
ility
ot
wit
, is n
h re
3.7 Removing and installing fuel rail
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
l purpos

nform
ercia

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
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pyri by
Vo
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by
cted agen
Prote AG.
♦ Ratchet wrench - V.A.G 1331/1-

Polo 2010 ➤
♦ Socket - T40055-
♦ Pliers - 3314-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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au ra
ss c
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
Removing
rrectness of i
l purpos
WARNING
nf
ercia
or

m
m
atio
om

n in
or c

thi
te
sd
iva
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
op py
– Unscrew bolt -3- from retainer for high-pressure line. t. C rig
gh ht
pyri by
– Collect escaping fuel with a cleaning cloth.
co Vo
by lksw
cted agen
Prote AG.

Polo 2010 ➤
– Remove high-pressure line -2-; to do this, loosen union nuts

on high-pressure pump -5- and on fuel rail -1-.
– Open cable guide catch -arrows- to free wiring harness.
– Position pliers - 3314- with groove -arrow A- on support sleeve

shoulder -arrow B-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
– Carefully pull connectors off glow pin plugs

ility
ot p
-in direction of arrow-.

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
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
– Pull off electrical connectors -1…6-.

Renew connector seal of connectors -2-, -3- and -4-
⇒ Item 5 (page 194) ⇒ ETKA (Electronic Parts Catalogue) .
– Unscrew fuel return line bolts -arrows-.
Caution
♦ Mark allocation of high-pressure fuel lines to cylinders;

they must only ever be reused on the same cylinder.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
♦ The open connections must be sealed immediately withwaage
es n
suitable cap. lks ot g
Vo
by u ara
ed nte
ris
tho e or
au ac
ss
– Remove high-pressure lines between injectors and fuel rail.
ce
e
nl
pt
du
an
– Place the removed high-pressure lines on a clean cloth.
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 fuel rail; unscrew the two bolts -arrows- to do this. nform
ercia
Installing
m
at
om

ion
c
note the following:

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

Polo 2010 ➤
– Initially tighten securing bolts -arrows- to a maximum of 1 - 2

Nm.
• It must be possible to move the rail so the hoses can be fitted
free of stress. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
– Install high-pressure lines ⇒ page 202 . ed by ua
ran
ris tee
tho or
au ac
Note ss
ce
le
un
pt
an
d
♦ Observe cylinder-specific markings if reusing high-pressure
itte
y li
rm
lines.
ab
pe
ility
♦ The high-pressure lines may be re-used after the following ot
wit
, is n
checks:
h re
hole
spec
♦ Check taper seal of respective high-pressure line for defor‐
es, in part or in w
mation and cracks.
t to the co
♦ The inside of the line must be free of deformations, constric‐
tions and damage.
rrectness of i
♦ Corroded lines should no longer be used.
l purpos
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
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
4 High-pressure pump
⇒ “4.1 Assembly overview - high-pressure pump”, page 213
⇒ “4.2 Removing and installing high-pressure pump”, page 214
⇒ “4.3 Checking vacuum at high-pressure fuel pump (venturi noz‐
zle) ”, page 219
⇒ “4.4 Checking vacuum between high-pressure fuel pump (ven‐
turi nozzle) and injectors ”, page 221
4.1 Assembly overview - high-pressure pump
1 - O-ring
❑ O-rings are only to be
renewed if necessary.
⇒ page 195
2 - Fuel return lines (from in‐
jectors)
❑ To high-pressure pump
❑ The fuel return line must AG. Volkswagen AG d
be free of kinks, damage agen oes
olksw not
V
and blockages. ed by gu
ara
ris nte
❑ Do not dismantle the ut
ho eo
ra
fuel return lines. ss a c
ce
le
3 - High-pressure line
un
pt
an
d
itte
❑ 28 Nm
y li
rm
ab
pe
❑ Between high-pressure
ility
ot
pump and fuel rail

wit
, is n
h re
❑ Install so that compo‐
hole
nent is not under tension spec

es, in part or in w
t to the co
Note
♦ The high-pressure line may be

rrectness of i

l purpos
checks:
♦ Check taper seal of high-pres‐
nform
ercia
sure line for deformation and

cracks.
m
a
com
tio
♦ The inside of the line must be

n in
r
free of deformations, constric‐

te o
thi
tions and damage.

s
iva
do
r
rp
cum
♦ Corroded lines should no longer

fo
en
g
be used.
n
t.
yi Co
Cop py
t. rig
gh ht
4 - High-pressure pump yri
p by
o Vo
by c lksw
❑ Removing and installing ⇒ page 214 cted agen
Prote AG.
❑ With fuel metering valve - N290- (do not open)
❑ After renewing, a first fuel filling must be performed (never allow the pump to run while it is still empty)
⇒ page 188 .
5 - Bolt
❑ 20 Nm + turn 180° further
6 - Bolt
❑ 20 Nm + 45° further
4. High-pressure pump 213

Polo 2010 ➤
7 - Bolts for high-pressure pump toothed belt pulley

❑ 20 Nm
8 - Toothed belt pulley on high-pressure pump
9 - Nut
❑ 95 Nm
10 - Hub
4.2 Removing and installing high-pressure

pump
Performing first fuel filling after installing high-pressure pump
⇒ page 188 .
Caution
To prevent the high-pressure fuel pump from running while it

. Volkswagen AG
is empty (very tight tolerances) and to ensurekthat w agethe
n AGengine does
starts quickly after parts have been renewed, ol s
y V it is important to
not
b gu
ara
observe the following: ris
ed
nte
tho eo
♦ If fuel system components between
ss
au fuel tank and fuel ra
c
high-pressure pump are removed or replaced:
ce
le
un
pt
an
♦ Basic setting “Checking fuel pre-supply pump” must be
d
itte
y li
carried out to bleed fuel system.
erm
ab
ility
ot p
♦ If a fuel pump, fuel line (between fuel tank and fuel high-
wit
is n
pressure pump) or fuel filter is removed or replaced:

h re
ole,
spec
♦ Basic setting “Testing fuel pre-supply pump” must be car‐
ried out »once« before first starting engine. t to the co
♦ If the high-pressure fuel pump is removed or renewed, the

basic setting “Checking fuel system pressurisation pump”
rrectne
must be performed »three times« before the engine is

started for the first time.
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.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2010 ➤

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
♦ Counter-hold tool - T10051- ss
au ac
ce
e
♦ Puller - T40064-
nl
pt
du
an
itte
y li
♦ Thrust piece - T40064/1-

erm
ab
ility
ot p
♦ Puller - T40064/2-
wit
, is n
h re

hole
spec

es, in part or in w
t to the co
Removing
rrectness of i

l purpos

nf
ercia
Caution
orm
m
atio
m

o
n in
c

or
thi
e
ness will need to be renewed.

t
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
215
cted agen
Prote AG.
4. High-pressure pump
Polo 2010 ➤
– Pull off connectors -10, 11 and 12-.

10 - Hall sender - G40-
12 - Fuel temperature sender - G81- in fuel supply line

– Lay coolant return line to side.
If the high-pressure pump is not replaced:
AG. Volkswagen AG d
– Collect escaping fuel with a cleaning
olks
wagcloth.
en oes
not
yV gu
db ara
ir se nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Pull off fuel hoses -1 and 6-. To do this, press the quick-release
h re
couplings onto the connections, press in the locking elements
hole
(keep pressed) and pull the quick-release couplings off. spec

es, in part or in w
t to the co
If the high-pressure pump is replaced: rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Pull fuel hoses -arrows- off the high-pressure pump.

s
iva
do
r
Continuation for both work processes (replacing high-pressure

rp
cum
fo
pump/not replacing high-pressure pump):

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

agen
AG. Volkswagen AG d
oes Polo 2010 ➤
ksw
3-cylinder commony Vol rail engine (1.2 l, EA189) -
not
Edition
gua 06.2019
db ran
rise te
– Carefully release fuel return line -arrow- aatho
ut high-pressure
eo
ra
pump. ss c
ce
e
nl
pt
– Carefully pull fuel return line out of high-pressure pump.
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

sure pump.
nf
ercia
orm
m
atio
om
n in
c
– Remove toothed belt from camshaft and high-pressure pump

or
thi
e
⇒ page 88 .
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unscrew bolts -1-.
– Remove toothed belt pulley from high-pressure pump.
– Unscrew nut -1- at hub of high-pressure pump. To do this,

counterhold with counterhold - T10051- .

lkswage es n
o ot g
Polo 2010 ➤ byV ua
d ran
ir se
3-cylinder common rail engine (1.2 l, EA189) - Edition
tho 06.2019 tee
or
au ac
ss
– Place puller - T40064- with thrust piece - T40064/1- and puller
ce
le
un
pt
- T40064/2- in position as shown and pull hub off high-pres‐
an
d
itte
sure pump. Counterhold with an 24 mm open-end spanner.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
– Unscrew securing bolts -arrows- of high-pressure pump. cial p
f inform
– Remove high-pressure pump.
mer
atio
m
Installing
o
n
c
i
or
n thi
te
sd
a
Caution
iv
o
pr
cum
r
fo
en
ng
Risk of irreparable damage to high-pressure pump if allowed

t.
yi Co
op
to run dry. C py
t. rig
gh ht
yri by
♦ If the high-pressure fuel pump has been removed or re‐ cop Vo
by lksw
placed, the high-pressure pump must be filled with fuel cted agen
Prote AG.
before engine is started ⇒ page 188
Note
♦ When installing the high-pressure pump, it is essential to en‐

sure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel lines.

♦ The bolts for high-pressure pump must be replaced.
♦ Specified torques for toothed belt drive: ⇒ page 83
Note
If the high-pressure pump has been renewed, the learnt values

of the fuel pressure regulating valve - N276- must be reset ⇒ Ve‐
hicle diagnostic tester; Guided functions; Resetting learnt values
of fuel pressure regulating valve.
– Filling/bleeding high-pressure pump and fuel system

⇒ page 188 .

Polo 2010 ➤
4.3 Checking vacuum at high-pressure fuel

pump (venturi nozzle)
Observe instructions for working on fuel system ⇒ page 185
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
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Pressure gauge - VAS 6551-

m
at
om
io
♦ Hose adapter - VAS 6551/1-
n
c
in t
or
his
e

at
do
priv
c
♦ Not illustrated
um
for
en
ng
t.
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Co
Cop py
t. rig
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pyri by
Vo
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by
♦ Vehicle diagnostic tester cted agen
Prote AG.
Test conditions:
Note
♦ Completion of the tests with OK in the low-pressure range is

a prerequisite for a correct vacuum measuring result.
♦ Start by checking delivery pressure and follow test procedures
in order to prevent any false renewal of high-pressure fuel
pump.
Checking delivery pressure of fuel pump ⇒ Fuel supply system;

Rep. gr. 20
Checking delivery pressure in fuel return line ⇒ Fuel supply sys‐
tem; Rep. gr. 20
Checking delivery rate of fuel pump ⇒ Fuel supply system; Rep.
gr. 20
• Battery voltage at least 12.5 V
• Fuel filter OK.
• Ignition off

Polo 2010 ➤
Checking
WARNING
♦ Always read rules for cleanliness and instructions for

working on fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
– Carefully release fuel return line at high-pressure pump.

– Connect free end of fuel return line to hose adapter - VAS

6551/3- , and hold it into a ≤ 3 litre measuring container -3-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
es, in part or in w
t to the co
– Connect pressure tester - VAS 6551- with hose adapter - VAS

6551/4- from connection -A- to high-pressure pump.
rrectness of i
– Close shut-off tap of pressure tester - VAS 6551- -A- + -B- and
l purpos
open -C-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
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220
cop Vo
by lksw
Rep. gr.23 - Mixture preparation - injection Prote
cted AG.
agen
Polo 2010 ➤
– Connect free connection -arrow- at high-pressure pump to

hose adapter - VAS 6550/4- .
– Ask a second mechanic for assistance.

– Switch on pressure tester - VAS 6551- by pressing On/Off
button and calibrate it.
– Switch on ignition.
– Start engine.
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ility
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hole
spec
es, in part or in w
t to the co
– Take pressure reading on pressure tester - VAS 6551- .

Specification: min. – 0.30 bar
rrectness of i
If the specified value is not reached, first check the delivery pres‐
l purpos
sure in the fuel return system. Repair return system if necessary

⇒ Fuel supply system; Rep. gr. 20 .
nform
ercia
If the specified value is reached: Repeat test at injector

⇒ page 221
m
a
com
tio
If the specified value is still not reached: Replace high-pressure

n in
r
pump ⇒ page 214 .

te o
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4.4 Checking vacuum between high-pres‐ Cop py
t. rig
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sure fuel pump (venturi nozzle) and in‐
ht
pyri by
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by
jectors cted agen
Prote AG.
Do not perform this test until the vacuum at the high-pressure

pump (venturi nozzle) has been checked
⇒ Fuel supply system; Rep. gr. 20

Polo 2010 ➤ G. Volkswagen AG d
gen A06.2019
3-cylinder common rail engine (1.2 l, EA189) -olkEdition
swa oes
no
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by ara
ed nte
– Make return line connection accessible. Release
ho
ris
catch -1- to eo
do this. aut ra
ss c
ce
le
– Pull fuel return line connection in direction of arrow off injector.
un
pt
an
d
itte
– Ask a second mechanic for assistance.
y li
rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Close shut-off tap of pressure tester - VAS 6551- -A- + -B- and
l purpos
open -C-.
– Connect connection -C- on pressure tester - VAS 6551- with
nform
ercia
hose adapter - VAS 6551/3- to fuel return line.

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tion in
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Cop py
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by
cted agen
– Connect hose adapter - VAS 6551/4- to fuel return line con‐
Prote AG.
nection on injector and hold free end into a ≤ 3 litre measuring

container -3-.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button and calibrate it.
– Start engine.

Polo 2010 ➤
– Take pressure reading on pressure tester - VAS 6551- .

Specification: min. – 0.10 bar
If the specified value is not reached, first check the delivery pres‐
sure in the fuel return system ⇒ Fuel supply system; Rep. gr.
20 .
If the specified value is still not reached: Replace fuel return line .
⇒ Item 2 (page 213)
– Drain measuring container.
Note
Then, check fuel system for leaks.
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spec
es, in part or in w
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rrectness of i
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orm
m
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om
n in
or c
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te
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Cop py
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by
cted agen
Prote AG.

Polo 2010 ➤
5 Senders and sensors agen

AG. Volkswagen AG d
oes
olksw not
⇒ “5.1 Removing and installing fuel pressure
ed by
V
regulating valve gu
ara
N276 ”, page 224 horis nte
eo
aut ra
⇒ “5.2 Checking fuel pressuresregulating valve N276 ”,
s c
page 226
ce
e
nl
pt
du
an
itte
⇒ “5.3 Removing and installing fuel pressure sender G247 ”, page
y li
erm
ab
228
ility
ot p
⇒ “5.4 Removing and installing pressure differential sender G 505
wit
, is n
h re
”, page 229
hole
spec
5.1 Removing and installing fuel pressure
es, in part or in w
t to the co
regulating valve - N276-
rrectness of i
♦ Torque wrench
l purpos
♦ Engine plug set - VAS 6122-
nf
ercia
orm
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atio
om
n in
or c
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Polo 2010 ➤
Fuel pressure regulating valve - N276- -5- is located on fuel rail.

Removing
Fuel rail must be removed for further work.
– Clean fuel rail (e.g. with commercial cleaning solution) before
removing.
– Also thoroughly clean threaded area of fuel pressure regulat‐
ing valve - N276- .
• Under no circumstances may dirt enter the hole of the fuel rail.
• It must be ensured that noencleaning agent
AG. Volkswagen Agets
G do
into the con‐
nector housing of the
olkfuel
swag pressure control valvees n- N276- .
o V t gu
by ara
• Collect escaping
ris fuel with a cleaning cloth.
ed nte
ho eo
aut ra
ss c
ce
Note
le
un
pt
an
d
itte
y li
Seal off fuel rail opening immediately with a suitable plug to pre‐
erm
ab
vent dirt from entering.
ility
ot p
wit
is n
h re
– Removing high-pressure accumulator ⇒ page 208 .
ole,
spec
– Dry fuel pressure regulating valve - N276- .

– Counterhold on housing hexagon then loosen threaded union. t to the co
Then, unscrew regulating valve by hand.
rrectne
– Extract dirt from bore of fuel rail (threads and sealing surface).
Do not use tools or other instruments for this purpose.
ss o
Installing
cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
♦ The fuel pressure regulating valve - N276- cannot be re-used.

te
sd
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r
♦ Make sure that sealing surfaces (deformable sealing lip) and

p
cum
r
fo
threads on new fuel pressure regulating valve - N276- are un‐

en
ng
t.
yi
damaged.
Co
Cop py
t. rig
gh
♦ Check sealing surface hole.
ht
pyri by
Vo
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by
♦ Start of thread and deformable sealing lip of fuel pressure reg‐
cted agen
Prote AG.
ulating valve - N276- must be moistened with diesel.
♦ Moisten newly fitted O-ring with diesel just before starting as‐
sembly operations.
– Install new O-ring with damaging it ⇒ ETKA (Electronic Parts

Catalogue) .
– Tighten threaded unions of fuel pressure regulating valve -
N276- by hand ⇒ ETKA (Electronic Parts Catalogue] .
– Align new fuel pressure regulating valve - N276- so that con‐
necting wire is free of tension after connector is attached.
– Counterhold on housing hexagon and tighten threaded union.
♦ Specified torque: assembly overview - fuel rail ⇒ page 206 .
– Install high-pressure accumulator ⇒ page 208 .
– After installing, leave engine running at moderate speed for a
few minutes and then switch off again.
5. Senders and sensors 225

Polo 2010 ➤
– Check fuel system for leaks.
Note
If the fuel pressure regulating valve - N276- or the high-pressure

pump have been exchanged, the learnt values for the regulating
valve must be reset using the vehicle diagnostic tester : Guided
Functions; Resetting learnt values for fuel pressure regulating
valve.
– Read event memory.

– Then road-test the vehicle. Accelerate with full throttle at least
once, then check the high-pressure section again for leaks.
– Read event memory again.
5.2 Checking fuel pressure regulating valve

- N276-
Fuel pressure regulating valve - N276- (pressure control valve) is
located on fuel rail.
Fuel pressure regulating valve - N276- (pressure control valve)
only opens under cold starting conditions below a certain tem‐
perature.
Heated, regulated fuel is returned upstream of fuel filter.
Volkswa
This prevents fuel filter from
swa clogging at low temperatures.
gen AG
. gen AG
does
olk not
yV g
Fuel pressure regulating
edb valve - N276- -5- is located onuafuel
ran rail.
ris tee
tho or
u ac
sa
sWARNING
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un
pt
an
d
itte
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erm

ab
ility
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wit
is n

h re
ole,
spec
t to the co
• Engine at operating temperature.

• Air conditioner switched off
rrectne

ss
– Pull off fuel return line -1-.

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
– Use a dummy plug -1- to seal open return line connection.

– Connect fuel return line -2- to suitable hose -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
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nl
pt
du
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ab
– Hold the end of this hose -1- in a suitable container -2- to
ility
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measure the return flow rate.
wit
, is n
h re
– Start engine and run at idling speed.
hole
spec
es, in part or in w
• Specification 0 ml
t to the co
If the specification is not attained, the fuel pressure regulating
valve - N276- is defective. Renew ⇒ page 224
rrectness of i
l purpos
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ercia
orm
m
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Cop py
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pyri by
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by c lksw
cted agen
Prote AG.

Polo 2010 ➤
5.3 Removing and installing fuel pressure

sender - G247-
Fuel pressure regulating valve - G247- -6- is located on fuel rail.
It measures the fuel pressure and sends a voltage signal to the
control unit for direct diesel injection system - J248- .
Removing
Caution
First read through the rules for cleanliness and the instructions
for working on the fuel system.
Follow these instructions before starting work and while work‐
ing on the fuel system.

– Before removal, clean thread area in vicinity of fuel pressure
sender using e.g. a cold cleaning solvent. No dirt must enter
the bore in the fuel rail.
• Under no circumstances may dirt enter the hole of the fuel rail.
• It must be ensured that no cleaning agent gets into the con‐
nector housing of the fuel pressure sender - G247- .
– Dry fuel pressure sender - G247- .
– Pull electrical connector from fuel pressure sender - G247- .
Caution n AG. Volkswagen AG do

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Do not remove fuel pressure sender with open-ended spanner horis tee
or open ring spanner - Risk of damage! aut or
ac
ss
Use an extended socket insert.
ce
le
un
pt
an
d
itte
y li
rm
ab
– Collect escaping fuel with a cleaning cloth.
pe
ility
ot
wit
, is n
– Unscrew fuel pressure sender - G247- .
h re
hole
spec
– Use suction device to extract dirt from fuel rail bore (threads
es, in part or in w
and sealing surface). Do not use tools or other instruments for

this purpose. t to the co
rrectness of i
Note
l purpos
Seal off fuel rail hole immediately with a suitable plug to prevent
dirt from entering.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
Installing
Note
♦ Fuel pressure sender - G247- has a deformable sealing lip,

not a seal, for sealing purposes.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure sender - G247- are undamaged. The
fuel pressure sender - G247- can be re-used.
♦ Check the sealing surface of the fuel rail bore as well.
♦ The thread on the fuel pressure sender - G247- has a special
lubricating coating. The thread must be kept free of oil and
grease.
Caution
Do not tighten fuel pressure sender with open-ended spanner

or open ring spanner - Risk of damage!
Use an extended socket insert.
. Volkswagen AG
– Tighten fuel pressure sender - G247- by hand.kswagen AG does
not
Vol gu
– Then tighten sender. Specified torque ⇒ by
edItem 11 (page 208) .
ara
ris nte
tho eo
– After installing, leave engine running au at moderate speed for a ra
c
few minutes and then switch off again. ss
ce
e
nl
pt
du
– Checking fuel system for leaks ⇒ page 189 .
an
itte
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erm
ab
ility
ot p
– Then road test the vehicle, accelerating to full throttle at least
wit
, is n
h re
once. Check high pressure part of fuel system again for leaks.
hole
spec
es, in part or in w
t to the co
5.4 Removing and installing pressure differ‐
ential sender - G 505-
rrectness of i
l purpos
⇒ “5.4.1 Removing and installing pressure differential sender G

505 ”, page 229
nf
ercia
⇒ “5.4.2 Removing and installing pressure differential sender G

orm
505 (right-hand drive vehicles) ”, page 230

m
atio
om
n in
5.4.1 Removing and installing pressure differ‐

or c
thi
e
ential sender - G 505-

t
sd
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t.
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Note t. Cop py
rig
gh ht
yri by
♦ Pressure differential sender - G 505- determines charge status cop Vo
by lksw
of particulate filter.
cted agen
Prote AG.
♦ Different measurement methods are used.

♦ The component retains the same designation.

Polo 2010 ➤
Method 1 (differential-pressure measurement)

Pressure differential sender - G 505- is connected via 2 pipes to
the measuring points upstream and downstream of the particulate
filter. Assembly overview.
Method 2 (relative-pressure measurement)
Pressure differential sender - G 505- is connected via one pipe to
the particulate filter.
Removing
. Volkswagen AG
gen AG does
– Before pulling off, spray two hoses of pressure
Vol
ksw differential
a
not
sender - G 505- with solvent. ed by gu
ara
is nte
or
– Pull connector -2- from pressure
au differential
th sender - G 505- . eo
ra
ss c
– Pull hoses carefully and straight from unions (unions break off
ce
le
un
pt
pressure differential sender - G 505- very easily).
an
d
itte
y li
– Unscrew bolt -3-, remove pressure differential sender - G
erm
ab
ility
505- .
ot p
wit
is n
Installing
h re
ole,
spec
– When installing, note the following:
t to the co
• Specified torque for pressure differential sender - G 505- bolt,
see assembly overview - Lambda probe
⇒ Item 2 (page 249)
rrectnes
Note
s o
cial p
f in
♦ Before installing, blow out hoses of pressure differential send‐
form
mer
er - G 505- to particulate filter with compressed air (hoses can atio

m
become obstructed or may ice up due to condensation).

o
n
c
i
or
♦ Make sure that hoses are securely fitted and seal properly.
thi
te
sd
iva
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pr
cum
r
An adaptation must be performed after renewing pressure differ‐

fo
en
ng
ential sender - G 505- and/or particulate filter. (The procedure is

t.
yi Co
op
also described under Guided Functions). C py
t. rig
gh ht
yri
Select correct vehicle in guided fault finding.
p by
o Vo
by c lksw
cted agen
Prote AG.
5.4.2 Removing and installing pressure differ‐

ential sender - G 505- (right-hand drive
vehicles)
Pressure differential sender - G 505- is connected via 2 pipes to
the measuring points upstream and downstream of the particulate
filter. Assembly overview - Lambda probe ⇒ Item 8 (page 252) .
Pressure differential sender - G 505- determines charge status of
particulate filter.
Removing
– Before pulling off, spray two hoses of pressure differential
sender - G 505- with solvent.

Polo 2010 ➤
– Pull electrical connector -2- from pressure differential sender

- G 505- .
– Pull hoses carefully and straight from unions (unions break off
pressure differential sender - G 505- very easily).
– Unscrew nut -1-, remove pressure differential sender - G 505- .
Installing
. Volkswage
gen AG
– When installing, knote
swa the following:
n AG d
oes
ol n ot g
V
• Specifiedistorqueby u
for pressure differential sender a-raG
ed nte505- bolt,
see assembly
utho
r
overview - Lambda probe eo
⇒ Item
ss a 10 (page 252) ra
c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
♦ Before installing, blow out hoses of pressure differential send‐
wit
, is n
er - G 505- to particulate filter with compressed air (hoses can
h re
become obstructed or may ice up due to condensation).
hole
spec
es, in part or in w
♦ Make sure that hoses are securely fitted and seal properly.
t to the co
An adaptation must be performed after renewing pressure differ‐
ential sender - G 505- and/or particulate filter. (The procedure is
rrectness of i
also described under Guided Functions).
l purpos
Select correct vehicle in guided fault finding.

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.

Polo 2010 ➤
6 Lambda probe
⇒ “6.1 Assembly overview - lambda probe and exhaust temper‐
ature sensors”, page 232
⇒ “6.2 Removing and installing Lambda probe G39 with Lambda
probe heater Z19 ”, page 232 gen AG
. Volkswagen AG
d a oes
ksw not
Vol
6.1 Assembly overview - lambda probe and exhaust temperature sensors ed
by gu
ara
nte
oris eo
th
au ra
c
ss
ce
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nl
sender 4 - G648-
pt
du
an
itte
y li
erm
ab
⇒ Rep. gr. 26
ility
ot p
wit
, is n
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sender 1 - G235-
hole
spec
es, in part or in w
⇒ Rep. gr. 26
t to the co
sender 3 - G495-
rrectness of i
l purpos
⇒ Rep. gr. 26
4 - Pressure differential sender
nf
ercia
- G505-
orm
m
atio
m
⇒ page 229
o
n in
or c
❑ 45 Nm
thi
te
sd
iva
o
5 - Lambda probe - G39- with
r
rp
cu
o
m
Lambda probe heater - Z19-
f
en
ng
t.
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❑ Removing and installing Cop py
⇒ page 232
t. rig
gh ht
pyri by
❑ 55 Nm
co Vo
by lksw
cted agen
Prote AG.
6.2 Removing and installing Lambda probe

- G39- with Lambda probe heater - Z19-

Polo 2010 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Removing
ce
e
nl
pt
du
an
itte
– Pull off engine cover panel ⇒ page 24 .
y li
erm
ab
ility
– Detach electrical connector -1- of Lambda probe - G39- .
ot p
wit
, is n
– Unscrew Lambda probe - G39- -2- using tool from Lambda
h re
hole
probe open ring spanner set - 3337- .
spec
es, in part or in w
Installing
t to the co
Install in reverse order of removal, observing the following.
rrectness of i
Note
l purpos
♦ New Lambda probes are coated with an assembly paste; the
nf
ercia
paste must not get into the slots in the Lambda probe.
orm
m
atio
♦ In the case of a used Lambda probe, grease only the thread
om
with high-temperature paste. This paste must not get into the
n in
or c
slots on the Lambda probe body. High-temperature paste ⇒

thi
te
Electronic Parts Catalogue . sd

iva
o
r
rp
cu
o
♦ When installing, the Lambda probe's electrical wiring connec‐

m
f
en
ng
t.
tion must always be re-attached in the same locations to
yi Co
op
prevent the Lambda probe cable from coming into contact with
C py
t. rig
gh
the exhaust pipe.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
• Specified torque ⇒ page 232
6. Lambda probe 233

Polo 2010 ➤
wage - Edition 06.2019
e ks s no
Vol t gu
d by ara
e nte
ris
7 Air filter autho eo
ra
c
ss
⇒ “7.1 Assembly overview - air filter”, page 234
ce
e
nl
pt
du
an
itte
⇒ “7.2 Removing and installing air filter housing”, page 235
y li
erm
ab
ility
7.1 Assembly overview - air filter ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
❑ With captive bolt, 9 Nm
2 - Clip
rrectness of i
3 - Heater for crankcase
breather
l purpos
❑ For vehicles in cold cli‐

mate zones
nf
ercia
or
4 - Vacuum hose
m
m
atio
m
❑ From charge pressure

o
n in
c
control solenoid valve -

or
thi
e
N75-
t
sd
iva
⇒ “2.1 Vacuum hose
o
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rp
cu
connection diagram”,
o
m
f
en
ng
page 190
t.
yi Co
Cop py
5 - Spring-type clip
t. rig
gh ht
pyri by
Vo
o
6 - Suction hose
c by lksw
cted agen
Prote AG.
❑ To turbocharger
7 - Hose
❑ For crankcase ventila‐
tion.
❑ Press release buttons to
detach
8 - 2 Nm
9 - Air mass meter - G70-
10 - O-ring
11 - 8 Nm
12 - Air filter upper part
13 - Hose
❑ For preheating
❑ For vehicles in cold climate zones
14 - Filter element
❑ To remove, turn 1/4 turns anti-clockwise
15 - 8 Nm
16 - Rubber mounting
17 - Air filter lower part
❑ Bolted to lock carrier.

Polo 2010 ➤
19 - 2 Nm
20 - Air intake hose
❑ Intake connecting pipe
AG. Volkswagen AG d
21 - Water drainage pipe ksw
agen oes
not
Vol
❑ Observe installation position d by gu
ara
rise nte
o
22 - Rubber mounting auth eo
ra
s c
❑ Renew if damaged s
ce
le
un
pt
an
d
itte
y li
rm
ab
7.2 Removing and installing air filter hous‐
pe
ility
ot
wit
ing
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
– Pull connector off air mass meter - G70- -2-.
rrectness of i
– Open clip -1- and pull off hose to turbocharger.
l purpos
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
– Remove vacuum lines upwards from air filter -1- together with cted agen
Prote AG.
bracket.
– Loosen threaded connection at air filter housing -arrow-.

Remove connecting hose -4-.
– Remove entire air filter housing.
Remove suction hose.
Note
As it is difficult to gain access to clip on suction hose, it is better

to remove intake connecting pipe from turbocharger.
7. Air filter 235

Polo 2010 ➤
– Remove crankcase breather hose -3-.

– Pull vacuum hose -2- off suction hose -1-, and lay it to one
side. Unclip bracket.
– Completely undo bolt -4- (make sure bolt is captive).
– Swing intake union to the right and remove with suction hose
-1-.
Install suction hose.
note the following:
– When mounting intake connecting pipe on turbocharger, it

must be ensured that intake connecting pipe is correctly seat‐
ed on the bolt of the turbocharger. -arrow-. AG. Volkswagen A
agen G do
es n
ksw
Installing by Vol ot g
ua
ed ran
Install in reverse order. oris tee
th or
au ac
When doing this, observe the following:
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Guide water drainage pipe -arrow- between gearbox and
es, in part or in w
body.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Check under the wing to see whether the water drainage pipe
o
m
f
en
ng
has been installed correctly.

t.
yi Co
op py
♦ Specified torques: ⇒ page 234
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
8 Intake manifold
⇒ “8.1 Assembly overview - intake manifold with attachments”,
page 237
⇒ “8.2 Removing and installing intake manifold”, page 237
8.1 Assembly overview - intake manifold with attachments
1 - Exhaust gas recirculation

cooler changeover valve -
N345-
AG. Volkswagen AG d
2 - Bolt agen oes
olksw not
yV gu
❑ 8 Nm ised b ara
nte
or eo
h
3 - Bolt s aut ra
c
s
❑ 8 Nm
ce
le
un
pt
an
d
4 - Charge air pressure sender

itte
y li
- G31-
rm
ab
pe
ility
ot
5 - Seal
wit
, is n
h re
❑ Renew
hole
spec
6 - Connecting pipe
es, in part or in w
t to the co
❑ To cylinder head/ex‐
haust gas recirculation
cooler.
rrectness of i
7 - Bolt
l purpos
❑ 9 Nm
8 - Clip
nform
ercia
❑ 4 Nm
m
a
com
ti
❑ Renew
on in
r
te o
thi
9 - Throttle valve module -

s
iva
do
J338-
r
rp
cum
fo
10 - Bolt
en
ng
t.
yi Co
op
❑ 10 Nm C py
ht. rig
rig ht
11 - Seal
py by
co Vo
by lksw
cted
❑ Renew
agen
Prote AG.
❑ Individual seals can also

be installed.
12 - Intake manifold
❑ With intake manifold flap control unit - GX14-
❑ With optimised swirl for intake air.
❑ Must not be dismantled.
13 - Bolt
❑ 8 Nm
8.2 Removing and installing intake manifold

8. Intake manifold 237

Polo 2010 ➤
AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1331- ksw
agen oes
not
Vol
by gu
d ara
rise nte
tho eo
au 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
♦ Pliers - 3314-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.

Removing
Caution

ness will need to be renewed. Do not compress the pliers -
3314- to firmly to separate the connectors, otherwise the
support sleeve may be damaged.

Polo 2010 ➤
– Unscrew fuel return line bolts -arrows-.
– Carefully release fuel return line at high-pressure pump

-arrow-.
– Pull connector off glow pin plugs ⇒ page 281 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
– Unscrew bolt -arrow-, and lay exhaust
ss a
gas recirculation cooler c
changeover valve - N345- aside.
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
rrectnes
– Separate connectors -6, 7, 9, 11-.

s o
cial p
f i
6 - Intake manifold flap control unit - GX14-

nform
mer
7 - Charge air pressure sender - G31-

atio
om
n
c
9 - Throttle valve module - J338-

i
or
n thi
te
sd
a

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.
8. Intake manifold 239

Polo 2010 ➤
wage es n
– Unscrew coolant return lineolks
y V bolts -arrows-.
ot g
d b ua
e ran
– Lay coolant returnthline
oris
to side. tee
or
au ac
– Remove fuel rail
ss ⇒ page 208 .
ce
le
un
pt
an
d
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
– Open clamps -1 and 3-.
rrectness of i
– Unscrew intake manifold securing bolts
l purpos
⇒ Item 13 (page 237) diagonally from outside to inside.

– Carefully remove intake manifold.
nform
ercia
Installing
m
a
com
tio
Install in reverse order of removal.
n in
r
te o
thi
s
iva
do
WARNING
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.
– Renew seals.
– Now insert securing bolts into holes in intake manifold.
– Carefully guide the intake manifold together with the seals and
securing bolts to the installation location.
– Tighten intake manifold securing bolts diagonally from outside
to inside. Specified torque ⇒ Item 13 (page 237) .

Polo 2010 ➤
9 Engine control unit

⇒ “9.1 Reading and deleting engine control unit event memory”,
page 241
⇒ “9.2 Adapting functions and components”, page 241
AG . Volkswage
⇒ “9.3 Removing and installing engine control wunit
agenwith no ant- AG does
n
theft protection ”, page 242 Volks not
gu
by a d ran
ise
⇒ “9.4 Removing and installing anti-theft
ut
ho
r
engine control unit ”, tee
or
page 242 ss
a ac
ce
e
9.1 Reading and deleting engine control unit

nl
pt
du
an
itte
event memory
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Procedure
t to the co
– Start engine and run at idling speed.
rrectness of i
Only when engine does not start:
l purpos
nform
ercia
Select operating mode:

m
at
– Press button on display for “Vehicle self-diagnosis”.
om
ion
c
in t
r
Select vehicle system:

o
his
ate
do
riv
– Press button “01 - Engine electronics” on display.

p
cum
for
Engine control unit coding and identification are displayed. en

ng
t.
yi Co
op py
Selecting diagnostic function:
. C rig
ht ht
rig by
py
– Press “02 - Read event memory” button on the display.
co Vo
by lksw
cted agen
Prote AG.
– If no fault is stored in the engine control unit “0 faults detected”
is displayed.
– If faults are stored in the engine control unit, they are shown
one below the other on the display.
– Press ← button.
– Press “05 - Clear event memory” button on the display.
– Press “06 - End output” function.
9.2 Adapting functions and components

Procedure
Select “Guided fault finding” on vehicle diagnostic tester .
When all control units have been read:
– Press “GoTo” button.
– Select “Function/component selection”.
– Select “Drive”.
– Select “Engine code”.
9. Engine control unit 241

Polo 2010 ➤
– Select “01 Systems capable of self-diagnosis”.

– Select “engine control”.
– Select “Functions”.
– Select “Function or component”.
9.3 Removing and installing engine control AG. Volkswagen AG d

agen
unit with no ant-theft protection by Volksw
oes
not
gu
ara
ed nte
Connect vehicle diagnostic tester and carry out “Renewing control
tho
ris e or
unit” in guided functions if engine control unit is to be renewed.
sa
u ac
s
ce
le
un
pt
an
d
itte
Removing
y li
rm
ab
pe
ility
ot
wit
, is n
– Release connectors from engine control unit and pull off.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– Press clips -arrows A- outwards and pull engine control unit
n in
r
out to side -B-.

te o
thi
s
iva
do
Installing
r
rp
cum
fo
en
– Insert new engine control unit and press to left.
ng
t.
yi Co
op py
– Connect connectors and lock. t. C rig
gh ht
pyri by
Vo
– If engine control unit has been renewed, clear learnt values
co lksw
by
cted agen
and adapt engine control unit Vehicle diagnostic tester “Gui‐ Prote AG.
ded function”.
– Read event memory, rectify and then erase any faults ⇒ Ve‐
hicle diagnostic tester “Guided fault finding”.
– The readiness code must be generated if the event memory
has been cleared.
– Perform road test.
– Again read control unit event memory.
9.4 Removing and installing anti-theft en‐

gine control unit
Connect vehicle diagnostic tester and carry out “Renewing control
unit” in guided functions if engine control unit is to be renewed.
Removing

Polo 2010 ➤
– Open line guide -1- and raise catch -2-.

– Remove engine control unit from its bracket.
– Unscrew shear bolt -1- using pliers.

– Turn engine control unit -2- around and also unscrew second
shear bolt using pliers.
– Pull bracket -1- and protective housing -2- off engine control
unit -3- in -direction of arrow-.
– Release connectors from engine control unit and pull off.
Installing
– Connect connectors and lock.
– Push protective housing over engine control unit.
– Install protective housing bracket with new shear
agen
AG. Vbolts.
olkswagen AG
do w es n
olks ot g
– Evenly tighten shear bolts until bolt
d b heads shear off.
yV ua
ran
e
ris tee
utho or
a ac
ss
– Insert engine control unit into mounting bracket on bulkhead
ce
e
nl
pt
du
until it audibly engages in catches -1-.

an
itte
y li
erm
ab
– Press line into wiring guide -1- and seal.

ility
ot p
– If engine control unit has been renewed, clear learnt values

wit
, is n
h re
and adapt engine control unit Vehicle diagnostic tester “Gui‐

hole
ded function”.
spec
es, in part or in w
– Read event memory, rectify any faults and then clear event
t to the co
memory vehicle diagnostic tester “Guided fault finding”.

– The readiness code must be generated if the event memory
rrectness of i
has been cleared.

l purpos

– Again read control unit event memory.
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
243
co Vo
by lksw
cted 9. Engine control unit
agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Polo 2010 ➤ orise nte
h eo
3-cylinder common rail engine (1.2
aut l, EA189) - Edition 06.2019 ra
c
ss
ce
e
nl
pt
du
26 – Exhaust system
an
itte
y li
erm
ab
ility
ot p
wit
1 Exhaust pipes and silencers
, is n
h re
hole
spec
⇒ “1.1 Assembly overview - silencers”, page 244
es, in part or in w
t to the co
⇒ “1.2 Separating exhaust pipes from silencers”, page 244
⇒ “1.3 Aligning exhaust system free of stress”, page 246
rrectness of i
⇒ “1.4 Installation position of clamp”, page 247
l purpos
1.1 Assembly overview - silencers
nf
ercia
orm
1 - Exhaust pipe with rear si‐
m
atio
m
lencer
o
n in
or c
❑ Coupling point
thi
te
sd
a
❑ Marked by indentation
iv
o
r
rp
cu
on exhaust pipe.
o
m
f
en
ng
❑ As standard, exhaust
t.
yi Co
op
pipe and rear silencer
C py
t. rig
gh
are installed as a single
ht
pyri by
Vo
component. For repairs,
o
by c lksw
cted agen
exhaust pipe and silenc‐ Prote AG.
er are supplied with a
clamp separately If the
rear silencer is to be re‐
placed ⇒ page 244 .
2 - Retaining ring
❑ 23 Nm
3 - 20 Nm
4 - Tunnel cross-piece
1.2 Separating exhaust pipes from silencers

244 Rep. gr.26 - Exhaust system

Polo 2010 ➤
♦ Body saw e.g. -V.A.G 1523 A-
♦ Or
♦ Chain-type pipe cutter - VAS 6254-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
♦ Safety glasses
rm
ab
pe
ility
Procedure
ot
wit
, is n
h re
To separate exhaust pipe and silence, exhaust pipe is engineered

hole
spec
with a separation point marked by indentations.

es, in part or in w
t to the co
WARNING
rrectness of i
Wear protective goggles.

l purpos
– Cut through exhaust pipe at right angles using body saw at

nform
ercia
separating point -arrow 1-.

m
– Position double clamp -4- on side markings -arrow 2- and

com
tio
-arrow 3- when installing.

n 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.
1. Exhaust pipes and silencers 245

Polo 2010 ➤
– Install double clamp so that bolt ends do not protrude beyond

bottom of clamp.
• Bolt connections point to the right.
– Tighten bolt connections of double clamps evenly to 23 Nm.
Before tightening, align cold exhaust system free of stress
⇒ page 246 .
1.3 Aligning exhaust system free of stress

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
Condition aut
h
ra
ss c
• The exhaust system is cold.
ce
le
un
pt
an
d
Procedure
itte
y li
erm
ab
– Loosen threaded connections of the front clamp.

ility
ot p
wit
is n
– Align clamp on front exhaust pipe under consideration of di‐

h re
ole,
mension -a-. Dimension -a- = 5 mm

spec
t to the co
rrectness o
cial p
f inform
– Align clamp so that bolt ends do not protrude beyond lower

mer
atio
edge of clamp -arrow-.

om
n
c
– Tighten front threaded connection of clamp slightly.

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
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
– Then align exhaust system with mountings under considera‐

tion of dimension -a-. -Arrow- points in direction of travel.
Dimension -a- = 3 … 7 mm.
olkswagen AG
en AG. V
– Then evenly tighten securing nuts -arrows-
olks
wag of foremost clamp.
does
not
Specified torque: M8 = 25 Nm,eM10
d by V = 40 Nm. gu
ara
is nte
or
– Once clamp has been tightened,
au
th check set-up dimensions and eo
ra
correct if necessary. 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
1.4 Installation position of clamp
rrectness of i
Installation position of clamp
l purpos
– Position double clamp at distance -a- = 5 mm from marking on

front exhaust pipe.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
– Install double clamp so that bolt ends do not protrude beyond
rig ht
py by
o Vo
bottom of clamp. by c lksw
cted agen
Prote AG.
• Bolt connections point to the right.
– Tighten bolt connections of double clamps evenly to 23 Nm.
Before tightening, align cold exhaust system free of stress
⇒ page 246 .
1. Exhaust pipes and silencers 247

Polo 2010 ➤
2 Emission control
⇒ “2.1 Assembly overview - particulate filter”, page 248
⇒ “2.2 Removing and installing particulate filter”, page 253
2.1 Assembly overview - particulate filter

⇒ “2.1.1 Assembly overview - particulate filter (LHD)”, page 248
⇒ “2.1.2 Assembly overview - particulate filter (RHD)”,
page 251
2.1.1 Assembly overview - particulate filter

(LHD)
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork.
♦ If necessary, loosen double and single clamps and align si‐
lencers and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly loaded
⇒ page 246 .
♦ If particulate filter or pressure differential sender - G505- is
exchanged, pressure differential sender - G505- must be
adapted using vehicle diagnostic tester as a matter of priority:
Guided Functions; Adapting pressure differential sender -
G505- .
♦ Removing and installing exhaust manifold with turbocharger
⇒ page 171 .
♦ Do not bend the flexible joint in the frontn Aexhaust
G. Volkswpipe
agen Aby more
than 10° because it might otherwise
olks
wagbe
e
damaged. G do
es n
ot g
yV ua
♦ Renew seals, gaskets and db
iseself-locking nuts. ran
r tee
tho or
s au ac
s
ce
le
un
pt
an
d
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
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.

agen
AG. Volkswagen AG d
oes Polo 2010 ➤
ksw not
3-cylinder y Vcommon rail engine (1.2 l, EA189)
ol
gu - Edition 06.2019
db ara
rise nte
1 - Pressure differential sender tho eo
au ra
- G505- ss c
ce
le
un
pt
an
d
itte
Caution
y li
erm
ab
Risk of damage.
ility
ot p
The
♦ differential pressure
wit
is n
h re
sender - G505- is very
ole,
sensitive. Be careful not
spec
to knock against it when
t to the co
placing it down some‐
where with hoses con‐
nected.
rrectne
Only
♦ pull hoses off differ‐
ential pressure sender -
ss
G505- if it has to be
o
cial p
f
replaced.
inform
mer
atio
m
⇒ page 229
o
n
c
i
or
n thi
e
2 - 3 Nm
t
sd
iva
o
pr
c
3 - Control cable
um
r
fo
en
ng
t.
yi
4 - Clamps
Co
Cop py
t. rig
gh
ht
pyri by
Vo
sender 4 - G648-
co lksw
by
cted agen
Prote
❑ 45 Nm, observe warning
AG.
⇒ page 250
❑ When reinstalling tem‐
perature sender, grease
only the thread with
high-temperature paste
- G 052 112 A3- .
❑ To remove and install,
use wrench T10395/6 .
❑ Tighten with wrench
T10395/6 ⇒ page 250
6 - Lambda probe - G39-
7 - Heat shield
8 - 9 Nm
9 - Particulate filter
10 - Seal
❑ Renew
❑ Observe installation position
11 - Clip
❑ Renew after removal
❑ 7 Nm
12 - Nuts
❑ 25 Nm
13 - Bolts
❑ 25 Nm
14 - Bracket
❑ Bolted to engine bracket
2. Emission control 249

Polo 2010 ➤ AG. Volkswagen AG d
agen oes
Volksw- Edition 06.2019 not
g
y ua
db ran
rise tee
15 - Exhaust gas temperature sender 3 - G495-
tho or
au ac
❑ 45 Nm, observe warning ⇒ page s250s
ce
le
un
❑ Lubricate thread of sender using high-temperature paste - G 052 112 A3-
pt
an
d
itte
y li
❑ To remove and install, use T10395/6 - tool set- ⇒ page 250
rm
ab
pe
ility
16 - Bracket
ot
wit
, is n
h re
17 - 25 Nm
hole
spec
18 - Bracket
es, in part or in w
t to the co
❑ For pressure differential sender - G505- .
rrectness of i
l purpos
WARNING
nform
ercia
case.
m
a
com
t
Extending the torque wrench - V.A.G 1331- with the spanner
ion in
r
te o
thi
be achieved.
s
iva
do
r
rp
cum
fo
en
ng
Tightening exhaust gas temperature sender G495

t.
yi Co
Cop py
t. rig
– Lubricate thread of sender using high-temperature paste - G yri
gh by
ht
052 112 A3- . cop Vo
by lksw
cted agen
Prote
– Screw exhaust temperature sender 1 - G495- in by hand.
AG.
– Then tighten to specified torque using torque wrench - V.A.G

1331- together with wrench from tool set - T10395/6- . Observe
warning text ⇒ page 250 .
Tightening exhaust gas temperature sender G648

– Lubricate thread of sender using high-temperature paste - G
052 112 A3- .
– Screw exhaust temperature sender in by hand.

Polo 2010 ➤
2.1.2 Assembly overview - particulate filter

(RHD)
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork.
♦ If necessary, loosen double and single clamps and align si‐
lencers and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly loaded
⇒ page 246 .
♦ If catalytic converter with non-engine mounted particulate filter
or pressure differential sender - G505- is exchanged, pressure
differential sender - G505- must be adapted using vehicle di‐
agnostic tester : Guided functions; Adapting pressure differ‐
ential sender - G505- .
♦ Removing and installing exhaust manifold with turbocharger
⇒ page 171 .
♦ Do not bend the flexible joint in the front exhaust pipe by more
than 10° because it might otherwise be damaged.
en AG. V
olkswagen AG
ag does
lksw
♦ Renew seals, gaskets and self-locking
by nuts.
not
Vo gu
ara
ed nte
ris
tho eo
au ra
c
ss
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
co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
1 - Lambda probe - G39-

⇒ page 232
2 - Seal
❑ Renew
❑ Observe installation po‐
sition
3 - Clip
❑ Renew after removal
❑ 7 Nm
sender 4 - G648-
. Volkswagen AG
❑ 45 Nm, observe warning kswagen AG does
not
l
⇒ page 253 y Vo gu
edb ara
❑ Lubricate thread of horis nte
eo
sender using high-tem‐
s aut ra
c
perature pastes - G 052
ce
e
112 A3-
nl
pt
du
an
itte
❑ Tightening
y li
erm
ab
⇒ page 253 .
ility
ot p
wit
, is n
h re
sender 3 - G495-
hole
spec
❑ 45 Nm, observe warning
es, in part or in w
⇒ page 253
t to the co
❑ Lubricate thread of
sender using high-tem‐ rrectness of i
perature paste - G 052
112 A3-
l purpos
❑ Tightening
⇒ page 253 .
nform
ercia
6 - Pressure differential sender

m
- G505- bracket
at
om
ion
c
7 - Clamps
in t
or
his
ate
8 - Control lines
do
priv
cum
or
9 - Pressure differential sender - G505-

f
en
ng
t.
yi Co
❑ Removing and installing ⇒ page 230 t. Cop py
rig
gh ht
yri
10 - 4.5 Nm p by
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11 - 25 Nm Prote AG.
12 - 25 Nm
13 - Bracket
❑ Bolted to cylinder head
14 - Catalytic converter with non-engine-mounted particulate filter

Polo 2010 ➤
WARNING

case.
Extending the torque wrench - V.A.G 1331- with the spanner
be achieved. gen AG
. Volkswagen AG
d a oes
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Tightening exhaust gas
tho temperature sender G495 eo
au ra
c
ss
ce
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nl
pt
Note
du
an
itte
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erm
ab
Figure shows exhaust gas temperature sender 3 - G495- (before
ility
ot p
particulate filter). Tightening exhaust gas temperature sender 4 -
wit
, is n
G648- (after particulate filter) is carried out in same manner.
h re
hole
spec
es, in part or in w
– Lubricate thread of sender using high-temperature paste - G
t to the co
052 112 A3- .
– Screw exhaust temperature sender in by hand.
rrectness of i
l purpos
nf
ercia
o
2.2 Removing and installing particulate filter
rm
m
atio
m
⇒ “2.2.1 Removing and installing particulate filter (LHD)”,

o
n in
or c
page 253
thi
te
sd
iva
⇒ “2.2.2 Removing and installing particulate filter (RHD)”,

o
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rp
cu
page 259
o
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f
en
ng
t.
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2.2.1 Removing and installing particulate filter Cop py
t. rig
gh ht
(LHD) pyri by
Vo
o
by c lksw
cted agen
Prote
AG.

Polo 2010 ➤
♦ Tensioning strap - T00038-
♦ Engine and gearbox jack - VAG 1383A-

AG. Volkswagen AG d
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ce
le
un
pt
an
d
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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 thi
te
sd
iva
o
pr
cum
r
fo
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t.
yi Co
Removing Cop py
ht. rig
rig ht
– Turn wheels to straight-ahead position. py by
co Vo
by lksw
cted agen
– Loosen universal joint ⇒ Running gear, axles, steering; Rep. Prote AG.
gr. 48 ; Removing and installing steering column .

Polo 2010 ➤
– To do this, remove cover -2- and unscrew plastic nuts -1-.
AG. Volkswagen AG d
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d b ara
rise nte
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– Unscrew bolt -1- from universal joint and pull universal joint off
ce
le
un
pt
in direction of arrow.
an
d
itte
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– Remove engine cover panel ⇒ page 24 . erm
ab
ility
ot p
– Detach following connectors and make lines accessible.
wit
is n
h re
ole,
spec
t to the co
rrectness o
♦ -1- exhaust temperature sender 1 - G235- connector
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
♦ -4- connector for Lambda probe - G39-
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.
– Separate connector to pressure differential sender - G505-

-2-.
– Pull lines out of retainers on engine and remove heat shield
from particulate filter; if necessary remove cable ties.
– Unscrew Lambda probe - G39- using Lambda probe open ring
spanner set - 3337- ⇒ Item 6 (page 249) .
– Unscrew exhaust temperature sender 3 -G495- using wrench
- T10395/6- ⇒ Item 15 (page 250) .

Polo 2010 ➤
– Remove securing clamp -1- between particulate filter and tur‐

bocharger.
– Unscrew bolts -2-.
– Undo bolt -3- and swivel bracket towards the front.
Rep. gr. 50 .
AG. Volkswagen AG d
agen oes
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un
pt
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rm
ab
pe
ility
ot
wit
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– Open bracket -B- of hydraulic lines -A-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Remove pendulum support -arrows-.

s
iva
do
r
rp
Do not loosen item -1-.

um
fo
en
ng
t.
yi
– Place engine and gearbox jack engine and gearbox jack - VAG
Co
op py
1383A- below subframe.
. C rig
ht ht
rig by
py Vo
– Unscrew subframe bolts individually and replace with locking
co lksw
by
cted agen
pins. ⇒ Running gear, axles, steering; Rep. gr. 40 Prote AG.
– Loosen anti-roll bar at top of coupling rod ⇒ Running gear,

axles, steering; Rep. gr. 40 .
– Carefully lower subframe with engine and gearbox jack - VAG
1383A- ; steering remains on subframe.
The hydraulic steering circuit does not need to be opened for this
⇒ Running gear, axles, steering; Rep. gr. 40 .

Polo 2010 ➤
– Lower on the right side max. 10 cm -movement arrow-.

– To prevent the hydraulic lines being overstretched, lower on
the left side max. 7 cm.
Note
Secure subframe with steering rack to underbody of vehicle using

tensioning strap - T00038- , so that the hydraulic lines are not
stressed.
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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– Unscrew bolts -1- and remove heat shield for right drive shaft. s
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
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-

from exhaust pipe downstream of particulate filter. nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew bolts -1- and then nuts -2-.

– Remove particulate filter bracket.

Polo 2010 ➤
Note
♦ Do not bend the flexible joint in the front exhaust pipe by more
♦ If the particulate filter is to be re-installed, a transportation
sleeve -arrow- must always be secured to the flexible joint in
front exhaust pipe.

– Detach front exhaust pipe from mounting brackets.
Carefully remove front exhaust pipe with particulate filter together
with pressure differential sender - G505- above lowered sub‐
frame.
– Remove particulate filter by turning 180° around its own axis.

Installing
Note
♦ Renew seals, self-locking nuts and clip for particulate

wage
n AGfilter.
. Volkswagen AG
doe
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Vol t gu
♦ Renew defective cable ties; install in the
ed same location when
by ara
assembling. ho
ris nte
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ce
le
un
pt
note the following:

an
d
itte
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erm
ab
Tightening sequence
ility
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wit
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1) Position particulate filter on turbo charger and loosely at‐

h re
ole,
tach clip -1-

spec
2) Screw bolts and nuts -2…5- in by hand

t to the co
• It must still be possible to move particulate filter and

bracket
rrectne
3) Tighten clamp -1- ⇒ page 248 .

4) Tighten bolts and nuts -2, 3, 5- ⇒ page 248 .
ss o
5) Bolts -4- ⇒ page 248 .

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2010 ➤
Specified torque for bolts for drive shaft heat shield -1- ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Suspension ,
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe with steering rack .
– Align exhaust system free of stress ⇒ page 246 .
2.2.2 Removing and installing particulate filter

(RHD) . Volkswage AG n AG d
w agen oes
Special tools and workshop equipment
yV
olks required not
gu
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ed
♦ Torque wrench - V.A.G
ho
ris 1331- nte
eo
t
au ra
c
ss
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
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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.
♦ Tensioning strap - T00038-

Polo 2010 ➤
♦ Engine and gearbox jack - VAG 1383A-
wage es n
♦ Tool set - T10395- yV
olks ot g
d b ua
ran
ir se tee
tho
u or
a ac
ss
ce
e
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
Removing
rrectness of i
– Turn wheels to straight-ahead position.
l purpos
– Loosen universal joint ⇒ Running gear, axles, steering; Rep.

gr. 48 ; Removing and installing steering column .
nf
ercia
orm
– To do this, remove cover -2- and unscrew plastic nuts -1-.
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
co lksw
by
cted agen
Prote AG.
– Unscrew bolt -1- from universal joint and pull universal joint off
in direction of arrow.

Polo 2010 ➤
– Disconnect connectors -1- for exhaust temperature sender 1

- G235- .
– Disconnect connectors -2- for Lambda probe - G39- .
– Unscrew Lambda probe - G39- -1- using Lambda probe open

ring spanner set - 3337- .
– Remove securing clamp -2- between catalytic converter with
non-engine-mounted particulate filter and turbocharger.
Rep. gr. 50 ; Body - front; Assembly overview - sound insu‐
lation.
wage es n
– Separate connector -2- to pressure
Vol
ks differential sender - ot g
by ua
G505- . ise
d ran
tee
r
tho
– Unscrew pressure differential
sa
u sender - G505- -1-. or
ac
s
ce
– Separate connector -3- to pressure differential sender -

le
un
pt
G505- .
an
d
itte
y li
erm
ab
– Pull lines from retainers, remove cable ties if necessary.

ility
ot p
wit
Do not bend the flexible joint in the front exhaust pipe by more
is n
h re

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
If the catalytic converter with non-engine-mounted particulate fil‐

o
n
c
i
or
ter is to be re-installed, a transportation sleeve -arrow- must

thi
e
always be secured to the flexible joint in front exhaust pipe.

t
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.

Polo 2010 ➤
– Open bracket -B- of hydraulic lines -A-.
olkswagen AG
en AG. V
– Remove pendulum supportolk-arrows-.
swa
g does
not
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ara
d
Do not loosen item -1-.orise nte
h eo
ut ra
– Place engine andss a gearbox jack engine and gearbox jack - VAG c
1383A- below subframe.
ce
e
nl
pt
du
an
– Unscrew bolts from subframe and renew them by locating pins
itte
y li
erm
ab
ility
ot p
– Loosen anti-roll bar at top of coupling rod ⇒ Running gear,
wit
, is n
axles, steering; Rep. gr. 40 .
h re
hole
spec
– Lower subframe with engine and gearbox jack - VAG 1383A- ;
es, in part or in w
steering remains on subframe.
t to the co
The hydraulic steering circuit does not need to be opened for this
rrectness of i
– Lower on the right side max. 10 cm -movement arrow-.
l purpos
– To prevent the hydraulic lines being overstretched, lower on

nf
ercia
the left side max. 7 cm.

orm
m
atio
om
n in
Note
or c
thi
te
sd
iva
Secure subframe with steering rack to underside of vehicle with

o
r
rp
cu
tensioning strap - T00038- .

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2010 ➤
– Remove securing bolts -1- and remove cover from cylinder

block for right drive shaft.
– Unscrew exhaust gas temperature sender 3 - G495- using -
T10395/6- ⇒ Item 5 (page 252) from front exhaust pipe.
– Remove right underbody panelling ⇒ General body repairs,

exterior; Rep. gr. 66 .
– Remove cover from connector for exhaust temperature sender

4 - G648- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
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ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
– Disconnect connector for exhaust temperature sender 4 -

ole,
G648- .
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
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
– Unscrew bolts -1- and then nuts -2-.

– Remove particulate filter bracket.
Note
Do not bend the flexible joint in the front exhaust pipe by more
If the particulate filter is to be re-installed, a transportation sleeve

-arrow- must always be secured to the flexible joint in front ex‐
haust pipe. olkswage es n
o
yV t gu
db ara
ir se 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
es, in part or in w
t to the co
– Detach front exhaust pipe from mounting brackets.
rrectness of i
Carefully remove front exhaust pipe with particulate filter together
l purpos
with pressure differential sender - G505- above lowered sub‐

frame.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
– Remove catalytic converter with non-engine-mounted partic‐ op
yi Co
ulate filter by turning 180° around its own axis.
C py
t. rig
gh ht
yri by
Installing cop Vo
by lksw
cted agen
Prote AG.
Note
♦ Renew seals, self-locking nuts and clamp for catalytic con‐

verter.
♦ Reinstall all cable ties in the same locations when installing.

note the following:
– Seal ⇒ Item 2 (page 252) . Renew.

AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Polo 2010 ➤
e
horis 3-cylinder common railnengine
tee (1.2 l, EA189) - Edition 06.2019
aut or
ac
ss
Tightening sequence
ce
e
nl
pt
du
an
♦ 1) Mounting of catalytic converter with particulate filter instal‐ itte
y li
led away from engine (RHD vehicles) -1- on turbocharger,
erm
ab
clamp -2- (positioning only)
ility
ot p
wit
, is n
♦ 2. Bracket on cylinder block with nuts -4- + -6- (for positioning
h re
only). Bolts -5- + -7- also (for positioning)
hole
spec
es, in part or in w
♦ 3. Tighten clamp -2- to turbocharger 7 Nm
t to the co
♦ 4) Tighten left nut -6- to crankcase 25 Nm
♦ 5) Tighten right nut -4- to crankcase 25 Nm
rrectness of i
♦ 6) Tighten left bolt -7- of bracket to diesel particulate filter
l purpos
25 Nm
♦ 7) Tighten right bolt -5- of bracket to diesel particulate filter
nform
ercia
25 Nm
m
at
om
ion
c
in t
or
his
ate
do
riv
Specified torque for bolts for drive shaft heat shield -1- ⇒ Running
p
cum
or
gear, axles, steering; Rep. gr. 40 ; Suspension ,

f
en
ng
t.
yi Co
Specified torque for exhaust temperature sender/catalytic con‐ . Cop py
verter with non-engine-mounted particulate filter (right-hand drive
ht rig
rig ht
by
vehicles) ⇒ page 251 copy Vo
by lksw
cted agen
Prote
– Align exhaust system free of stress ⇒ page 246 .
AG.

Polo 2010 ➤
3-cylinder common rail engine
gen AG
. Volks(1.2
wagel,n A
EA189)
Gd - Edition 06.2019
wa oes
olks not
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ara
ed
3 Exhaust gas recirculation
ris nte
tho eo
au ra
c
ss
⇒ “3.1 Assembly overview - exhaust gas recirculation”,
ce
e
nl
page 266
pt
du
an
itte
y li
⇒ “3.2 Removing and installing exhaust gas recirculation cooler”,
erm
ab
page 267
ility
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wit
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⇒ “3.3 Checking changeover for exhaust gas recirculation cooler”,
h re
hole
page 270
spec
es, in part or in w
⇒ “3.4 Checking exhaust gas recirculation cooler for leaks”, page
t to the co
271
⇒ “3.5 Cleaning exhaust gas recirculation system”, page 275
rrectness of i
3.1 Assembly overview - exhaust gas recirculation
l purpos
1 - Bolt
nform
ercia
❑ 9 Nm
m
at
om
io
2 - Connecting pipe
n
c
in t
or
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ate
do
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Caution
p
cum
for
en
g
Ensure that flexible joint

n
t.
yi Co
of connecting pipe is not Cop py
.
bent and stretched.
t rig
gh ht
yri by
There is a danger of cop Vo
by lksw
cracking. cted agen
Prote AG.
3 - Bolt
❑ 9 Nm
4 - Seal
❑ Renew
5 - Vacuum line
❑ Do not alter shape.
❑ Vacuum hose connec‐
tion diagram
⇒ page 190
6 - Bolt
❑ 9 Nm
7 - Seal
❑ Renew
8 - Connecting pipe
Caution
of connecting pipe is not
bent and stretched.
There is a danger of
cracking.
9 - Bolt
❑ 9 Nm
10 - Clip
❑ Renew

Polo 2010 ➤
❑ 4 Nm
11 - Exhaust gas recirculation cooler
❑ With integrated exhaust gas recirculation actuator - V338- with exhaust gas recirculation potentiometer
- G212- .
❑ Checking changeover ⇒ page g270 . . Volkswagen AG d
AG
a en oes
ksw
❑ Removing and installing by
V⇒ page 267
ol not
gu
ara
ed
❑ Checking exhausthogasris recirculation cooler for leaks ⇒ page 271 nte
e
t or
au ac
12 - Bolt ss
ce
le
❑ 9 Nm
un
pt
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d
itte
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13 - Seal
rm
ab
pe
ility
❑ Renew
ot
wit
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14 - Seal
h re
hole
spec
❑ Renew
es, in part or in w
t to the co
15 - Connecting pipe
Caution
rrectness of i
l purpos
of connecting pipe is not

bent and stretched.
There is a danger of
nform
ercia
cracking.
m
a
com
tion in
r
16 - Nut
te o
thi
s
iva
❑ Renew do
r
rp
cum
❑ 22 Nm
fo
en
ng
t.
yi Co
17 - Bolt Cop py
t. rig
gh
❑ 9 Nm
ht
pyri by
Vo
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by c lksw
cted
18 - Seal
agen
Prote AG.
❑ Renew
3.2 Removing and installing exhaust gas re‐

circulation cooler
3. Exhaust gas recirculation 267

Polo 2010 ➤
♦ Hose clamps up to 25 mm - 3094-
♦ Hose clip pliers -V.A.G 1921 - W00- 0464-
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
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
268
cted agen
Prote
Rep. gr.26 - Exhaust system
AG.
Polo 2010 ➤
Removing
– Remove air filter housing with air mass meter - G70- and suc‐
tion hose ⇒ page 235 .
– Unclip vacuum line -2- from bracket -arrow- and push it down‐
wards.
– Remove front right wheel. AG. Volkswagen AG d
agen oes
olksw not
– Remove front right wheel housing liner ⇒ d General
by
V body re‐ gu
ara
pairs ⇒ Rep. gr. 66 . orise nte
eo
h
ut ra
– Remove noise insulation ⇒ Rep. gr.
ss a 50 . c
ce
le
– Remove particulate filter ⇒ page 253 .

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Remove connection pipe -2- leading to cooler for exhaust gas
h re
ole,
recirculation.
spec
– Unscrew connecting pipe -1- only at exhaust gas recirculation
t to the co
cooler -arrows-.
– Catch leaking engine oil with used oil collection and extraction rrectne
unit - V.A.G 1782- .
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
o
by c lksw
cted agen
Prote AG.

Polo 2010 ➤
– Undo union nut -1- with 17 mm open-end ring spanner .

– Unscrew bolts -2, 3, 5 and 6-.
– Detach oil supply line -7-.
– Pull turbocharger support -4- off the oil return line -8-.
– Remove heat shielding covering at vacuum unit.
– Pull vacuum line off vacuum unit.
– Pull connector off exhaust gas recirculation actuator - V338- .
– Pinch off coolant hoses leading to exhaust gas recirculation
cooler using hose clamps, up to 25 mm - 3094- .
– Collect escaping coolant with drip tray for workshop hoists -
VAS 6208- .
– Pull coolant hoses off exhaust gas recirculation cooler.
– Unscrew bolts and remove exhaust gas recirculation cooler.
Installing
Specified torques ⇒ page 266n A. G. Volkswagen A
ge G do
swa es
• Installation is carried
by
Vol out in the reverse order; note
k not
guthe follow‐
ara
ing: ris
ed
nte
tho eo
s au ra
c
s
Note
ce
le
un
pt
an
d
itte
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♦ Renew gaskets, seals and self-locking nuts ⇒ Electronic parts

rm
ab
catalogue .
pe
ility
ot
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♦ Secure all hose connections with the hose clips corresponding

h re
to original equipment ⇒ Electronic Parts Catalogue .

hole
spec
es, in part or in w
♦ If particulate filter or pressure differential sender - G505- is

t to the co
renewed, pressure differential sender - G505- must always be

adapted using vehicle diagnostic tester : Guided functions;
Adapting pressure differential sender - G505- .
rrectness of i
l purpos

– Checking engine oil level ⇒ page 125 .
nform
ercia
3.3 Checking changeover for exhaust gas

m
a
com
tion in
recirculation cooler
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♦ Hand operated vacuum pump - VAS 6213-

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Prote AG.

Polo 2010 ➤
Procedure
– Remove noise insulation ⇒ General body repairs, exterior ⇒
Rep. gr. 50 .
– Unscrew bolts -1- and remove cover for right drive shaft.
– Remove heat shield sleeve.
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spec
Note
t to the co
In order to create a “vacuum”, move slide ring -1- on hand vacuum
pump - VAS 6213- to position -A-.
rrectness o
cial p
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mer
atio
om
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c
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sd
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– Pull vacuum hose off vacuum unit and connect hand vacuum
i
o
pr
cum
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pump - VAS 6213- instead.

fo
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ng
t.
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– Use hand vacuum pump to generate vacuum. Cop py
t. rig
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• The linkage of the exhaust gas recirculation cooler change‐ p by
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over must move -arrows-.
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Prote AG.
If linkage does not move or only moves in jerks:
♦ Vacuum actuator is defective.
♦ Changeover flap for exhaust gas recirculation is tight.
– Replace exhaust gas recirculation cooler ⇒ page 267 .
Note
Reinstall heat insulation sleeve in the same location when as‐

sembling.
3.4 Checking exhaust gas recirculation

cooler for leaks
Note
A pressure of 0.8 bar is applied to the exhaust side of the exhaust

gas recirculation cooler. While so, the pressure in the cooling
system is measured.

Polo 2010 ➤
♦ Charge air system tester - V.A.G 1687-
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♦ Adapter - V.A.G 1687/11-
wit
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h re
♦ Adapter - V.A.G 1687/15- for exhaust pipes of 60 mm and
hole
spec
65 mm in diameter
es, in part or in w
t to the co
♦ Adapter - V.A.G 1687/16- for exhaust pipes of 55 mm in di‐
ameter
rrectness of i
♦ Y-branch - VAS 691 005/1-
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♦ Test adapter - VAS 691 005/5- cted agen
Prote AG.
♦ Turbocharger tester - V.A.G 1397A-
Test specification:
• Coolant temperature must be at least 40 °C.

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Polo 2010 ➤
h
s aut
3-cylinder common r a rail
c engine (1.2 l, EA189) - Edition 06.2019
s
ce
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nl
Connecting turbocharger tester - V.A.G 1397A- :
pt
du
an
itte
y li
– Screw adapter - VAS 691 005/5- onto coolant expansion tank.
erm
ab
ility
ot p
– Fit Y-branch - VAS 691 005/1- onto adapter - VAS 691 005/5- .
wit
, is n
h re
– Close valve -1- for connection »C«, and open valve -2- for
hole
spec
connection »A«.
es, in part or in w
t to the co
– Connect hose from connection »A« of Y-branch to connection
»II« of turbocharger tester - V.A.G 1397A- .
– Set turbocharger tester - V.A.G 1397A- to switch position
rrectness of i
»II« (gauge pressure measurement), and switch it on. The
l purpos
setting »II« must be visible.
nform
mercia
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c
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or
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ate
do
priv
cum
for
en
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Connecting charge air system tester - V.A.G 1687- :

t.
yi Co
Cop py
t. rig
– If fitted, unclip wire to exhaust flap control unit -1-.
opyri
gh by
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– Loosen clamp -2- on exhaust pipe, and push it towards rear.
by
cted agen
Prote AG.
– On vehicles without a tunnel cross-piece, use a tensioning

strap -2- to tie up exhaust pipe -1-.
– Connect adapter - V.A.G 1687/11- with hose -A- to exhaust

pipe (engine side). Secure hose with hose clips.
Use hose -A- for exhaust pipes of 55 mm in diameter = hose
- V.A.G 1687/16- .
Use hose -A- for exhaust pipes of 60 mm and 65 mm in diam‐
eter = hose - V.A.G 1687/15- .
– Connect charge air system tester - V.A.G 1687- to adapter -
V.A.G 1687/11- .

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Polo 2010 ➤ by Vol
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3-cylinder common rail engine o(1.2ris l, EA189) - Edition 06.2019
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Prepare charge air system tester - V.A.G
s 1687- as follows:
ce
le
un
pt
– Completely unscrew pressure regulating valve -2-, close
an
d
itte
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valves -3- and -4-.
rm
ab
pe
ility
• To turn pressure regulating valve -2-, rotary knob must be
ot
wit
, is n
pulled upwards.
h re
hole
– Apply compressed air -1- to charge air system tester - V.A.G
spec
es, in part or in w
1687- .
t to the co
rrectness of i
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– Open valve -3-.
nform
ercia
– Adjust pressure to 0.8 bar with pressure control valve -2-.

m
a
– Open valve -4- and wait until test circuit is full. If necessary,
com
tio
adjust pressure to 0.8 bar.
n in
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te o
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Note
um
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t.
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A small amount of air escapes through the valves and enters the Cop py
t. rig
engine. Therefore a holding pressure test is not possible. gh ht
pyri by
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Prote AG.
Reading turbocharger tester - V.A.G 1397A- :

• Observe turbocharger tester for approx. 5 minutes.
• The pressure indicated on the turbocharger tester must not
exceed 0.025 bar.
– If the pressure on the turbocharger tester rises above
0.025 bar, compressed air is leaking from the exhaust side into
the cooling system. The exhaust gas recirculation cooler has
a leak. Renew exhaust gas recirculation cooler.
Note
When coolant cools down, a vacuum may build up. The vacuum
is indicated by a »minus« symbol on the turbocharger tester .
Values preceded by a »minus« symbol do not indicate a leak! If
you are uncertain, equalise the pressure in the cooling system
and repeat the test.
Cleaning Y-branch - VAS 691 005/1- :
Note
After the leakage test has been completed, the Y-branch - VAS
691 005/1- must be cleaned and any moisture which may have
entered must be removed.
– Insert cleaning nozzle -D- into hose on connection -A- of Y

junction .
– Fit adapter - VAS 691 005/5- onto hose of connection -B-.
– Fit compressed air hose to connection -C-.
– Open shut-off taps, and blow out hose for approx. 15 seconds.

Polo 2010 ➤
3.5 Cleaning exhaust gas recirculation sys‐

tem
Note AG. Volkswagen AG d

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♦ The exhaust gas recirculation module comprisesisethe exhaust
d ara
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gas recirculation cooler and the exhaust gas urecirculation
thor eo
valve - N18- integrated in it. ss a ra
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♦ It is only possible to perform the cleaning process on exhaust
nl
pt
du
an
gas recirculation modules as of part number - 03P 131 512
itte
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E- .
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♦ Before starting work, check the part number -1- using an en‐ ot p
wit
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doscope (e.g. VAS 6748A/1).
h re
hole
spec
♦ To do this, insert endoscope between cylinder head and ex‐
es, in part or in w
haust manifold through opening in exhaust manifold -arrow-,
t to the co
and guide it slightly towards right (seen in direction of travel).
♦ For reasons of clarity, the particulate filter is not shown in the
rrectness of i
lower section of the figure.
l purpos
Explanation
With some extreme modes of driving (e.g. short journeys) there
nform
ercia
is a risk of varnish and coke deposits building up on the inside of

m
at
the exhaust gas recirculation cooler. In this case, the exhaust
om
io
emissions warning lamp lights up in the dash panel insert, and
n
c
in t
or
the following codes are stored in the event memory:
his
ate
do
riv
♦ P0401 “EGR system flow rate too low”

p
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for
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♦ P046C “Exhaust gas recirculation sender 1 implausible signal”

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♦ P0405 “Exhaust gas recirculation sender signal too weak”
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In most cases, coking or carbonisation can be eliminated by per‐ by c lksw
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forming the flushing and cleaning procedure described as follows Prote AG.
⇒ page 275 .
3.5.1 Initiating cleaning of exhaust gas recir‐

culation system
♦ Cooler flushing system for exhaust gas recirculation - VAS 542
007-

– Open and remove clamp -1-.

Polo 2010 ➤
– Unscrew bolts -2-, remove connecting pipe -3- to intake mani‐

fold.
– Unscrew bolts -arrows-, pull out pipe union -1- from intake
manifold.
– Fit adapter - VAS 542 007/7- -1- on opening of cylinder head.
– Screw in original bolts -arrows- of connecting pipe and tighten

by hand. Ensure that the seal on the adapter is not crimped.
AG. Volkswagen AG d
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spec
es, in part or in w
– Unscrew nuts -4- and bolts -5-, remove bracket.

t to the co
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nform
mercia
at
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ion
c
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or
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ate
do
priv
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Cop py
t. rig
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Prote AG.

Polo 2010 ➤
– Open clamp -1- and remove, push particulate filter to one side.
– Unscrew bolts -1- and nuts -2-.
– Remove connecting pipe -3- between exhaust manifold and
exhaust gas recirculation cooler.
– Release and pull off electrical connector -4- on exhaust gas

recirculation valve - N18- .
Note
wage e
For reasons of clarity, the Voturbocharger
lks support is shown
s no
t gremoved
by
in the figure. It is not
isednecessary to remove the support. ua
ran
t
r ee
ho
aut or
ac
ss
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un
pt
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d
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rm
ab
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ility
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– Fit adapter - VAS 542 007/7- -1- on opening of exhaust gas

wit
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recirculation cooler.
h re
hole
spec
– Screw in original bolts -arrows- of connecting pipe and tighten

es, in part or in w
by hand. Ensure that the seal on the adapter is not crimped.

t to the co
– Join supply hose - VAS 542 007/2-2- of cleaning equipment to

adapter on exhaust gas recirculation cooler.
rrectness of i
– Join return hose - VAS 542 007/2-3- of cleaning equipment to

l purpos
adapter on cylinder head.

– Connect battery charger to vehicle battery.
nform
ercia
– Connect terminal clamps of valve positioner - VAS 542 007/6-

m
to vehicle battery.
com
tion in
r
– Connect terminal clamps of pump - VAS 542 007/3- to vehicle

te o
thi
battery.
s
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Prepare cooler flushing system for exhaust gas recirculation -

fo
en
g
VAS 542 007-

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t.
yi Co
Cop py
t.
– Fill canister - VAS 542 007/1- with 9 litres of warm (approx.
rig
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40°C - 50°C) tap water. cop Vo
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Prote
– Pour 1 litre of cleaning solution - D 600 200 A2- into the can‐
AG.
ister.
– Join suction hose - VAS 542 007/2-1- of pump to connection
-1- on canister lid.

Polo 2010 ➤
– Insert open end of return hose - VAS 542 007/2-3- into opening
-arrow- of canister lid up to approx. half canister height.
– Fit connector of valve adjuster - VAS 542 007/6- on exhaust
gas recirculation valve - N18- .
– Switch on valve adjuster - VAS 542 007/6- to open exhaust
gas recirculation valve.
Note
♦ Ensure that the tap of the relief valve on the supply hose is
closed.
♦ If activation of the exhaust gas recirculation valve via the valve
adjuster - VAS 542 007/6- including approx. 1.6 bar pressure
from the pump - VAS 542 007/3- is not sufficient to open the
exhaust gas recirculation valve, the pump switches off after a
brief period. In this case, the exhaust gas recirculation valve
has a mechanical defect and the exhaust gas recirculation
valve must be renewed. Before disconnecting the supply
hose, carefully open the relief valve tap to release the pressure
and collect the escaping cleaning solution. swa
gen AG
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– While the cleaning process is running, cleanorthe
ise connecting nte
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pipes ⇒ page 280 . auth ra
ss c
– Actuate pump - VAS 542 007/3- as follows:
ce
e
nl
pt
du
an
itte
Pump - VAS 542 Time Scenario
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erm
ab
007/3-
ility
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Switch on 25 min. Clean
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Switch off 10 min. Period for cleaning
hole
spec
solution to take ef‐
es, in part or in w
fect
t to the co
Switch on 25 min. Clean
Switch off --- End of cleaning
rrectness of i
process
l purpos
– Disconnect intake hose from canister, switch on pump until no

more cleaning solution is delivered (system is emptied in doing
nf
ercia
so).
orm
m
– Pull out return hose from canister, pay attention to escaping

atio
om
cleaning solution.
n in
or c
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– Empty canister, observe country-specific disposal regulations.

t
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– Fill canister with 10 litres of warm (approx. 40°C - 50°C) tap

o
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f
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water.
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op py
– Join suction hose - VAS 542 007/2-1- of pump to connection
t. C rig
gh ht
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on canister lid. p by
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– Feed return hose - VAS 542 007/2-3- into a suitable container Prote AG.
(with a capacity of at least 12 litres) and secure in place.
– Switch on pump - VAS 542 007/3- until entire contents of can‐
ister have flown through exhaust gas recirculation system.
– Release and pull off supply hose - VAS 542 007/2-2- from
adapter on exhaust gas recirculation cooler.
– Connect compressed air adapter - VAS 542 007/5- to adapter
on exhaust gas recirculation cooler.
– Insert open end of return hose - VAS 542 007/2-3- into opening
-arrow- of canister lid up to approx. half canister height.

AG. Volkswagen AG d
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d b ara
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3-cylinder thorcommon rail engine (1.2 l, EA189) - Edition e06.2019
or
au ac
ss
– Suction hose - VAS 542 007/2-1- of pump must be joined to
ce
e
nl
pt
connection -1- on canister lid.
du
an
itte
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– Fit compressed air line to compressed air adapter - VAS 542
erm
ab
ility
007/5- , and completely blow out remaining water from ex‐
ot p
wit
haust gas recirculation system.
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
The water must be removed from the exhaust gas recirculation
system without trace. Otherwise there may be problems with
rrectness of i
starting the engine.
l purpos
– Release and pull off compressed air adapter - VAS 542
nform
ercia
007/5- .
m
– Detach adapter from exhaust gas recirculation cooler.
at
om
ion
c
– Pull off connector of valve adjuster - VAS 542 007/6- from ex‐
in t
or
his
e
haust gas recirculation valve - N18- , fit original connector.

at
do
priv
c
– Check effectiveness of cleaning with ⇒ Vehicle diagnostic
um
for
tester.
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ng
t.
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♦ Drive t. C rig
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♦ 01 - Self-diagnosis compatible systems
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Prote AG.
♦ 01 - Diesel direct injection and glow plug system
EDC 17
♦ 01 - Engine electronics functions

♦ 01 - Checking exhaust gas recirculation valve 1 -
GX5- after cleaning in accordance with workshop
manual
If the result of the test is »Not OK«, the exhaust gas recirculation
cooler with integrated exhaust gas recirculation valve - N18- must
be renewed ⇒ page 267 .
After cleaning has been successfully conducted:
– Install connecting pipe with new seals and new nuts
⇒ page 266 .
– Bring particulate filter to installation position with new gasket
and new clamp, and secure it ⇒ page 258 .
– Fit noise insulation ⇒ Rep. gr. 50 .
– Release and pull off return hose on cylinder head adapter.
– Insert pipe union -1- in intake manifold. Note: opening of union
points towards throttle valve module.
– Screw in bolts -arrows- and tighten to 9 Nm.

Polo 2010 ➤
– Remove adapter on cylinder head, install connecting pipe with

new seal ⇒ page 266 .
– Fit engine cover panel ⇒ page 24 .
– Therefore, read event memory and erase entries if necessary.
3.5.2 Cleaning connecting pipes and pipe un‐

ion
♦ Ultrasonic cleaning device - VAS 6418-
– Close drain tap -arrow- of ultrasonic cleaning unit - VAS 6418-
at right-hand side of housing.
Note
The ultrasonic bath can be heated up faster by using warm tap

water.
– Fill ultrasonic cleaning device - VAS 6418- with 1800 ml of tap

water and 200 ml of cleaner - D 600 200 A2- .
– Insert connecting pipes and pipe union. Adjust position of con‐
necting pipes in bath where necessary.
– Switch on cleaning unit by pressing on/off button
olkswage-C-.
en AG. V
ag
n AG does
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– Turn rotary temperature switch
rise -B- until lamp indicator is at 40°
d b ara
nte
C warm-up temperatureutho eo
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s a c
– Set rotary switch for operating period -A- to “10” -arrow-.
s
ce
le
un
pt
– Press and hold ► -D- for longer than 2 seconds and, in doing
an
d
itte
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so, bring equipment into operation.

rm
ab
pe
ility
ot
wit
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Note
hole
spec
es, in part or in w
Temperature-controlled cleaning is now activated. During the

t to the co
warm-up period, ultrasonic waves are activated to mix the clean‐

ing fluid. Once the preselected temperature is reached, the ultra‐
sonic waves are switched to continuous operation. Cleaning time
rrectness of i
must be at least 10 minutes, and cleaning only starts at a tem‐

perature of at least 40°C.
l purpos
– Once cleaning is complete, flush connecting pipes and pipe

nform
ercia
union with clean water and blow out with compressed air.
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tion in
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

Polo 2010 ➤
28 – Glow plug system

1 Glow plug system
⇒ “1.1 Checking glow plug system”, page 281
⇒ “1.2 Removing and installing ceramic glow pin plugs; carrying
out resistor test”, page 281
⇒ “1.3 Removing and installing Hall sender G40 ”, page 284
⇒ “1.4 Removing and installing knock sensor G61 ”, page 286
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
287
1.1 Checking glow plug system

♦ The glow plug system is controlled by means of an automatic
glow period control unit - J179- The automatic glow period
control unit - J179- is capable of self-diagnosis.
♦ Control unit for glow plug system is located in mounting for
fuse holder B - SB- on front left in engine compartment ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations.
♦ An entry is made in the event memory in the engine control
unit - J623- if a fault occurs in the glow plug system.
♦ The procedure for checking the glow plug system is described
in “guided fault finding”.
♦ For faster starting, the vehicle is equipped with electronically
controlled glow plugs and a separate glow period control unit.
♦ Each glow plug is activated and diagnosed individually.
1.2 Removing and installing ceramic

en AG. V
olkswagen Aglow
G
pin plugs; carrying out resistor test
wag does
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
i
or
n thi
te
sd
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Cop py
t. rig
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co lksw
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Prote AG.
1. Glow plug system 281

Polo 2010 ➤

equipment required
AG. Volkswagen AG d
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ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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om
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c
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or
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te
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
♦ Jointed spanner - 3220-

♦ Hand multimeter - V.A.G 1526 A-
♦ Adapter set - V.A.G 1594 C-
Test conditions
• Engine is cold
• Ignition switched off
Procedure
Note
♦ Ceramic glow pin plugs are fitted in this engine.

♦ Do not cant ceramic glow pin plugs when removing and in‐
stalling.
– Remove engine cover panel ⇒ page 24
282 Rep. gr.28 - Glow plug system

Polo 2010 ➤
– Open catches -arrows- of cable routing and free wiring har‐

ness.
AG. Volkswagen AG d
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– Pulls connector -6- off fuel pressure sender - G247- . c
s
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Caution
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♦ Carefully pull connector off glow pin plugs.
ot
wit
, is n
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♦ If the connector is damaged when pulling it off, the com‐
hole
spec
plete wiring harness including connectors must be re‐
es, in part or in w
placed (an individual connector cannot be replaced).
t to the co
rrectness of i
l purpos
– Position pliers - 3314- with groove -arrow A- on support sleeve

shoulder -arrow B-.
nform
mercia
a
com
tion in
r
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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.

Polo 2010 ➤
– Carefully pull connectors off glow pin plugs

-in direction of arrow-.
– Clean glow pin plug openings in cylinder head. It must be en‐
sured that no dirt falls into the cylinder.
Cleaning procedure:
1. Use a vacuum cleaner to remove coarse dirt.
2. Spray brake cleaner or suitable cleaning agent into glow pin
plug opening, let it work in briefly, and blow out with com‐
pressed air.
3. Then use an oil-soaked cloth to clean the glow pin plug
opening.
Caution
When loosening the glow plug the max. permissible loosening

torque of 20 Nm must not be exceeded!
– To loosen glow pin plugs, use 10 mm socket spanner - 3220-

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1.3 Removing and installing Hall sender -

G40-

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– Use a screwdriver to remove webs and cover of repair opening

-arrows-.
– Remove Hall sender - G40- from cylinder head. Guide con‐
nector through repair opening in toothed belt guard.
Installing
lowing:
♦ Seal repair aperture in toothed belt guard with rubber plugs as
specified in ⇒ Electronic parts catalogue (ETKA) .
– Fit toothed belt and adjust the valve timing ⇒ page 92 .

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1.4 Removing and installing knock sensor -

G61-
⇒ “1.4.1 Removing”, page 286
⇒ “1.4.2 Installing”, page 287
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1.4.2 Installing
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Specified torque for securing bolt -3- of the knock sensor: 20 Nm.
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Specified torque for throttle flap control module - J338-

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1.5 Removing and installing engine speed

sender - G28-

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♦ Hexagon key extension, 4 mm - T10370-
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Polo Arun Cfwa

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D3E80270E6B

1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.6 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

3.4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

3.5 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1.1 Assembly overview - sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1.4 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

2.2 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3.1 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

3.7 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

4.3 Checking vacuum at high-pressure fuel pump (venturi nozzle) . . . . . . . . . . . . . . . . . . . . 219

5.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

5.4 Removing and installing pressure differential sender G 505 . . . . . . . . . . . . . . . . . . . . . . . . 229

6 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

7 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

7.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

7.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

8 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

9.4 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

1.3 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

1.4 Removing and installing knock sensor G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

The four-digit engine code can be found on the identification plate,

The engine number (“engine code” and “serial number”) can be

In addition, there is a sticker on the toothed belt guard with “engine

code” and “serial number”.

The engine number consists of up to 9 characters (alphanumeric). yi

2.1 Safety measures when working on fuel

lines can reach 100 °C after the engine is switched off.

Risk of injury from highly pressurised fuel.

Danger of fire caused by escaping fuel

2 Rep. gr.00 - Technical data

2.2 Safety measures when working on vehicles with a start/stop system

– Have a second person operate the test and measuring equip‐

ment on the rear seat. an

2.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant

Danger of scalding due to steam and hot coolant.

– Wear protective gloves.

– Reduce excess pressure by covering cap of coolant expan‐

sion tank with cloths and opening it carefully.

2.5 Safety precautions when working on the SCR system