1.2Ltr 3 cylinder petrol engines.pdf

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Service.
Self-Study Programme 260
The 1.2 ltr. 3-cylinder petrol engines
Design and Function
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The two 1.2 ltr. engines mark the introduction of
3-cylinder petrol engines at Volkswagen.
This pair of entry-level engines rounds off the
range of engines of the 2002 Polo.
The following objectives were paramount in the
development programme:
– good fuel economy
– compliance with emission standard EU4
– low level of servicing
– low weight
– same smooth running as a 4-cylinder engine
The one engine featuring 2 valves per cylinder
has a power output of 40 kW while the second
engine featuring 4 valves per cylinder produces
47 kW.
260_011
We shall present the design and function of the
two 1.2 ltr. petrol engines to you on the pages
which follow.
Because the base engine of both power plants is
identical, with the exception of the cylinder head,
the description for the most part presents the
1.2 ltr./47 kW engine.
NEW
Important
Note
The Self-Study Programme describes the design and
function of new developments!
The contents are not updated.
Please always refer to the relevant service
literature for up-to-date inspection,
adjustment and repair instructions.
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At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive of camshafts and of oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder head and camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crank assembly with balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil filter and oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel system without return flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel filter with fuel pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine cover with air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine management system. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Single-spark ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel pump feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Exhaust post-treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Extended service interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3
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Introduction
The 1.2 ltr. 3-cylinder petrol engines
The base engine of both power plants is
identical, consisting of the cylinder block with the
top and bottom parts, the crank assembly, the oil
pump, the oil pan and the ancillaries.
The engines differ only in the cylinder heads,
with either 2 or 4 valves per cylinder, and the
resulting adaptations.
260_012
260_013
The 1.2 ltr./40 kW 3-cylinder petrol engine
with 2-valve technology
The 1.2 ltr./47 kW 3-cylinder petrol engine
with 4-valve technology
Technical highlights - engine mechanics
Technical highlights - engine mechanics
– Camshaft driven by chain
– Split cylinder block
– Crank assembly with balancer shaft
– Cross-flow cooling in cylinder head
– Upright oil filter
– Crankcase ventilation
– Camshaft driven by chain
– Split cylinder block
– Crank assembly with balancer shaft
– Cross-flow cooling in cylinder head
– Upright oil filter
– Fuel system without return flow
– Crankcase ventilation
Technical highlights - engine management
Technical highlights - engine management
– Single-spark ignition coils
– Emission control system with catalytic
converter close to engine and two step-type
lambda probes
– Single-spark ignition coils
– Electric exhaust gas recirculation valve
– Emission control system with catalytic
converter close to engine, one broadband
pre-cat lambda probe and one step-type
post-cat lambda probe
4
 
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Technical data
Power and torque curve
of the 1.2 ltr. 6V engine
Power and torque curve
of the 1.2 ltr. 12V engine
60
60
50
50
140
140
40
40
120
120
100
100
30
80
30
80
80
20
20
0
1000
2000
3000
4000
5000
6000
7000
0
1000
2000
3000
4000
5000
6000
7000
260_014
260_015
(1/min)
(1/min)
Engine speed
Engine speed
Engine code
AWY
AZQ
Displacement
1198
1198
Type
3-cylinder in-line engine
3-cylinder in-line engine
Valves per cylinder
2
4
Bore
76.5 mm
76.5 mm
Stroke
86.9 mm
86.9 mm
Compression ratio
10.3 : 1
10.5 : 1
Maximum power output
40 kW at 4750 rpm
47 kW at 5400 rpm
Maximum torque
106 Nm at 3000 rpm
112 Nm at 3000 rpm
Engine management system
Simos 3PD
Simos 3PE
Fuel
Unleaded premium with RON 95
(unleaded regular with RON 91
with slight reduction in output)
Unleaded premium with RON 95
(unleaded regular with RON 91
with slight reduction in output)
Emission control system
Three-way catalytic converter with
lambda control
Three-way catalytic converter with
lambda control
Emission standard
EU4
EU4
5
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