1991 User Manual

Following the launch of the Volkswagen Polo GT TSI and Cross Polo earlier this year, the carmaker introduced another Polo variant in the form of the diesel-powered Polo GT TDI in September. And there’s good news in store for buyers interested in the new 1.6-litre diesel engine-equipped Polo. Just two months after the new car’s launch, Volkswagen dealerships are already offering the car with a flat Rs 25,000 discount. What’s more, dealerships are also throwing in three years’ worth of insurance for free, along with three years of extended warranty and three years of free maintenance for the car. This scheme applies only if you buy the hatchback on loan though. Some dealerships are also offering a Rs 15,000 cash discount on the Volkswagen Cross Polo to try and counter the poor demand for the hatchback in India. The 1.2-litre turbo-petrol-powered Volkswagen Polo GT TSI, however, doesn’t have any discounts or schemes available on it. We also found out that the 1.6-litre petrol variant of the Volkswagen Vento also has the same deals going on it as the Polo GT TDI, which is a Rs 25,000 discount, or three years’ worth of insurance, extended warranty and maintenance free if you buy the car on loan.

German carmaker Volkswagen is in the midst of planning a compact saloon for India. Fast emerging as one of the most profitable segments to be in, the sales of compact saloons are booming despite the downturn in the market. The Maruti Swift Dzire, for example, even in these difficult times, averages approximately 16,000 cars a month. New entrants to this sub-segment are doing well too. Sales of the new Honda Amaze have steadily been rising. Honda sold a total of 9564 Amazes this month, and the trend is still on the up. As a result, putting together the right compact saloon has become priority number one at Volkswagen India, with the engineering and product teams working flat-out to get the right car to the market. But what makes for a successful compact saloon? Sure, it’s all about the right price to begin with, but as customers today evolve, there are other essential elements to the cars that are important too. The right amount of space, enough features to excite potential customers and the right powertrain are just some of them. No wonder then, Volkswagen is pulling out all stops to get things right. Word from inside the company is that the German carmaker, crazy as it may sound, is working not on one car, but two! However, only one car will be finally chosen for production. The first of this pair of cars VW is looking at to fulfill the compact saloon role is, obviously, a truncated or chopped Vento. The Vento may basically just be a Polo with an extended wheelbase and boot, but the sub-four-metre version will address many of the shortcomings of both cars. Built on the same 2552mm wheelbase as the Vento, this car will have more space on the inside than the Polo, and because it will be taxed as a compact, it will be much more affordable than the Vento. That’s two birds with one stone. Also, because VW will have to pay less tax, it will have a larger budget to spend on features, options and accessories. The company, however, is facing a design challenge as the car will have to be heavily modified, both at the front and rear, to make it duck under four metres, and it could look odd. To compound matters, VW wouldn’t be able to sell this car in other markets, so justifying the expense will be difficult. Volkswagen is also looking at the alternative of an even more affordable sub-four-metre car. While the Vento is based on the Polo (PQ25 platform), the company could create a saloon version of the Up city car (PQ12 New Small Family platform) for markets like India, where legroom at the rear is important. The Up currently has a wheelbase of 2420mm. That’s shorter than something like the Dzire at 2430mm, yet longer than the Amaze’s 2405mm. But Volkswagen is unlikely to be able to package the interiors as tightly as Honda has; the latter masterfully uses a slim dashboard and flat seats in the Amaze and Brio for great space efficiency. The German carmaker could, however, build the Up saloon on the Taigun’s longer 2470mm wheelbase; the Taigun, after all, is built on the same platform as the Up. This would help the manufacturer leverage tremendous economies of scale since the Taigun has all but been signed off for India. However, whichever car VW opts for, it will have to move forward on a couple of issues before the car comes to market.

For a start, there’s the issue of the diesel engine. The company’s 1500cc diesel is already being worked on (coded EA189), but it will have to be ready if VW chooses to go with the sub-four-metre Vento or the car won’t qualify for an excise cut. And should the Up-based saloon be selected, VW will have to work hard to fit its new 1,400cc three-cylinder diesel (coded EA288) under the hood. This engine will, in all likelihood, power the Taigun. But VW will have to extend the nose of the car to make it fit; the engine is a bit too wide. The other thing Volkswagen may have to do for the Indian market is lower its sky-high quality standards. All Volkswagens, Polos included, are built to the same exacting global standards, which often surpass the quality levels of many competitors. Most of the time, these details are invisible to the untrained eye. And spending money on something the customer can’t see, unfortunately, is a luxury VW can’t afford if it wants to stay competitive with the players in India. VW is clear; it wants the best possible compact saloon for India, and that’s great news if you are in the market for one.

Volkswagen today announced that additional features have been plonked in some variants of the Vento and the Polo. The Vento now gets a 2-DIN music system with USB, Bluetooth and AUX in the Comfortline and Highline variants. Also, the Vento Highline now gets automatic climate control. The Polo Highline now comes with the new RCD 320 music system with USB, AUX and Bluetooth, while the lesser Comfortline variant gets the RCD 310 system with USB and AUX only. Accordingly, VW has hiked the prices for these cars by about 2.27 percent. This should see an increase of about Rs 10,000-12,000 for the Polo and Rs 10,000-20,000 for the Vento.

The Volkswagen Tiguan compact SUV has been recalled in the UK over concerns that one of its lighting circuits could fail. Volkswagen Tiguan vehicles built between 2008 and mid-2011 have been recalled to have a fuse replaced. VW says there's a chance the fuse could trip, which can lead to the failure of one of the Tiguan's on-board lighting circuits. The failure could lead to a partial loss of lighting on the vehicle. Globally, Volkswagen Tiguan recall affects 800,000 vehicles, including 147,000 units in its home market of Germany. Although not an official recall yet, Volkswagen UK is also considering recalling up to 30,000 vehicles equipped with its 7-speed DSG DQ200 gearbox. If initiated, the recall would involve replacing the synthetic oil used by those vehicles with mineral oil, in a move intended to safeguard against electrical failures. As a worst case scenario, this could lead to a loss of drive. The firm says it is currently in talks with VOSA over whether to issue a full recall for the UK, but a voluntary recall is already in place in other countries. Reports suggest that as many as 1.6 million vehicles worldwide are affected by the 7-speed DSG DQ200 recall. By far the largest market affected is China, where as many as 640,309 cars potentially in need of the oil change. VW is also recalling 4200 units of its Amorak in this country, and 239,000 units worldwide, to check for possible fuel leaks. The recall affects all Amarok vans built since launch in 2011 up to June 2013.Volkswagen won't comment on how much the global recall programme will cost, or whether the measures could harm profits for the group.

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Volkswagen 1.9 TDI Industrial engine detailed instructions regarding testing, adjustment and repair can be found in the Workshop Manual "Volkswagen Industrial Engine".

Contents:
- Combustion process
- Injectors
- Needle Lift Sender
- Air-mass Flow Meter
- Modulating piston movement sender
- Installation position
- System overview
- Fuel regulation
- Injection commencement control
- Exhaust gas recirculation
- Charge pressure control
- Glow plug system
- Emission characteristics
- Internal functions in the control unit
- Self-diagnosis
- Performance diagram
- Specifications

In the direct injection engine, diesel fuel is injected directly into the main combustion chamber. This results in more efficient combustion and lower consumption.
The intake port, pistons and injectors have been designed specifically to optimise
the combustion process with respect to noise emission and running characteristics.
Inlet swirl port
The intake port is shaped in such a way that it induces a swirling movement of the intake air and, as a result, produces greater turbulence in the combustion chamber and piston recess.
Piston recess
The shape of the piston recess has been optimised specially for this engine.
5-hole injector
The fuel is injected into the piston recess in two stages and is ignited by the hot air. The two-stage injection process avoids a sharp
pressure rise.

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