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Service.

Self-Study Programme 218

The Lupo 3L

Design and Function

Volkswagen developed the world's first
3-litre car on the basis of the Lupo. This car is
now in series production.
The development goal was to design a fully
fledged vehicle that achieves a fuel consumption
of 3 litres per 100 km.
The Lupo 3L still meets the Volkswagen Group's
requirements relating toenvironmental
compatibility, safety and comfort.

This task could only be fulfilled by using the
latest technologies and production processes.
That is why roughly 80% of all parts used in the
standard Lupo have been redesigned.
This Self-Study Programme gives you a general
insight into the 3-litre car.

The following Self-Study Programmes relating to the Lupo 3L are also available:
SSP 209
SSP216
SSP 221
SSP 223
SSP 225

1.9 l TDI Engine with Pump Injection System
LUPO 3L Body
The DS085 Electronic Manual Gearbox
The 1. 2 l TDI Engine
Electro-mechanical Power Steering Gear

New

The Self-Study Programme
is not a Workshop Manual.

2

Please always refer to the relevant Service Literature
for all inspection, adjustment and repair instructions.

Important
NoteTable of contents
The trendsetter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

The 1.2 l TDI engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electronic manual gearbox 085. . . . . . . . . . . . . . . . . 22

The running gear . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32

The electrical system . . . . . . . . . . . . . . . . . . . . . . . . . 41

Heating and air conditioning . . . . . . . . . . . . . . . . . . . 46

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3

The trendsetter
Towards a new understanding
of the motor vehicle
The mass mobilisation of mankind has had
a profound effect on theenvironment.
The issues central to the debate on the
environment are:
- economical use of raw materials
and energy,
- air and
water pollution control
- potential climatic changes.
218_112

The 3-litre car has become a buzzword.
The ´3-litre car´ is an eco-friendly concept
embracing all the stages in the life-cycle of a
product from manufacturing and utilisation
through to recycling.Volkswagen has responded to this challenge by
developing the Lupo 3L.
The resulting vehicle reflects a new trend towards
ultra-low fuel consumption without doing without
mobility, comfort and safety.

218_111

The Lupo 3L as a technological
pathfinder for future vehicles
The Lupo will also become the trendsetter for other vehicles:
The lightweight design concept and drivetrain technology, forexample, will in future not only be reflected in the Lupo 3L.

4

The 3-litre concept
The demand for a fuel consumption of 3-litres
per 100 km sets high design standards.

There is a conflict between saving weight
another aims:

How can these standards be met?

-

1. By systematically saving weight
throughout the vehicle
2. By improving the
drivetrain technology
3. By reducingaerodynamic drag
4. By reducing
rolling resistance
Only small improvements are achievable with
regard to rolling resistance and aerodynamic
drag. Weight savings and drivetrain technology
are therefore the key factors from a design
viewpoint.

to maximise safety
to offer a high level of comfort
to provide room for four persons
to keep environmental pollution down to a
minimum byselecting appropriate materials
and manufacturing processes, and
- to be able to recycle materials sorted into
clean material streams
Volkswagen had set itself the goal of designing a
vehicle which fulfills all of these conflicting
requirements. It was therefore necessary to find
the best possible compromise for each of these
requirements.

DIESEL

3-litre
218_093

5

The trendsetter...