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Polo 1995 ➤
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4-Cyl. injection engine (2 valve, roller rocker finger),
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Mechanics
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Engine ID AKK AKP ALD AUC AUD
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Polo 1995 ➤
4-Cyl. injection engine (2 valve, roller rocker finger),
Mechanics
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00 - Technical data itte
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10 - Removing and installing engine
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13 - Crankshaft group
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15 - Cylinder head, Valve gear
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17 - Lubrication
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19 - Cooling system
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20 - Fuel supply system
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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 © 2010 Volkswagen AG, Wolfsburg 00050207920

Polo 1995 ➤
4-Cyl. injection engine (2 valve, roller rocker finger), Mechanics - Edition 10.1999
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.6 Assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.7 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . . .12
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.3 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2 Removing and installing cylinder block, sealing flange and flywheel/drive plate . . . . . . . . . .25
2.1 Removing and installing cylinder block, sealing flange and flywheel/drive plate . . . . . . . . . .25
2.2 Aluminium cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.3 Renewing crankshaft oil seal -belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.5 Renewing crankshaft sealing flange -flywheel end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.6 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3 Dismantling and assemblingspistons AG. Volkswagen AG.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
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3.2 Piston and cylinder
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15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
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1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

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1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

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1.2 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

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1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

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1.4 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

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2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

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2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
2.3 Replacing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
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2.4 Removing and installing cylinder head cover and camshaft . . . . . . . . . . . . . . . . . . . . . . . .75
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2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
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1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

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1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

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1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

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1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

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1.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

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19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
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Contents i
Polo 1995 ➤
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
1.2 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
1.3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
1.4 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . e.n.A.G.. V. o. lk. s.w.a.ge. n.A.G. . . . . . . . . .105
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Removing and installing radiator . . . . . . . . . . . . . . . . . V. o.lk.sw
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . u.th.o . . . . .
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1 Removing and installing parts of fuel supply ssystem ....
. . . . . . . . . . . . . . . . . . . . . . . . . .109 c
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1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
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1.2 Removing and installing fuel tank with its attachments and fuel filter . . . . . . . . . . . . . . . . . .110
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1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .115
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1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
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1.5 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
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1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
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1.7 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
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1.8 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
1.9 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
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2 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
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2.1 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
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2.2 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
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2.3 Servicing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
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2.4 Checking electronic accelerator warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
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2.5 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
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3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
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3.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

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3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
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3.3 Servicing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
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3.4 Checking tank venting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 t. Cop py
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3.5 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 gh ht
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . . . . . .141
1.3 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
1.4 Checking catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
2.1 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
2.2 Servicing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
2.3 Checking potentiometer for exhaust gas recirculation (G212) . . . . . . . . . . . . . . . . . . . . . . . .153
ii Contents
Polo 1995 ➤
00 - Technical data
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1.1 - Technical
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1.2 - Engine number
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-> The engine number ("Code letters" and "Serial number") can be found on the front of the cylinder block at
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the gearbox end below the thermostat housing.

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Additionally there is a sticker on the toothed belt guard with "Engine code" and "Serial number".
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The engine code is also included on the vehicle data plate.
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1.3 - Engine data
Code AKK ALD AUC AUD, AKP1)

Manufactured 08.99 ▸ 08.99 ▸ 08.99 ▸ 08.99 ▸
Exhaust emissions fulfil MVEG II standard MVEG II standard EU4 standard EU4 standard
ECE standard2)
Displacement cm3 1390 999 999 1390
Output kW at rpm 44/4700 37/5000 37/5000 44(401))/5000
Torque Nm at rpm 116/3000 86/3000...3600 86/3000...3600 116/3000
Bore ø mm 76.5 67.1 67.1 76.5
Stroke mm 75.6 70.6 70.6 75.6

Compression ratio 10.4 10.5 10.5 10.4
RON at least 95 unleaded3) 95 unleaded3) 95 unleaded3) 95 unleaded3)
Injection, ignition Motronic Motronic Motronic Motronic
ME 7.5.10 ME 7.5.10 ME 7.5.10 ME 7.5.10
Knock control yes yes yes yes
Self-diagnosis yes yes yes yes
1.1 - Technical data 1

Polo 1995 ➤

Lambda regulation 1 Lambda probe 1 Lambda probe 2 Lambda probes 2 Lambda probes
Catalyst yes2) yes yes4) yes4)
Exhaust gas recirculation no no yes no
Charging no no no no
1) Austria: Reduction in output due to plate in front of exhaust pipe with catalyst
2) ECE standard =uncoated catalytic converter, lead resistant Lambda probe, leaded fuel possible
3) In exceptional circumstances min. 91 RON, however with reduced performance
4) Additionally with integrated pre-catalyst in exhaust manifold

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2 00 - Technical data
Polo 1995 ➤

1.1 - Removing and installing engine
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Special tools, workshop equipment, test and measuring appliances and auxiliary items required
◆ 2024 A Lifting tackle

◆ VW 313 Support clamp
◆ VW 540 Engine and gearbox support
◆ V.A.G 1202 A Workshop crane
◆ V.A.G 1306 Drip tray
◆ V.A.G 1331 Torque wrench (5...50 Nm)
1.1 - Removing and installing engine 3

Polo 1995 ➤
◆ -> V.A.G 1332 Torque wrench (40...200 Nm)
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◆ -> V.A.G 1921 Pliers for spring-type clips or VAS 5024 assembly tool for spring-type clips
◆ G 000 100 grease (vehicles with manual gearbox) AG. Volkswagen AG d
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1.2 - Notes on removing
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Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
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- The engine is removed forwards together with the gearbox.

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- With ignition switched off disconnect battery earth strap.

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- All cable ties which are opened or cut open when removing engine, must be replaced in the same position
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- Remove air cleaner:
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- Remove battery and battery retainer.

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- Open and close the expansion tank sealing cap to release pressure in cooling system.
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- Disconnect all electric wires from gearbox, alternator and starter and move clear.
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- Loosen or separate the following components:

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- The hose from intake manifold to activated charcoal filter system

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- The vacuum hose from inlet manifold at brake servo

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- The connector from coolant temperature sender and oil pressure switch
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- The collective connectors below the thermostat housing t. Cop py
- The ignition transformer and Hall sender connectors
rig
gh ht
yri by
- The engine speed sender connector op Vo
by c lksw
- Lambda probe connector in exhaust manifold cted agen
Prote AG.
- The 2-pin connector from knock sensor (rear of cylinder block)
- The road speed sender connector
4 10 - Removing and installing engine

Polo 1995 ➤
- The reversing light connector
Warning!
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off connection.
- Now separate fuel supply as well as fuel return pipes at connecting point on suspension strut turret.
- Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.
- Separate front exhaust pipe from exhaust manifold => Page 141 , exhaust manifold, front exhaust pipe
and catalyst with attachments. olksw AG. V agen AG
agen does
olksw not
yV gu
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rise nte
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ss
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nl
pt
du
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itte
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erm
ab
ility
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, is n
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hole
spec
satelettronica
es, in part or in w
t to the co
- -> Unbolt pendulum support at gearbox housing.
rrectness of i
Vehicles with manual gearbox
l purpos
- Disconnect clutch cable:
nform
ercia
=> Repair group 30; Servicing hydraulic clutch control Servicing hydraulic clutch control
m
at
om
ion
c
- Disconnect selector mechanism from gearbox.
in t
or
his
ate
do
riv
=> Repair group 34; Servicing gear change mechanism Servicing gear change mechanism
p
cum
for
en
ng
t.
Vehicles with automatic gearbox Cop
yi Co
py
t. rig
gh ht
- Remove selector lever cable from gearbox: yri
p by
o Vo
by c lksw
cted agen
Prote
=> Repair group 37; Servicing selector mechanism; Dismantling and assembling selector mechanism Servicing
AG.
selector mechanism Dismantling and assembling selector mechanism
Continuation for all vehicles
- Drain coolant => Page 105 .

- Loosen hose clips and pull coolant hoses off coolant thermostat housing.
- Loosen belt pulley securing bolts from power steering vane pump.
- Remove ribbed belt => Page 20 .
- Unbolt power steering vane pump and secure to sub-frame with wire; hoses remain connected:
=> Running gear, axles, steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines;
Removing and installing power steering vane pump. Assembly overview: vane pump, reservoir, hydraulic lines
Removing and installing power steering vane pump.
- Remove securing clamps for power steering pressure pipe.
Vehicles with air conditioner
- Removing air conditioner compressor:

- Observe additional information and removal instructions =>Page 12
1.2 - Notes on removing 5

Polo 1995 ➤
- Remove left and right-hand drive shaft on gearbox and tie up:
=> Running gear, axles, steering; Repair group 40; Servicing front suspension; Removing and installing drive
shafts Servicing front suspension Removing and installing drive shafts
- Removing lock carrier with attachments:
=> General body repairs exterior; Repair group 50; Body front; Assembly overview Body front Assembly over‐
view
satelettronica
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pt
du
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itte
- -> Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:
y li
erm
ab
ility
ot p
Pulley end:
wit
, is n
2nd hole in hook at position 1

h re
hole
Flywheel end: spec

es, in part or in w
2nd hole in hook at position 5

t to the co
Warning!
rrectness of i
The hooks and locating pins must be secured with locking pins.
l purpos
Notes:
nf
ercia
◆ The positions marked 1...4 on the bar must be towards the pulley end.
rm
m
atio
◆ The holes in the hook rails are counted up from the hook.
om
n in
or c
Vehicles with automatic gearbox

thi
te
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:

Polo 1995 ➤
Pulley end:
4th hole in hook at position 1
Flywheel end:
1st hole in hook at position 5
Warning!
The hooks and locating pins must be secured with locking pins.
AG. Volkswagen AG d
agen oes
ksw
Notes: byV
ol not
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ris nte
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nl
pt
du
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ility
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spec
es, in part or in w
t to the co
satelettronica
rrectness of i
◆ The positions marked 1...4 on the bar must be towards the pulley end.
l purpos
◆ The holes in the hook rails are counted up from the hook.
nform
mercia
at
- -> Unbolt assembly at gearbox and engine mountings -arrows-.
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Unbolt assembly at gearbox and engine mountings -arrows-.

- Remove gearbox mounting -arrows-.
- Lower assembly until it is released from the gearbox mounting.

- Pull assembly out forwards. When doing this, if necessary turn assembly and lower slightly.
Note:
When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.
1.2 - Notes on removing 7

Polo 1995 ➤
1.3 - Securing engine to assembly stand
When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the
engine and gearbox box support VW 540.
Work sequence
- Remove gearbox.
- Secure torque converter against "falling out" after separating engine from gearbox.
- Secure engine to support clamp VW 313 using engine and gearbox support VW 540.
AG. Volkswagen AG d
1.4 - Notes on installing olksw
agen oes
not
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d by ara
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satelettronica
or eo
h
ut
Installation is carried out in the reversesssequence, when doing this note the following: r ac
a
ce
le
un
pt
an
d
itte
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rm
ab
- Check clutch release bearing for wear, renew if necessary.
pe
ility
- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000
ot
wit
, is n
100.
h re
hole
spec
es, in part or in w
t to the co
- Only use nuts approved in parts programme to secure torque converter to drive plate.
rrectness of i
l purpos
- Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if neces‐
sary.
- When swinging the assembly in, ensure that clearance exists between the drive shafts.
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.
- -> When installing the engine mounting ensure that the pins on the bonded rubber mounting engage in the
engine support bracket -arrows-.
- Align engine mountings stress-free by rocking.
Note:
Assembly mounting tightening torques

Polo 1995 ➤
=> Page 10 .
- Install drive shafts:
- Installing P.A.S. vane pump:
=> Running gear, axles, steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines;
Removing and installing power steering vane pump. Assembly overview: vane pump, reservoir, hydraulic lines
Removing and installing power steering vane pump.
Vehicles with air conditioner
- Install air conditioner compressor.
- Electrical connections and routing:
=> Electrical system; Repair group 97
satelettronica
- Install ribbed belt => Page 20 .
- Installing clutch cable:
=> Repair group 30; Servicing hydraulic clutch control Servicing hydraulic clutch control
- Connecting selector mechanism to gearbox.
=> Repair group 34; Servicing gear change mechanism Servicing gear change mechanism
- Install selector cable on gearbox, adjust if necessary:

gen AG
. Volkswagen AG
d
wa oes
olks not
yV gu
=> Repair group 37; Servicing selector ise mechanism;
d b Dismantling and assemblingara selector mechanism Servicing
nte
selector mechanism Dismantling and hor assembling selector mechanism eo
aut ra
ss c
ce
le
un
pt
an
d
itte
- Filling with coolant => Page 105

y li
rm
ab
- Install air cleaner:

pe
ility
ot
wit
, is n
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner. Servicing injection
h re
hole
system Dismantling and assembling air cleaner.

spec
es, in part or in w
t to the co
- Perform the work sequence "Procedure after interrupting voltage supply".
=> Repair group 24; Engine control unit; Procedure after interrupting voltage supply. Engine control unit Pro‐
rrectness of i
cedure after interrupting voltage supply.

l purpos
Note:
The readiness code is reset or erased each time fault memory is erased.
nform
mercia
- Carry out a test drive and interrogate fault memory:

com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
9
co Vo
by lksw
cted agen
1.4 - Notes on installing
Prote AG.
Polo 1995 ➤
=> Repair group 01; Fault memory; Interrogating and erasing fault memory of engine control unit Fault memory
Interrogating and erasing fault memory of engine control unit
1.5 - Tightening torques
Bolted connection Tightening torque

Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M 12 60 Nm
in variation of this
Exhaust pipe to manifold 40 Nm
1.6 - Assembly mounting
satelettronica
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
Tightening torques
y li
rm
ab
pe
ility
Note:
ot
wit
, is n
h re
The assembly mounting securing bolts are stretch bolts and must be replaced.
hole
spec
es, in part or in w
-> Engine mounting

t to the co
A = 50 Nm
B = 25 Nm
rrectness of i
C = 40 Nm + turn 90°(1/4 turn)further

D = 20 Nm + turn 90°(1/4 turn)further
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 1995 ➤
-> Gearbox mounting
A = 60 Nm + turn 90°(1/4 turn)further
B = 20 Nm + turn 90°(1/4 turn)further
C = 50 Nm
-> Gearbox mounting
satelettronica
C = 30 Nm
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
-> Pendulum support

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
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 by
11
cop Vo
by lksw
cted 1.6 - Assembly mounting
agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Polo 1995 ➤ oris nte
eo
th
4-Cyl. injection engine
s au (2 valve, roller rocker finger), Mechanics ra
c - Edition 10.1999
s
ce
e
nl
-> Pendulum support
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1.7 - Additional information and removal instructions for vehicles with air conditioner
es, in part or in w
t to the co
rrectness of i
Warning!
The air conditioning system refrigerant circuit must not be opened.
l purpos
nf
ercia
o
Note:
rm
m
atio
om
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
n in
or c
not stretched, kinked or bent.
thi
te
sd
iva
o
r
rp
cu
To facilitate removing and installing the engine without opening the refrigerant circuit:
o
m
f
en
ng
t.
yi Co
- Unbolt retaining clamp(s) for refrigerant lines.
op
satelettronica
C py
. rig
ht ht
rig by
copy Vo
by lksw
cted
- Remove lock carrier with attachments:
agen
Prote AG.
=> General body repairs exterior; Repair group 50; Body front; Removing and installing lock carrier with at‐
tachments Body front Removing and installing lock carrier with attachments
- Remove air conditioner compressor with attached refrigerant hoses from support:
=> Heating, air conditioner system; Repair group 87
- Set the lock carrier with radiator, condenser and air conditioner compressor to the side so that the refrigerant
hoses and pipes -arrows- are not strained.

Polo 1995 ➤
13 - Crankshaft group
1 - Dismantling and assembling engine

1.1 - Dismantling and assembling engine
lkswage es n
o ot g
byV ua
d ran
ir se tee
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satelettronica
th or
au ac
ss
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le
un
pt
an
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itte
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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.
I =>Page 14
II =>Page 18
1.1 - Dismantling and assembling engine 13

Polo 1995 ➤
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
satelettronica
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
op py
Part I t. C rig
gh ht
pyri by
Vo
o
by c
1 Toothed belt guard - upper part
lksw
cted agen
Prote AG.
2 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 57
3 20 Nm
4 Toothed belt guard - coolant pump
5 20 Nm + 1/4 turn (90 °) further
◆ To loosen and tighten, hold with retainer 3036
◆ Renew
6 Camshaft sprocket
◆ Note position when installing the toothed belt
=> Page 57
14 13 - Crankshaft group
Polo 1995 ➤
satelettronica
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
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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
7 10 Nm
◆ Install with D6
nf
ercia
8 10 Nm
orm
9 Rear toothed belt guard

m
atio
m
10 Coolant pump
o
n in
or c
◆ With integrated seal

thi
te
◆ Seal must not be separated from coolant pump

sd
iva
o
r
◆ Replace damaged or leaking coolant pump together with seal

rp
cu
o
◆ Check for ease of movement

f
en
ng
t.
yi Co
11 Tensioner t. Cop py
rig
◆ Checking => Page 23 gh ht
yri by
◆ Removing, installing and tensioning cop Vo
by lksw
=> Page 57
cted agen
Prote AG.
12 20 Nm
13 Console

Polo 1995 ➤
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
satelettronica
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.
14 Crankshaft toothed belt sprocket

=> Page 57
15 40 Nm + 1/4turn (90 °) further
◆ Renew
16 12 Nm
◆ Renew
17 Belt pulley
◆ When installing note fixing arrangement
18 20 Nm
19 Ribbed belt
◆ Mark direction of rotation before removing
◆ Removing and installing ribbed belt => Page 20
Polo 1995 ➤
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
satelettronica
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
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
20 90 Nm + 1/4 turn (90 °) further

◆ Renew
◆ Oil threads
◆ Hold toothed belt sprocket with toothed belt sprocket holder 3099
◆ The turning further can be done in several stages
◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690
21 Toothed belt guard - lower part

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Polo 1995 ➤ thor eo
u ra
4-Cyl. injection engine (2 valve,
ss a roller rocker finger), Mechanics - Edition
c 10.1999
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
op py
satelettronica
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Part II
Note:
Servicing the clutch:
=> Repair group 30; Servicing clutch; Removing and installing clutch Servicing clutch Removing and installing
clutch
1 Cylinder block
◆ Dismantling and assembling aluminium cylinder block => Page 26
◆ Dismantling and assembling pistons and conrods
=> Page 44
2 45 Nm
◆ Renew
3 Oil filter
◆ Loosen at hexagon bolt head
◆ Tighten by hand
◆ Note instructions on filter when installing
Polo 1995 ➤
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
satelettronica
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.
4 Compact bracket
◆ For vane pump and alternator
◆ Removing and installing compact bracket on vehicles with air conditioner:
=> Heating, Air conditioning; Repair group 87
5 15 Nm
◆ Loosen and tighten the flywheel end bolts only with socket insert 3249
6 Sump
◆ Removing and installing
=> Page 88
7 Oil drain plug, 30 Nm
◆ With attached seal
◆ Renew
8 M8: 20 Nm + 1/4 turn (90 °) further
9 45 Nm

Polo 1995 ➤
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
satelettronica
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
e
10 Washer
at
do
riv
11 Tensioning roller
p
cum
for
12 Tensioning element
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
1.2 - Removing and installing ribbed belt cted agen
Prote AG.
Polo 1995 ➤
Vehicles without power assisted steering
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ -> 3297 Tensioning lever
Work sequence
- Mark direction of rotation of ribbed belt.

- Loosen alternator securing bolts.
satelettronica
- -> Install tensioning lever 3297, secure with spring clip and swivel alternator down (to turn 3297 use e.g.
. Volkswagen AG
torque wrench). wagen AG does
- Remove/fit ribbed bbeltolks not
yV gu
ara
ed nte
ris
Note: au
tho e or
ac
ss
ce
When installing the ribbed belt ensure that it sits correctly in the pulleys.
e
nl
pt
du
an
itte
y li
- After fitting ribbed belt with alternator loose, rotate engine several times (approx. 10 revolutions of engine
erm
ab
by operating starter briefly.

ility
ot p
- First tighten lower and then upper alternator bolts to

wit
, is n
25 Nm.
h re
hole
spec
Vehicles with power assisted steering

es, in part or in w
t to the co
Removing
rrectness of i
- Remove ribbed belt cover.

- Mark ribbed belt direction of rotation.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
cu
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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.
- -> Using a spanner on the securing bolt swivel tensioning roller in direction of arrow.
- Remove ribbed V-belt.
1.2 - Removing and installing ribbed belt 21

Polo 1995 ➤
Installing
- Place ribbed V-belt onto crankshaft pulley first. Slide belt onto tensioning roller last.
Ribbed belt routing
-> Basic belt drive
satelettronica
1- Crankshaft/pulley
2- Ribbed belt
3- Pulley - Alternator
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
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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
-> Belt drive without air conditioner compressor
rrectness of i
l purpos
2- Ribbed belt
3- Pulley - P.A.S. vane pump
nform
ercia
5- Tensioner
m
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 1995 ➤
-> Belt drive with air conditioner compressor
2- Tensioner
4- Air conditioner compressor
5- Pulley - P.A.S. vane pump
Note: AG. Volkswagen AG d

agen oes
lksw not
When installing the d byribbed
Vo
V-belt, ensure the belt runs gu in the right direction and
ara seats correctly on the belt
pulleys. orise nte
eo
th
au ra
The rest ofs the assembly is basically a reverse of the dismantling
s c
sequence.
ce
le
un
pt
an
d
itte
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rm
ab
1.3 - Checking semi-automatic toothed belt tensioning roller
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
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.
◆ 10-222A Support bracket

◆ 10-222A/1 Support for support bracket
1.2 - Removing and installing ribbed belt 23

Polo 1995 ➤
Test sequence
The engine must be lowered slightly as follows to enable the crankshaft sprocket to be removed:
satelettronica
- -> Fit support 10-222A with legs 10-222A/1 as shown.

- Take-up weight of engine, and remove right engine AGmounting.
. Volkswagen AG
- Lower engine slightly. swagen does
olk not
- Remove ribbed belt => Page 20 . d by V gu
ara
- Remove belt pulley as well as upper oriseand lower toothed belt guard. nte
eo
- Now turn the crankshaft two turns
aut in direction of rotation until it is at top dead centre
h
ra No. 1 cylinder.
ss cce
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un
pt
an
d
itte
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erm
ab
ility
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is n
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ole,
spec
t to the co
rrectness o
- -> Note the position of the tensioning roller indicator -arrow-. Press the toothed belt with firm thumb pressure.
cial p
f in
The indicator must move.

form
mer
- Release tension on toothed belt.

atio
- Turn crankshaft two turns in engine direction of rotation.

om
- Then check the position of the indicator. It must have returned to its original position.
c
i
or
n thi
te
sd
a
If tensioning roller does not return to initial position:

iv
o
pr
cum
r
fo
en
ng
- Replace tensioning roller.

t.
yi Co
Cop py
t. rig
If the tensioning roller is OK:
gh ht
pyri by
Vo
co lksw
by
cted agen
- Reinstall belt pulley and toothed belt guard upper and lower parts. Prote AG.
- Refit right engine mounting with new bolts => Page 10 , Engine assembly mounting.
- Refit the ribbed belt and the cover.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b ara
nte Polo 1995 ➤
autho
roller rocker finger), Mechanics - Edition
eo
r ac
10.1999
ss
Note:
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
The rest of the assembly is basically a reverse of the dismantling sequence.
wit
, is n
h re
hole
spec
es, in part or in w
2 - Removing and installing cylinder block, sealing flange and flywheel/drive
t to the co
plate
rrectness of i
2.1 - Removing and installing cylinder block, sealing flange and flywheel/drive plate
l purpos
nf
ercia
orm
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
satelettronica
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3 - Checking semi-automatic toothed belt tensioning roller 25

Polo 1995 ➤
2.2 - Aluminium cylinder block
Warning!
The crankshaft must not be removed. Just loosening the main bearing caps will cause deformation of the
cylinder block bearing pedestals. This deformation will cause a reduction of the bearing clearance. Even if the
bearing shells are not renewed bearing damage could occur due to a different bearing clearance.
If the bearing cap bolts are loosened, the cylinder block must be replaced complete with the crankshaft.
Measuring the main bearing clearance is not possible with normal workshop equipment.
satelettronica
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
nform
mercia
at
om
ion
c
in t
Note:
or
his
ate
do
riv
For repairs to the clutch:

p
cum
for
=> Repair group 30; Servicing clutch; Removing and installing clutch Servicing clutch Removing and installing
en
ng
t.
yi Co
clutch . Cop py
rig
ht ht
rig
1 10 Nm py by
co Vo
by lksw
2 Suction pipe cted agen
Prote AG.
3 Aluminium cylinder block
Polo 1995 ➤
4 Knock sensor
5 20 Nm
◆ Tightening torque influences the function of the knock sensor
6 60 Nm + 1/4 turn (90 °) further
◆ Renew
satelettronica
lkswage es n
o ot g
byV ua
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
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
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
7 Flywheel/drive plate
iv
o
r
rp
cu
◆ To remove and install flywheel counter-hold with 3067

o
m
f
en
ng
◆ Removing and installing drive plate on vehicles with automatic gearbox

t.
yi Co
op
=> Page 31 C py
t. rig
gh
8 12 Nm
ht
pyri by
Vo
co
◆ Renew
by lksw
cted agen
Prote AG.
9 Sealing flange with sender wheel and oil seal
◆ Only renew complete with oil seal and sender wheel
◆ Removing and installing sealing flange =>Page 34 , Renewing crankshaft sealing flange -flywheel end-
10 Gasket
◆ Renew
2.2 - Aluminium cylinder block 27

Polo 1995 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
nte
satelettronica
ris
ho eo
aut ra
ss c
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
ercia
11 Oil pump
◆ Only renew complete
m
a
com
ti
◆ When installing note follower -item 13 - on crankshaft
◆ Must be located on dowel sleeves on in
r
te o
thi
◆ Removing and installing => Page 83 , Removing and installing parts of lubrication system
s
iva
do
r
12 Oil seal
rp
cum
fo
◆ Renewing => Page 29

en
ng
t.
yi Co
op
13 Follower C py
ht. rig
◆ Coat with oil before installing oil pump
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Polo 1995 ➤
2.3 - Renewing crankshaft oil seal -belt pulley end
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
rm
ab
pe
ility
satelettronica
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.
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Cop py
ht. rig
rig ht
py by
Special tools, workshop equipment, test and measuring appliances and auxiliary items required co Vo
by lksw
cted agen
Prote AG.
◆ 3240 Oil seal extractor
◆ T10022 Sleeve
◆ T10022/1 Press piece
◆ T10022/2 Spindle
◆ 3099 Counter-hold tool
Removing
- First remove toothed belt

=> Page 57 .
- Then remove crankshaft toothed belt sprocket. To do this secure counter-hold tool 3099 to toothed belt
sprocket.
- To guide oil seal extractor screw crankshaft sprocket securing bolt into crankshaft onto stop.
- Unscrew inner part of oil seal extractor 3240 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.
2.3 - Renewing crankshaft oil seal -belt pulley end 29

Polo 1995 ➤ n AG. Volkswagen AG do
wage es n
yV
olks roller rocker finger), oMechanics
t gu - Edition 10.1999
d b a ran
e
ris tee
utho 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
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it as
l purpos
far as possible into oil seal.

- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.
nform
ercia
Installing
m
at
om
ion
c
in t
or
his
ate
do
riv
satelettronica
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- Lightly oil sealing lip of oil seal.

- -> Fit sleeve T10022 onto crankshaft journal and turn spindle T10022/2 in onto stop.
- Slide oil seal over guide sleeve.
- -> Press in oil seal onto stop with press piece T10022/1.
- Install toothed belt => Page 57 .
- Install crankshaft toothed belt sprocket and hold with counter-hold 3099.
Polo 1995 ➤
2.4 - Removing and installing drive plate
◆ VW 558 Retainer
◆ Hexagon bolt M8x45 and two M10 hexagon nuts
◆ Depth gauge
satelettronica
Loosening and tightening drive plate
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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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
ercia
orm
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atio
om
n in
or c
thi
te
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f
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- -> Secure counter-hold tool VW 558 to the drive plate with a hexagon bolt M8x45. Place two M10 hexagon Cop py
ht. rig
nuts between counter-hold tool and drive plate. rig ht
py by
co Vo
by lksw
cted
Position of counter-hold tool:
agen
Prote AG.
A - To loosen
B - To tighten
2.4 - Removing and installing drive plate 31

Polo 1995 ➤
Installing drive plate
satelettronica
- -> Locate drive plate and packing plate with recesses -1-.
- Fit new bolts -3- and tighten to
30 Nm. AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
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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
- -> Check dimension -a- at three points and calculate average.

Specification: 19.7...21.3 mm
l purpos
If the specification is not attained:

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
auth or
ac Polo 1995 ➤
4-Cyl. injection engine (2 valve, roller rocker finger), Mechanics
ss
- Edition 10.1999
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
. rig
satelettronica
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Remove drive plate again and fit shim -2-. Again tighten bolts -3- to
30 Nm.
- Tighten bolts -3- to 60 Nm and turn
90° (1/4 turn)
further (the additional 1/4 turn can be done in several stages).
2.4 - Removing and installing drive plate 33

Polo 1995 ➤
2.5 - Renewing crankshaft sealing flange -flywheel end-

n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
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
nform
mercia
at
satelettronica
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.
◆ T10017 Assembly device

◆ V.A.G 1332/9 Open ring spanner
◆ Hexagon bolts (Qty. 3)
M6 x 35 mm
◆ Feeler gauge
◆ Vernier gauge
Pressing sealing flange with sender wheel off crankshaft
Notes:
◆ To show the work sequence more clearly, the sequence is described for a removed engine.
◆ The work sequence is the same when the engine is in the vehicle and the gearbox removed.
Work sequence
- Remove the flywheel/drive plate.
Polo 1995 ➤
- -> Set camshaft sprocket to mark -arrow A-.

- Set crankshaft to TDC No. 1 cylinder. The ground tooth on the crankshaft toothed belt pulley must align with
the marking -2V- on the sealing flange -arrow B-.
- Remove oil sump =>Page 88 .
satelettronica
kswage es n
- -> Remove engine speed sender by V -arrow-.
ol ot g
ua
- Undo sealing flange securingir se bolts.
d ran
tee
tho
u or
a ac
Note: ss
ce
e
nl
pt
Sealing flange and sender wheel are pressed off the crankshaft together with Qty. 3 M6 x 35 mm bolts.
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
- -> Screw Qty. 3 M6 x 35 mm bolts into the threaded holes -arrows- of the sealing flange.
m
at
om
- Screw the bolts alternately (a 1/2 turn(180°) for each bolt) into the sealing flange and press the sealing flange
ion
c
along with the sender wheel off the crankshaft.

in t
or
his
ate
do
riv
Pressing sealing flange with sender wheel onto crankshaft

p
cum
for
en
g
Notes:
n
t.
yi Co
Cop py
.
◆ Gradual introduction of a new generation of sealing flanges with PTFE seal (Teflon). The sealing flange with
t rig
gh ht
yri by
spring ring will continue to be offered as spare part. cop Vo
by lksw
When fitting a new sealing flange, be careful to use the same type of sealing flange that was previously cted agen
Prote AG.
fitted.
2.5 - Renewing crankshaft sealing flange -flywheel end- 35

Polo 1995 ➤
◆ The sealing flange with a PTFE sealing ring is equipped with a sealing lip support ring. This support ring
serves the function of a fitting sleeve and may not be removed prior to installation.
◆ Sealing flange and sender wheel must not be separated or twisted after removal from packaging.
◆ The sender wheel of a sealing flange with spring ring has an Elastomer coating on the sealing surface to
crankshaft. This coating must never come into contact with dirt or grease.
◆ The sender wheel is held in its installation position by a fixture on the assembly device T10017 locating pin.
◆ Sealing flange and seal are one unit and must be replaced together with the sender wheel only.
◆ The assembly appliance T10017 maintains its installation position to the crankshaft via a guide pin which is
satelettronica
inserted into a threaded hole in the pressure plate/drive plate.
-> A - Hexagon nut

B - Clamping surface (ground section ofksspindle)n AG. Volkswagen AG do
l wage es n
o ot g
C - Tool bell housing d byV ua
ran
e
D - Socket head bolt thoris tee
or
u
E - Guide pin ss
a ac
F - Locating pin
ce
e
nl
pt
du
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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
ercia
A-Assembling sealing flange with sender wheel on assembly appliance T10017

orm
m
- -> Screw hexagon nut -A- to shortly before the clamping surface (ground section) -B- on the threaded spindle.
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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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.
Polo 1995 ➤
- -> Clamp assembly appliance T10017 in a vice on clamping surface (ground section) on threaded spindle.
- Press assembly bell housing -C- downwards so that it lies on the hexagon nut -A- -arrow-.
Note:
Inner part of assembly appliance and assembly bell housing must be at same height (level).
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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un
pt
an
d
itte
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erm
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ility
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wit
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h re
ole,
spec
t to the co
- -> Remove securing clip -A- on new sealing flange.
satelettronica
Note:
rrectne
The sender wheel must not be taken out of the sealing flange or twisted.
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.
-> The locating hole -B- on the sender wheel -C- must align with the marking -A- on the sealing flange.
- -> Place the sealing flange (with the forward side downwards) on a clean flat surface.
- Push the sender wheel (sealing lip support ring for PTFE sealing ring) -A- downwards in direction of arrow
until it lies on the flat surface.

Polo 1995 ➤
-> The upper edge of the sender wheel and the forward edge of the sealing flange must align -arrows-.
satelettronica
- -> Place the sealing flange, with the forward side on the assembly appliance T10017, so that the locating
pin -A- can be inserted in the sender wheel hole -B-.
Note:
Ensure the sealing flange lies flat on the assembly appliance.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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nl
pt
du
an
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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
- -> Push the sender wheel -B- (Sealing lip support ring for PTFE sealing ring) onto the surface of the assembly
t to the co
appliance whilst tightening the three knurled screws -A-, so that the locating pin cannot slide out of sender
wheel hole.
rrectness of i
Note:
l purpos
Ensure the sender wheel remains fixed on the assembly appliance when installing the sealing flange.
nform
ercia
B-Assembling appliance T10017 with sealing flange on crankshaft flange

m
at
om
io
Prerequisites
n
c
in t
or
his
e
• Crankshaft flange must be free of oil and grease.

at
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 1995 ➤
• Engine positioned at TDC No. 1 cylinder.
Work sequence
lkswage es n
o ot g
byV ua
d ran
ir se tee
- -> Unscrew
utho hexagon nut -A- to end of threaded spindle. or
- Pressss assembly appliance threaded spindle in direction aof
a
arrow, until the hexagon nut -A- lies against the
c
assembly bell housing -C-.
ce
e
nl
pt
- Align flat side of assembly bell housing towards oil sump side of crankcase sealing surface.
du
an
itte
y li
erm
ab
satelettronica
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
- -> Secure assembly appliance to crankshaft flange with hexagon socket head bolts -A-
atio
om
n in
or c
Note:
thi
te
sd
iva
o
r
rp
Screw hexagon socket head bolts -A- into crankshaft flange (approx. 5 threads).
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.
- -> Screw two M6 x 35 mm bolts -A- into cylinder block to guide sealing flange.

Polo 1995 ➤
C-Fitting assembly appliance T10017 onto crankshaft flange
- -> Slide assembly bell housing -A- in direction of arrow by hand until the sender wheel - B- (Sealing lip
support ring for PTFE sealing ring) lies against the crankshaft flange -C-.
Note:
The assembly appliance guide pin -D- is guided into threaded hole in crankshaft during the fitting sequence.
This ensures the sender wheel reaches its final installation position.
- Hold assembly bell housing in this position and screw both assembly appliance hexagon socket head bolts
satelettronica
hand tight.
- Screw hexagon nut -E- onto threaded spindle by hand until it lies against the assembly bell housing -A-.
lkswage es n
Vo ot g
D-Pressing sender wheel onto crankshaft flange with assembly d appliance T10017
by ua
ran
ir se te
- -> Tighten assembly appliance hexagon nut with torque uth wrench V.A.G 1331 and open jaw spannereV.A.G
o
or
1332/9. ss
a ac
Tightening torque: 35 Nm
ce
e
nl
pt
du
an
itte
y li
Note:
erm
ab
ility
A small air gap must be present between cylinder block and sealing flange after tightening hexagon nut to 35
ot p
Nm.
wit
, is n
h re
E-Checking sender wheel installation position on crankshaft

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
yri by
cop Vo
by lksw
cted agen
Prote AG.
Polo 1995 ➤
- -> Screw hexagon nut -A- to end of threaded spindle.
- Remove the two M6 x 35 mm hexagon bolts -B- from cylinder block.
- Screw the three thumb wheels -C- out of sealing flange.
- Pull assembly appliance assembly bell housing -D- back to hexagon nut -A- (Only for sealing flange with
spring ring).
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
-> The sender wheel has the correct installation position on crankshaft when a gap of
wit
is n
-a- = 0.5 mm
h re
ole,
exists between crankshaft flange -A- and sender wheel -B-.
satelettronica
spec
t to the co
Note:
If the sealing flange has a PTFE sealing ring, completely unbolt the assembly appliance T10017 and remove
rrectne
the sealing lip support ring.
To enable the measurements to be shown more clearly the crankshaft flange is illustrated without the fitted
ss
assembly appliance T10017.
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.
- -> Place a vernier caliper against the crankshaft flange -A- (hatched area).
- -> Measure the distance -a- between vernier caliper and sender wheel with a feeler gauge -A-.

Polo 1995 ➤
Is measurement -a- too small:
- Re-press sender wheel =>Page 42 .
When dimension -a- is achieved:

- Remove assembly appliance.
- Tighten the new securing bolts for the sealing flange using alternate and diagonal sequence.
AG. Volkswagen AG d
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satelettronica
- -> Install engine speed sender -arrow-.
rrectness of i
- Install sump => Page 88 .
- Install flywheel/drive plate with new bolts.
l purpos
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com
tion in
r
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Prote AG.
F-Re-pressing sender wheel

- -> Slide assembly bell housing -A- to sealing flange -B- by hand.
- Screw two M6 x 35 mm bolts -C- into cylinder block to guide sealing flange -B-.
- Screw hexagon nut -D- along threaded spindle, by hand, until it contacts the assembly bell housing -A-.
- -> Tighten assembly appliance hexagon nut with torque wrench V.A.G 1331 and open jaw spanner V.A.G
1332/9.
Polo 1995 ➤
- Check installation position of sender wheel on crankshaft again => Page 40 .
If dimension -a- is too small again:
- Tighten hexagon nut to

45 Nm.
- Check installation position of sender wheel on crankshaft again => Page 40 .
2.6 - Crankshaft dimensions
Honing dimensions Conrod journal ø

in mm Engine codes
ALD, AUC AKK, AKP, AUD
Basic dimension -0.022 -0.022
42.00
gen 47.80
AG. Volkswagen AG
does
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a
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1st undersizerised -0.022 -0.022 ara
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ra
ss a -0.037 -0.037 c
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2nd undersize -0.022 -0.022

nl
pt
satelettronica
du
41.50 47.30
an
itte
y li
-0.037 -0.037
erm
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3rd undersize -0.022 -0.022
ot p
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41.25 47.05
, is n
-0.037 -0.037 h re
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Cop py
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Polo 1995 ➤
3 - Dismantling and assembling pistons and conrods

3.1 - Dismantling and assembling pistons and conrods
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Cop py
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1 Circlip cop Vo
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2 Piston pin Prote AG.
◆ If difficult to remove, heat piston to 60 °C

◆ Remove and install with 10-14
3 Piston
◆ Checking => Fig. 3
◆ Mark installation position and cylinder number
◆ Arrow on piston crown points to pulley end
◆ Install using piston ring clamp
Polo 1995 ➤
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4 Compression rings
om
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c
◆ Offset gaps by 120 °

or
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◆ Remove and install compression rings with piston ring pliers

t
sd
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◆ "TOP" faces towards piston crown

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◆ Checking ring gap=> Fig. 1

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◆ Checking ring to groove clearance

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=> Fig. 2 C py
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◆ Remove and install spiral-type expander carefully by hand Prote
cted AG.
agen
◆ "TOP" faces towards piston crown
◆ Checking ring gap=> Fig. 1
◆ Checking ring to groove clearance
=> Fig. 2
6 Conrod
◆ Only renew as a set
◆ Mark cylinder number -A-
◆ Installation position:
Marking -B- faces towards pulley end
◆ Guided axially via piston
3.1 - Dismantling and assembling pistons and conrods 45

Polo 1995 ➤
AG. Volkswagen AG d
agen oes
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satelettronica
m
a
com
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t.
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Cop py
ht. rig
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co Vo
by lksw
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Prote AG.
7 Conrod bearing cap

◆ The caps only fit in one position and only on the appropriate con-rod, this is due to the breaking procedure
(cracking) separating the cap from the con-rod
8 Conrod bolt, 20 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Oil threads and contact surface
◆ To measure radial clearance tighten to 20 Nm but not further
9 Bearing shell
◆ Do not interchange used bearing shells
◆ Insert bearing shells centrally
◆ Check radial clearance with Plastigage:
New: 0.020...0.061 mm
Wear limit: 0.091 mm
Do not rotate crankshaft when checking radial clearance
Polo 1995 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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10 Cylinder block
ce
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un
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◆ Checking cylinder bores

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=>Fig. 4
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◆ Piston and cylinder dimensions

ility
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=>Page 49
wit
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spec
t to the co
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mer
atio
om
n
c
i
or
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sd
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-> Fig. 1 Checking piston ring gap

i
o
pr
cum
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fo
en
ng
- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.
t.
yi Co
Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
3.1 - Dismantling and assembling pistons and conrods 47

Polo 1995 ➤
Piston ring Wear limit

Compression rings 1.0 mm
Oil scraper ring 1.0 mm
AG. Volkswagen AG d
agen oes
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-> Fig. 2 Checking ring to groove clearance
l purpos
Clean groove before check.
nform
mercia
at
Piston ring Wear limit
om
ion
c
in t
Compression rings 0.15 mm
or
his
ate
Oil scraper ring 0.15 mm

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priv
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for
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.
-> Fig. 3 Checking piston
◆ External micrometer 60...90 mm
Polo 1995 ➤
- Approx. 10 mm from lower edge and offset 90 ° to piston pin axis. Deviations from nominal dimensions
max. 0.04 mm
Nominal dimension => Page 49 ; Piston and cylinder dimensions
satelettronica
-> Fig. 4 Checking cylinder bores
◆ Internal dial gauge 50...100 mm
- Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions, as illustrated. Deviation
from nominal dimension
max. 0.08 mm en AG. V
olkswagen AG
ag does
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Vol
Nominal dimension =>edPage
by 49 ; Piston and cylinder dimensions
gu
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Note: ss
au r ac
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Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with
pt
du
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adapter bracket VW 540, as incorrect measurements would then be possible.

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3.2 - Piston and cylinder dimensions

hole
spec
es, in part or in w
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Engine codes ALD and AUC

rrectness of i
Honing Piston-ø Cylinder bore-ø

dimension
l purpos
Basic dimen. mm 67.085 67.11

1st undersize mm 67.335 67.36
nform
ercia
2nd undersize mm 67.585 67.61

m
at
om
3rd undersize mm 67.835 67.86

ion
c
in t
or
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1) The dimension details are for uncoated pistons. Pistons which are coated in area of measurements
at
do
riv
may, according to time run, be up to 0.030 mm larger in diameter.

p
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49
agen
Prote AG.
3.1 - Dismantling and assembling pistons and conrods
Polo 1995 ➤
Engine codes AKK, AKP and AUD
Honing Piston-ø Cylinder bore-ø

dimension
Basic dimen. mm 76.475 76.51
1st undersize mm 76.725 76.76
2nd undersize mm 76.975 77.01
1) The dimension details are for uncoated pistons. Pistons which are coated in area of measurements
may, according to time run, be up to 0.030 mm larger in diameter.
satelettronica
AG. Volkswagen AG d
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Polo 1995 ➤
15 - Cylinder head, Valve gear
1 - Removing and installing cylinder head

1.1 - Removing and installing cylinder head
Checking compressions=> Page 63

Notes:
◆ When installing an exchange cylinder head, all the contact surfaces between the support elements, roller
rocker fingers and the cams must be oiled before installing the cylinder head cover.
◆ The plastic packing pieces for protecting the open valves must not be removed until immediately before
fitting cylinder head.
◆ If the cylinder head is replaced, all the coolant in the system must also be renewed.
◆ Removing and installing intake manifold:
=> Repair group 24; Servicing injection system; Removing and installing parts of injection system Servicing
injection system Removing and installing parts of injection system
satelettronica
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1.1 - Removing and installing cylinder head 51

Polo 1995 ➤
1 20 Nm + 1/4 turn (90 °) further
◆ Hold with counter-hold 3036 to loosen and tighten the camshaft sprocket
◆ Renew
2 Camshaft sprocket
=> Page 57 agen
AG. Volkswagen AG d
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3 10 Nm by
Vol not
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◆ Install with D6 orise nte
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◆ Renew aut
h
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4 Rear toothed belt guard s
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satelettronica
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mercia
a
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tion in
r
te o
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iva
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5 Cylinder head cover

◆ Sealing surface must not be treated
◆ With integrated camshaft bearings
=> Page 75
◆ Remove remnants of old sealant
◆ Coat with AMV 154 103 before fitting
◆ Install vertically from above with dowel pins in holes in cylinder head
6 Cylinder head bolt
◆ Renew
◆ Note installation instructions and sequence when loosening and tightening
52 15 - Cylinder head, Valve gear

AG. Volkswagen AG d
agen oes
o lksw not
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d b ara
nte Polo 1995 ➤
4-Cyl. injectionauengine
tho
(2 valve, roller rocker finger), Mechanics eo
ra - Edition 10.1999
ss c
=> Page 59
ce
le
un
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an
d
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ility
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wit
, is n
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spec
es, in part or in w
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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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satelettronica
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7 Screening cover
◆ Observe installation position
◆ Is clipped in or out
8 Cap
◆ Renew seal if damaged
9 Boot
◆ Renew if damaged
10 6 Nm + 1/4turn (90 °) further
◆ Renew
◆ Note installation instructions and sequence when loosening and tightening
=> Page 75
11 10 Nm
12 Bracket
◆ For wiring harness
13 Fitted pin

Polo 1995 ➤
satelettronica
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14 Roller rocker finger

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◆ Check roller bearing

wit
is n
◆ Oil contact surface

h re
ole,
◆ Use securing clip to clip onto support element when installing

spec
15 Support element
t to the co
◆ Do not interchange
◆ With hydraulic valve clearance compensation
rrectne
16 Cylinder head gasket

◆ Metal gasket
ss
◆ Renew
o
cial p
◆ If replaced renew the complete

inform
coolant
mer
17 Cylinder head
atio
om
◆ Reworking of sealing surface on camshaft side not permissible

n
c
i
or

thi
te
sd
a
=> Page 59
iv
o
pr
cum
r
fo
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 1995 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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tho eo
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un
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an
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ility
18 Lifting eye
ot
wit
, is n
19 20 Nm + 1/4 turn (90 °) further

h re
hole
◆ Renew
spec
es, in part or in w
20 Camshaft
t to the co
◆ => Page 65 , Servicing valve gear

=> Page 75
rrectness of i
21 Oil seal
l purpos
◆ Lightly oil sealing lip of oil seal

◆ Renew=> Page 73
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
lkswage es n
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an
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es, in part or in w
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-> Fig. 1 Checking cylinder head for distortion
rrectness of i
l purpos
Max. permissible distortion: 0.05 mm
nform
ercia
1.2 - Removing, installing and tensioning toothed belts

m
a
com
tio
satelettronica
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r
te o
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s
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Cop py
t. rig
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Vo
co lksw
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Prote AG.

Polo 1995 ➤
(Adjusting valve timing)
◆ 10-222A Support bracket

◆ 10-222A/1 Support for support bracket
AG. Volkswagen AG d
agen oes
olksw not
Removing d by
V gu
ara
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un
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satelettronica
rrectness of i
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nform
ercia

m
a
com
t
- -> Fit support 10-222A with legs 10-222A/1 as shown.
ion in
- Take-up weight of engine, and remove right engine mounting.
r
te o
thi
- Lower engine slightly.
s
iva
do
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rp
cum
- Remove belt pulley as well as upper and lower toothed belt guard.
fo
en
g
- Mark D.O.R. of toothed belt.

n
t.
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- Release tensioner and take off toothed belt. C py
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pyri by
Installing
o Vo
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Prote AG.
Prerequisites
• The engine must be no more than warm to touch.

• The pistons must not be positioned at TDC.
Note:
If a piston is at TDC the valves could strike the piston when turning the camshaft.
1.2 - Removing, installing and tensioning toothed belts 57

wage es n
Polo 1995 ➤ yV
olks ot g
b ua
4-Cyl. injection engine (2 valve,ir se
d roller rocker finger), Mechanics ran - Edition
tee 10.1999
tho
u or
Work sequence ss
a ac
ce
e
nl
pt
du
- -> Set camshaft sprocket to mark -arrow A-.
an
itte
- Set crankshaft to TDC No. 1 cylinder. The ground tooth on the crankshaft toothed belt pulley must align with
y li
erm
ab
the marking -2V- on the sealing flange -arrow B-.
ility
ot p
- Fit toothed belt. For used belts note direction of rotation.
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
ercia
orm
m
atio
om
n in
or c
thi
te
- -> Tighten tensioning roller securing bolt hand-tight. The slot in the base plate -1- must locate around se‐
sd
iva
o
r
curing bolt -2- .

rp
cu
o
m
- Tension toothed belt by turning the tensioning roller in direction of arrow until the indicator -3- aligns with
satelettronica
f
en
ng
t.
yi
the groove in the base plate -arrow-.
Co
op py
- Tighten clamping nut on tensioning roller. t. C rig
gh ht
Tightening torque: 20 Nm pyri by
Vo
co lksw
by
cted agen
Prote
- Now turn the crankshaft two turns in engine direction of rotation until it is again at top dead centre No. 1
AG.
cylinder.
- Now the position of the toothed belts and tensioning roller must be checked again.
- Install toothed belt guard upper and lower parts.
- Install belt pulley (note fixing arrangement).
- Refit right engine mounting with new bolts => Page 10 , Engine assembly mounting.
- Refit the ribbed belt and the cover.
Note:

AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Polo 1995 ➤
ise nte
4-Cyl.thor injection engine (2 valve, roller rocker
eo finger), Mechanics - Edition 10.1999
au ra
s c
1.3 - Removing and installing cylinder head
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
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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
satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
◆ 3450 Guide pin

◆ V.A.G 1921 Pliers for spring-type clips or VAS 5024 assembly tool for spring-type clips
Prerequisites
• The engine must be no more than warm to touch.
Notes:
◆ When repairing an engine where it is not necessary to dismantle the cylinder head, the cylinder head can
be removed without removing cylinder head cover or camshaft.
◆ Then start with work sequence 1.
If the cylinder head is to be dismantled

=> Work sequence 2 on Page 60 .

Polo 1995 ➤
Work sequence
- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With the ignition switched off disconnect the battery earth strap.
- Loosen toothed belt tensioning roller and remove toothed belt from camshaft sprocket. Description of work
=> Page 57 , Removing, installing and tensioning toothed belt.
- Open cylinder head cover sealing cap, unclip the screening cover and take it out.
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
- -> Pull 3-pin connector
utho off Hall sender -arrow-. or
- Pull 4-pin connector
ss
a off ignition transformer and remove ignition ac transformer.
- Further work necessary:
ce
e
nl
pt
=> Work sequence 1 and 2 continued

du
an
itte
on this page.
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erm
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ility
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Work sequence 2
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- Remove cylinder head cover,

hole
spec
=> Page 75 .
es, in part or in w
t to the co
Work sequence 1 and 2

- Lift engine slightly and refit the right engine mounting.
rrectness of i
l purpos
Warning!
nf
ercia
orm
m
- Now separate fuel supply as well as fuel return pipes at connecting point on suspension strut.
atio
om
- Seal the pipes so that the fuel system is not contaminated by dirt etc.
n in
or c
- Loosen or separate the following components:

thi
te
- The connector from coolant temperature sender and oil pressure switch
sd
iva
o
r
- The collective connectors below thermostat housing

rp
cu
o
- The engine speed sender connector

f
en
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t.
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- Lambda probe connector in exhaust manifold
Co
op py
- Connector on knock sensor t. C rig
gh ht
- Oil pressure switch connector pyri by
Vo
co
- Exhaust gas recirculation valve connector (vehicles with EGR)
by lksw
cted agen
Prote AG.
- Remove fuel rail with all injectors from cylinder head.
=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail with injectors Servicing
injection system Dismantling and assembling fuel rail with injectors
- Drain coolant => Page 105 .
- Pull the clamps which secure the coolant pipe to coolant pump off the thermostat housing.
- Remove thermostat housing from cylinder head.

Polo 1995 ➤
- Disconnect all other inter-connecting, coolant, vacuum and intake hoses from cylinder head.
- Remove front exhaust pipe from exhaust manifold.

- Loosen dipstick guide pipe from cylinder head.
- Remove lifting eye in area of oil filler hole.
- -> Loosen socket head bolts in the sequence given and then remove completely.
- Carefully lift cylinder head off.
Volkswag
AG. en AG
agen does
lksw not
Installing d by Vo gu
ara
satelettronica
e nte
ris
ho eo
Notes:au t ra
ss c
ce
le
◆ Only remove the new cylinder head gasket from its packing immediately before installing.
un
pt
an
d
◆ Handle the new gasket with extreme care. Damaging will lead to leaks.
itte
y li
rm
ab
pe
ility
- Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and
ot
wit
piston.
, is n
h re
- Also prevent dirt and emery cloth particles from getting into the coolant.
hole
- Carefully clean cylinder head and cylinder block sealing surfaces. Thereby ensuring that no scoring or
spec
es, in part or in w
scratches are formed (when using abrasive paper the grade must not be less than 100).
t to the co
- Carefully remove metal particles, emery remains and cloths.

- Set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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cum
fo
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t.
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Cop py
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yri by
- -> To centralize cylinder head, screw guide pins from 3450/1 into holes for rear outer cylinder head bolts -
op Vo
by c lksw
cted
arrows-.
agen
Prote AG.
- Place new cylinder head gasket on centralizing pins -A-. Lettering (Part No.) must be readable.
- Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
- Unscrew guide pins through bolt holes using pin driver from 3450. To do this turn pin driver anti-clockwise
until the pins are free.
- Fit remaining cylinder head bolts and tighten hand-tight.

Polo 1995 ➤
- -> Tighten cylinder head in tightening sequence as follows:

- Tighten all bolts to 30 Nm.
- Then tighten all bolts a 1/4 turn (90 °) further using a rigid wrench.
- Then tighten all bolts again a 1/4 turn (90 °) further.
Note:
When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
satelettronica
- Install camshaft and cylinder head cover (if necessary) => Page 76 .
- Install toothed belt and set valve timing => Page 57 .
- Perform the work sequence "Procedure after interrupting voltage supply".
=> Repair group 24; Engine control unit; Procedure after interrupting voltage supply. Engine control unit Pro‐
cedure after interrupting voltage supply.
Note:
The readiness code is reset or erased each time fault memory is erased.
wage es n
- Install air cleaner: yV
olks ot g
d b ua
ran
ir se tee
=> Repair group 24; Servicing
utho injection system; Dismantling and assembling or air cleaner. Servicing injection
system Dismantling and ss assembling air cleaner.
a ac
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
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.

Polo 1995 ➤
1.4 - Checking compression pressures
satelettronica
AG. Volkswagen AG d
agen oes
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rise nte
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au ra
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un
pt
an
d
itte
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rm
ab
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ility
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◆ 3122 B Spark plug spanner

wit
, is n

h re
hole
◆ V.A.G 1763 Compression tester

spec
es, in part or in w
t to the co
Test conditions
• Engine oil temperature must be at least 30 °C.

rrectness of i
Work sequence
l purpos

nform
ercia
m
a
com

ion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote
63
AG.
1.4 - Checking compression pressures
Polo 1995 ➤
lkswage es n
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d ran
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tho
u or
a ac
- Remove spark plugs with spark plug spanner 3122B.
ss
ce
e
- -> Pull connector off Hall sender.

nl
pt
du
- Remove fuse 40 for fuel pump.
an
itte
y li
- Use a second mechanic to depress the accelerator so that the throttle valve is fully open.
erm
ab
- Check compressions with compression tester V.A.G 1381 or V.A.G 1763.
ility
ot p
wit
, is n
Note:
h re
hole
spec
See relevant test unit operating instructions for instructions on how to use test unit.
es, in part or in w
t to the co
satelettronica
- Operate starter until tester shows no further pressure increase.
rrectness of i
Compression pressure:
l purpos
New: 10...15 bar

Wear limit: 7 bar
nf
ercia
orm
Permissible difference between all cylinders: 3 bar
m
atio
om
n in
c
- Insert spark plugs with spark plug spanner 3122B and tighten to 30 Nm.
or
thi
e
- Interrogate fault memory:

t
sd
iva
o
r
rp
cu
o
=> Repair group 01; Fault memory; Interrogating and erasing fault memory Fault memory Interrogating and m
f
en
ng
t.
erasing fault memory
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
2 - Servicing valve gear

2.1 - Servicing valve gear
satelettronica
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
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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
r
Note:
o
his
ate
do
priv
Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug
um
for
thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.5
en
ng
t.
yi
mm in width, or when no more than the first turns of the spark plug thread are cracked.
Co
Cop py
t. rig
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yri by
1 Camshaft cop Vo
by lksw
cted
◆ Checking axial clearance
agen
Prote AG.
=> Page 69
=> Page 75
◆ Checking radial clearance with plastigage
Wear limit: 0.1 mm
◆ Run-out: max. 0.05 mm
◆ Identification and valve timing
=> Page 70 , Fig. 2
2.1 - Servicing valve gear 65

Polo 1995 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
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nl
pt
du
an
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ab
ility
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2 6 Nm + 1/4turn (90 °) further

hole
spec
◆ Renew
es, in part or in w
◆ Note installation instructions and sequence when loosening and tightening => Page 75
t to the co
3 Cylinder head cover

◆ Reworking the sealing surface is not permitted
rrectness of i
◆ With integrated camshaft bearings

l purpos
=> Page 75
◆ Remove remnants of old sealant
◆ Coat with AMV 154 103 before fitting
nf
ercia
◆ Install vertically from above with dowel pins in holes in cylinder head
rm
m
atio
4 Oil seal
om
n in
c
◆ Lightly oil sealing lip of oil seal

or
thi
e
◆ Renew=> Page 73
t
sd
iva
o
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cu
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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 1995 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
5 Roller rocker finger

un
pt
an
d
◆ Check roller bearing

itte
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erm
ab
ility
◆ Use securing clip to clip onto support element when installing

ot p
wit
is n
6 Support element
h re
ole,
◆ Do not interchange
spec
◆ With hydraulic valve clearance compensation


t to the co
7 20 Nm + 1/4 turn (90 °) further

◆ Renew
rrectne
8 Bracket/lifting eye
9 Cylinder head
ss
◆ Reworking of camshaft side sealing surface is not permitted

o
cial p
f i
◆ Reworking valve seats

nform
=> Page 71
mer
◆ Reworking sealing surface, cylinder block side => Fig. 1

atio
om
n
c
i
or
n thi
te
sd
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o
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cum
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fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
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
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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
satelettronica
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
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ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
10 Valves
◆ Do not rework only grinding-in is permitted
◆ Valve dimensions => Fig. 3
11 Valve guide
◆ Checking => Page 78
◆ Repair valve guide has a collar
12 Valve stem seal
◆ Renewing=> Page 80
13 Valve spring
◆ Removing and installing:
Cylinder head
removed: with 2037
installed: => Page 80 , renewing valve stem seals
14 Upper valve spring plate
15 Cotters

Polo 1995 ➤
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-> Fig. 1 Reworking cylinder head by Vsealing surface, cylinder block tside
ol o g
ua
d ran
ir se tee
tho
u or
a ac
Cylinder head reworking dimension:
ss
ce
le
a = At least 135.6 mm
un
pt
an
d
itte
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Checking camshaft axial clearance
erm
ab
ility
ot p
satelettronica
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
e
t
sd
iva
o
pr
cum
r
◆ -> VW 387 Universal dial gauge bracket

fo
en
ng
◆ Dial gauge
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Checking camshaft axial clearance
Check with support elements and cylinder head cover removed.
- Pull camshaft seal off with 3364. Pre-load camshaft at centre bearing -arrow- using thumb pressure and
check axial clearance by moving camshaft to and fro.

Polo 1995 ➤
Wear limit: max. 0.15 mm AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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le
un
pt
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ab
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ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
-> Fig.2 Camshaft identification, valve timing
l purpos
Marking between number 1 cylinder inlet and exhaust

cam tabs
nform
ercia
Engine codes "030 BP"

ALD, AUC
m
satelettronica
com
tio
Engine codes "030 BQ"
n in
r
AKK, AKP, AUD

te o
thi
s
iva
do
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rp
c
Valve timing at 1 mm valve lift
um
fo
en
ng
t.
yi Co
Engine code ALD, AUC AKK, AKP, AUD Cop py
ht. rig
ht
Inlet opens after TDC 9.9° 15°
rig by
copy Vo
by lksw
Inlet closes after BDC 28.9° 22.4° cted agen
Prote AG.
Exhaust opens before 30.1° 16.7°
BDC
Exhaust closes before 11.1° 9.3°
TDC
-> Fig. 3 Valve dimensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Engine codes ALD and AUC
Dimension Inlet valve Exhaust valve

øa mm 31.0 26.0

lkswage es n
o ot g
byV ua Polo 1995 ➤
d ran
ir se
4-Cyl. injection engine th (2 valve, roller rocker finger), Mechanics
o tee
or - Edition 10.1999
au ac
ss
ce
e
nl
pt
du
øb mm 5.98 5.96
an
itte
y li
erm
c mm 99.00 99.00
ab
ility
ot p
α <° 45 45
wit
Engine codes AKK, AKP and AUD , 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

p
cum
or
øa mm 33.5 28.0
f
en
ng
t.
satelettronica
yi Co
øb mm 5.98 t. Cop
5.96 py
rig
c mm 99.20 99.20
gh ht
pyri by
Vo
co
α <° 45 45
by lksw
cted agen
Prote AG.
2.2 - Reworking valve seats

◆ Depth gauge
◆ Valve seat refacing tool
Notes:
◆ When repairing engines with leaking valves, it is not sufficient to replace or renew valve seats and valves.
It is also necessary to check the valve guides for wear. This particularly important on high mileage engines
=> Page 78 .
◆ The valve seats should only be reworked just enough to produce a perfect seating pattern. The maximum
permissible reworking dimension must be calculated before work is carried out. If the reworking dimension
is exceeded, the function of the hydraulic tappets can no longer be guaranteed and therefore the cylinder
head should be renewed.
The max. permissible reworking dimension is calculated as follows:

- Insert valve and press firmly against seat.
Note:
If the valve is to be renewed as part of a repair, use a new valve for the calculation.

Polo 1995 ➤
- -> Measure distance -a- between end of valve stem and upper edge of cylinder head.
- Calculate max. permissible reworking dimension from measured distance and minimum dimension.
Minimum dimension:
Inlet valve and outlet valve 32.1 mm
agen
AG. Volkswagen AG d
o
w es n
olks ot g
yV ua
Measured distance minusisminimum
ed
b
dimension ran
= max. permissible reworking
tho
r
dimension. tee
or
au ac
ss
Example:
ce
le
un
pt
an
d
itte
y li
- Measured gap 32.5 mm
rm
ab
Minimum dimension 32.1 mm
pe
ility
ot
wit
= Max. permissible reworking dimension* 0.4 mm
, is n
h re
hole
spec
*) The max. permissible reworking dimension is shown on illustrations for reworking valve seats as
es, in part or in w
dimension "b".
t to the co
rrectness of i
l purpos
satelettronica
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
yri
-> Reworking inlet valve seat p by
co Vo
by lksw
cted agen
Prote AG.
a = ø29.4 mm - ALD, AUC
b = ø 31.9 mm - AKK, AKP, AUD
c = max. permissible reworking dimension*
Z = max. 1.8 ... 2.0 mm
α = Lower edge of cylinder head
β = 45°valve seat angle
γ = 30°upper correction angle
= 60°lower correction angle
Note:
Valve seat rings having restrictor may only be reworked so far that the restrictor is not damaged.

Polo 1995 ➤
-> Reworking exhaust valve seat
a = ø24.6 mm - ALD, AUC olkswage es n
ot g
b = ø 26.6 mm - AKK, AKP, d b AUD
yV ua
ran
c = max. permissible reworking
rise dimension* tee
ho
Z = max. 1.8 ... 2.0 amm
ut or
ac
α = Lower edge ofsscylinder head
ce
le
β = 45°valve seat angle
un
pt
γ = 30°upper correction angle
an
d
itte
y li
= 60°lower correction angle
erm
ab
ility
ot p
wit
is n
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ole,
2.3 - Replacing camshaft oil seal
spec
t to the co
rrectness o
cial p
f inform
mer
satelettronica
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.
◆ 3036 Counter hold tool

◆ 3240 Oil seal extractor
◆ 3241 Fitting sleeves
◆ T10015/3 Fitting sleeve bolt
◆ T10022/1 Press piece
2.2 - Reworking valve seats 73

Polo 1995 ➤
Removing
- Remove toothed belt guard - upper part.

- Release toothed belt tensioning device and remove toothed belt from camshaft sprocket, =>Page 57 ,
Removing, installing and tensioning toothed belt.
- Turn crankshaft back slightly.
- Remove camshaft sprocket. When loosening camshaft sprocket bolt counter-hold with 3036.
- Remove rear toothed belt guard.
- Screw camshaft sprocket securing bolt into camshaft onto stop by hand, to guide seal extractor.
satelettronica
- Unscrew inner part of oil seal extractor 3240 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into
oil seal as far as possible. agen
AG. Volkswagen AG d
oes
- Loosen knurled screw and turn inner part
Vol of
ksw extractor against camshaft
not until oil seal has been extracted.
g
y ua
db ran
ise
- Remove camshaft sprocket securing
tho
r
screw. tee
or
s au ac
s
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
rrectness of i
l purpos
Installing
nform
mercia
at
- Lightly oil sealing lip of oil seal.

om
io
- -> Fit guide sleeve 3241/2 onto camshaft journal.

n
c
in t
r
- Slide oil seal over guide sleeve.

o
his
te
- Remove guide sleeve.

a
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 1995 ➤
- -> Press oil seal with press piece T10022/1 and bolt from T10015/3 in onto stop. Place washer between
press sleeve and hexagon head bolt.
- Install camshaft sprocket and tighten new bolt (use counter-hold tool 3036).
Tightening torque:
20 Nm and 1/4turn (90 °) further.
Installing toothed belt and adjusting timing => Page 57 .
satelettronica
2.4 - Removing and installing cylinder head cover and camshaft
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
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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
◆ 3036 Counter-hold
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
cted agen
Prote AG.

◆ AMV 154 103 Sealant
2.3 - Replacing camshaft oil seal 75

Polo 1995 ➤
Removing
Notes:
◆ The sealing surfaces on cylinder head cover and cylinder head must not be reworked.
◆ In this cylinder head the camshaft bearings are integrated into the cylinder head and cylinder head cover.
Before removing cylinder head cover, the toothed belt tension must be relieved.
◆ If the cylinder head cover has been loosened, replace camshaft oil seal.
Work sequence
- With the ignition switched off disconnect the battery earth strap.
- Loosen toothed belt tensioning roller and remove toothed belt from camshaft sprocket. Description of work
=> Page 57 , Removing, installing and tensioning toothed belt.
- Remove camshaft sprocket. When loosening camshaft sprocket bolt counter-hold with 3036.
- Remove rear toothed belt guard.
- Unscrew ignition transformer screws out of cylinder head cover.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
satelettronica
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
- -> Pull 3-pin connector off Hall sender -arrow-.
t to the co
- Open cylinder head cover sealing cap and unclip screening cover and remove.
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
ht. rig
- -> Remove cylinder head cover bolts in the sequence prescribed and loosen items 8 and 9 using diagonally
rig ht
py by
o Vo
and alternating sequence. by c lksw
cted agen
- Carefully remove cylinder head cover. Prote AG.
- Lift camshaft carefully, remove and place on a clean surface.
- Remove roller rocker finger together with support elements and place on a clean surface.
- Ensure the roller rocker fingers and the support elements are not interchanged.
Installing
Prerequisites
• Prevent dirt and sealant remnants from entering cylinder head.
• Sealing surfaces must be free of oil and grease.
• When installing cylinder head cover or camshaft, the cams for Cyl. 1 must face upwards.

AG. Volkswagen AG d
agen
o lksw
oes
not Polo 1995 ➤
yV gu
4-Cyl. injection ised engine
b (2 valve, roller rocker finger),
ara
nte Mechanics - Edition 10.1999
or eo
h
ut
• The pistons
ss amust not be positioned at TDC. ra
c
ce
le
un
pt
- Remove sealant remnants on cylinder head and camshaft housing with a commercially available sealant
an
d
itte
remover.
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
m
- Oil the camshaft contact surfaces.

o
n
c
i
- Insert support element in cylinder head and fit roller rocker finger onto respective valve stem end and support
or
n thi
e
element.
t
sd
iva
- -> Ensure all roller rocker fingers contact the valve ends -1- correctly and they are clipped into their respective
o
pr
cum
r
fo
support elements -2-.
satelettronica
en
ng
t.
yi Co
op py
- Carefully place camshaft in camshaft bearing of cylinder head. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
- -> Apply a thin even coat of sealant onto the clean cylinder head cover sealing surface.
Note:
The sealant must not be applied too thick, otherwise excess sealant can enter the oil channels or camshaft
bearing and cause damage to the engine.
- -> Install the cylinder head cover carefully from above ensuring that the dowel pins fit in holes -arrows- in
the cylinder head.
2.4 - Removing and installing cylinder head cover and camshaft 77

Polo 1995 ➤
Notes:
AG. Volkswagen AG d
agen oe
◆ Positioning and securingythe Vol cylinder head cover must be
ksw s no completed without interruption, as the sealing
t gu
surfaces start to cureiseimmediately
db they have contact. ara
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◆ The cylinder head thcover
or bolts must be replaced. eo
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- -> First tighten bolts items 1 and 2 alternately using diagonal sequence and tighten to 6 Nm.
- Then tighten the other bolts to 6 Nm in sequence prescribed.
nform
ercia
- Then tighten all bolts a 1/4 turn (90 °) further.
satelettronica
m
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Note:
n in
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Sealant must be left dry for approx. 30 minutes after installing cylinder head cover.
s
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- Install new oil seal in camshaft,

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=> Page 73 .
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Installing toothed belt and adjusting timing => Page 57 .
2.5 - Checking valve guides
◆ -> VW 387 Universal dial gauge bracket

◆ Dial gauge

Polo 1995 ➤
Test sequence
- -> Insert new valve into guide until end of valve stem is flush with end of guide. Due to the slight difference
in stem dimensions, ensure that only an inlet valve is used in the inlet guide and an exhaust valve in the
exhaust guide.
- Determine rock.
Wear limit: 0.8 mm
satelettronica
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2.5 - Checking valve guides 79

Polo 1995 ➤
2.6 - Renewing valve stem seals
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◆ V.A.G 1331 Torque wrench (5...50 Nm) C py
ht. rig
◆ VW 541/1A Valve lever rig ht
py by
◆ VW 541/5 Thrust piece co Vo
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cted
◆ VW 653/3 Pressure hose
agen
Prote AG.
◆ 2036 Assembly appliance
◆ 3364 Puller

Polo 1995 ➤
◆ -> 3365 Press tool
Removing
- First remove toothed belt
=> Page 57 .
- Then remove camshaft => Page 75 .
- Remove roller rocker finger together with support elements and place on a clean surface.
- Ensure the roller rocker fingers and the support elements are not interchanged.
satelettronica
AG. Volkswagen AG d
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- Remove spark plugs. orise nte
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- Set piston of appropriate
aut
h cylinder to "bottom dead centre". ra
- -> Fit assembly
s tool 2063 to cylinder head using old bolts from cylinder
s c
head cover.
ce
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an
- Screw pressure hose VW 653/3 into the spark plug thread.

d
itte
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- Connect pressure hose to a compressed air system of at least

erm
ab
6 bar.
ility
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- Remove valve springs with lever VW 541/1A and press piece VW 541/5.
wit
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Note:
spec
Tight cotters can be loosened by tapping lightly on the lever.

t to the co
- Pull off valve stem seals with 3364.

rrectness o
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Prote AG.
2.6 - Renewing valve stem seals 81

Polo 1995 ➤
Installing
- -> Place the plastic sleeve supplied on the appropriate valve stem. This will prevent the new valve stem seal
being damaged.
- Insert new valve stem seal in fitting tool 3365.
- Oil valve stem seal sealing lip and press carefully onto the valve guide.
satelettronica
AG. Volkswagen AG d
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Prote AG.

Polo 1995 ➤
en roller
AG. Volksrocker
wagen AG finger), Mechanics - Edition 10.1999
ag does
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Vol
17 - Lubrication by gu
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1 - Removing and installing parts of the lubrication system
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1.1 - Removing and installing parts of the lubrication system
h re
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spec
Note:
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The oil level must not be above the max. mark - danger of damaging catalyst!
Marks => Page 88 , Fig. 1 .
rrectne
Checking oil pressure => Page 93
Oil system capacity1):
s
with oil filter 3.2 ltr.
s o
cial p
f
1) Up-to-date figures:
inform
=> Exhaust emissions test binder
mer
atio
Engine oil specifications:
om
n
Use engine oil to VW standard 500 00, 501 01 or 502 00. Only in exceptional cases: Multi-grade oils corre‐
c
i
or
n
sponding to API-SF or SG.
thi
e
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1.1 - Removing and installing parts of the lubrication system 83

Polo 1995 ➤
1 0.3...0.6 bar oil pressure switch (F1), 25 Nm
◆ Checking => Page 93
2 Guide tube agen
AG. Volkswagen AG d
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3 Self-tapping bolt byV
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◆ max. rotational speed if using opower
ris
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tools: 350 rpm nte
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◆ Fixture to intake manifold auth ra
s c
4 Sealing cap s
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e
nl
pt
◆ Renew seal if damaged du
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5 Guide
erm
ab
◆ Pull off to extract oil
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6 Dipstick
, is n
h re
◆ The oil level must not be above the max. mark!
hole
spec
◆ Markings => Fig. 1
es, in part or in w
t to the co
7 Camshaft sprocket
=> Page 57
rrectness of i
l purpos
nform
ercia
satelettronica
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Cop py
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Prote AG.
8 Oil filter
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Observe installation instructions on oil filter
9 Gasket
◆ Renew
84 17 - Lubrication
AG. Volkswagen AG d Polo 1995 ➤
agen
4-Cyl. injection engine (2 valve, roller
Vol rocker
ksw finger), Mechanics
oes
not - Edition 10.1999
y gu
db ara
se
◆ Must be located on dowel sleevestho
ri nte
eo
10 Tensioner s au ra
c
s
ce
e
nl
pt
du
=> Page 57
an
itte
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11 20 Nm
erm
ab
ility
12 Toothed belt
ot p
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, is n
◆ Mark D.O.R. before removing
h re
◆ Check for wear
hole
spec
◆ Do not kink
es, in part or in w
t to the co
=> Page 57
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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satelettronica
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Prote AG.
15 Belt pulley
16 90 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Oil threads
◆ Hold toothed belt sprocket with toothed belt sprocket holder 3099
◆ The turning further can be done in several stages
◆ The turning further angle can be measured with a commercial protractor e.g. Hazet 6690
17 Crankshaft toothed belt sprocket
1.1 - Removing and installing parts of the lubrication system 85

Polo 1995 ➤
=> Page 57
18 12 Nm
◆ Renew
19 Oil seal
◆ Renewing => Page 29
satelettronica
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20 Oil pump
thi
te
sd
a
◆ Only renew complete

iv
o
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◆ When installing note drive cam on crankshaft

o
m
f
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ng
=> item 24
t.
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◆ Must be located on dowel sleeves Cop py
. rig
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=> Page 90 cop Vo
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21 Gasket Prote AG.
◆ Renew
22 10 Nm
23 Suction pipe
◆ Clean strainer if soiled
24 Drive cam
◆ Coat with oil before installing oil pump
25 Cable guide
86 17 - Lubrication
Polo 1995 ➤
26 Oil drain plug, 30 Nm

◆ With attached seal
◆ Renew
satelettronica
AG. Volkswagen AG d
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27 Sump
erm
ab
ility
◆ Removing and installing engines with liquid gasket

ot p
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=> Page 88
, is n
h re
◆ Clean sealing surface before installing

hole
◆ Install with silicone sealant

spec
es, in part or in w
D 176 404 A2
t to the co
=> Page 88
28 15 Nm
◆ Loosen and tighten the flywheel end bolts only with socket insert 3249
rrectness of i
29 O-ring
l purpos
◆ Renew
30 10 Nm
nform
ercia
31 Oil separator
m
at
32 To air cleaner
om
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Cop py
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Prote 1.1 - Removing and installing parts of the lubrication system
AG.
Polo 1995 ➤
AG. Volkswagen AG d
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tho eo
au ra
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nl
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du
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erm
ab
ility
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-> Fig. 1 Markings on oil dipstick
, is n
h re
hole
spec
1- max. mark
es, in part or in w
2- min. mark
t to the co
a- Area above hatched field up to max. mark: Do not replenish with engine oil!
b- Oil level within hatched field: can be replenished with engine oil
c- Area from min. mark up to hatched field: replenish with max. 0.5 ltr. of engine oil!
rrectness of i
satelettronica
l purpos
1.2 - Removing and installing oil sump
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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for
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Cop py
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Prote AG.
◆ -> 3249 Socket

◆ Hand drill with plastic brush
◆ Flat scraper
◆ Silicone sealant D176404 A2
88 17 - Lubrication
AG. Volkswagen AG d
agen oes
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by
Vol Polo n1995
ot g
ua ➤
d
4-Cyl. injection engine (2 valve, roller rockerorfinger),
ise Mechanics - Edition 10.1999 ran
tee
th or
au ac
Work sequence ss
ce
le
un
pt
- Drain engine oil.
an
d
itte
y li
- Remove cable guide from the sump.
rm
ab
- Unbolt right-hand drive shaft at gearbox.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- Remove cover plate for flywheel.
- Unbolt sump sealed with liquid gasket.
- Remove sump, it may be necessary to release sump by tapping lightly with a rubber head hammer.
rrectness of i
- Remove sealant residue on cylinder block with a flat scraper.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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cum
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satelettronica
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
- -> Remove sealant residue on the sump with a rotating brush, e.g. a hand drill with a plastic brush (wear
eye protection).
- Clean sealing surface, must be free of oil and grease.
Installing
Notes:
◆ Note the use by date of the sealant.

◆ Sump must be installed within 5 minutes of applying silicone sealing compound.
◆ Sump can be offered up easier and with greater security if, for guide purposes, M6 studs are inserted into
the cylinder block flange at two positions.
- -> Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
- Apply silicone sealing compound, as shown, to clean sump sealing surface. Sealing compound bead must
be.
- 2...3 mm thick.
- and run on inside of bolt holes -arrows-.
1.2 - Removing and installing oil sump 89

Polo 1995 ➤
Note:
The sealing compound bead must not be thicker, otherwise excessive sealing compound will enter the sump
and may block the oil suction pipe strainer.
- Install sump immediately and tighten all sump bolts lightly.
- Tighten sump bolts to n AG. Volkswagen AG do
15 Nm. wage es n
olks ot
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Note: rise nte
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s au ra
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After installing sump the sealant must
s
be allowed to dry for approx. 30 minutes before engine oil is replenished.
ce
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un
pt
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erm
ab
1.3 - Removing and installing oil pump
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t to the co
rrectne
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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Cop py
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Vo
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Prote AG.
◆ T10022 Sleeve
◆ 3083 Oil seal fitting tool
90 17 - Lubrication
Polo 1995 ➤
◆ 3099 Counter-hold tool
AG. Volkswagen AG d
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Removing aut
h
ra
ss c
ce
e
- Remove toothed belt => Page 57 , removing, installing and tensioning toothed belt.
nl
pt
du
an
- -> Position crankshaft at TDC No. 1 cylinder -arrow-:
itte
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erm
ab
ility
The chamfered tooth of toothed belt sprocket must align with the marking (2V) on the oil pump.
ot p
satelettronica
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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
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orm
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atio
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thi
e
- -> Turn crankshaft/toothed belt sprocket three teeth anti-clockwise away from TDC:
t
sd
iva
o
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cu
The third tooth -arrow- to the right of the ground down tooth -A- on the toothed belt sprocket must align with
o
m
f
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ng
TDC mark (2V) on the oil pump housing.

t.
yi Co
Cop py
ht. rig
Note:
rig ht
py by
co Vo
by lksw
cted agen
This procedure moves the crankshaft to the correct installation position for the oil pump. One of the polygon
Prote AG.
cams on the crankshaft is uppermost.
- Loosen securing bolt from crankshaft toothed belt sprocket. To do this secure toothed belt sprocket using
counter-hold tool 3099.
- Remove the toothed belt sprocket camshaft and toothed belt tensioning roller.
- Remove sump => Page 88 .
- Remove suction pipe => Page 86 , item 23 .
- Remove oil pump.
- Remove gasket.
- Remove sealant remnants on cylinder block with a flat scraper.
1.3 - Removing and installing oil pump 91

AG. Volkswagen AG d
agen o
Polo 1995 ➤ Vol
ksw es n
ot g
by ua
rised roller rocker finger), Mechanics ran - Edition 10.1999
tee
o th or
s au ac
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- Clean sealing surfaces, they must be oil and grease free.
Installing
nform
ercia
Conditions
m
a
com
ti
• -> One of the polygon cams -arrow- on the crankshaft is uppermost.
on in
r
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thi
s
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do
r
rp
cum
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Work sequence
- -> Fit sleeve T10022 and hexagon socket head bolt from 3083 onto crankshaft and tighten hand tight.
- Fit new gasket onto guide pins -A-.
- -> Position one of the oil pump inner rotor markings arrow -A- on installation position mark arrow -B- on oil
pump housing cover.
- Coat the four crankshaft polygon cams with oil.
- Guide oil pump carefully onto crankshaft polygon cams.
- Align inner rotor to crankshaft polygon cams by turning slightly if necessary.

- Then slide oil pump carefully onto guide pins.
- Secure oil pump with new bolts.
- Remove sleeve T10022.
- Install suction pipe => Page 86 , item 23 .
92 17 - Lubrication
Polo 1995 ➤
- Install oil sump => Page 88 .
- Install toothed belt sprocket and tensioning roller, Installing and tensioning toothed belt => Page 57 , Re‐
moving, installing and tensioning toothed belt.
1.4 - Checking oil pressure and oil pressure switch
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
m
a
com
ti
◆ V.A.G 1342 Oil pressure tester

on in
◆ V.A.G 1527 B Diode test lamp

r
te o
thi
◆ V.A.G 1594 A Adapter set

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iva
do
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Function of the dynamic oil pressure warning indicator

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When not under pressure, the oil pressure switch is open and will close when the operating pressure is attained.
t. C rig
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The oil pressure warning will be activated
by lksw
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Prote
approx. 10 seconds
AG.
after switching the ignition on.
Switch-in delay of oil pressure warning
1.3 - Removing and installing oil pump 93

Polo 1995 ➤
approx. 3 seconds.
Switch-off delay of oil pressure warning

approx. 5 seconds.
Checking warning lamp
After switching on the ignition and engine not started the oil pressure warning lamp in dash panel insert must
light for
approx. 3 seconds AG. Volkswagen AG d
and then go out. The test willobe agen
lkswterminated if the engine
oes is running.
not
V gu
by ara
ed
Criteria for warning ho ris nte
eo
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sa c
The optical oil pressure warning
s switches on (the oil pressure warning lamp flashes) and the buzzer sounding
ce
le
three times for the acoustical warning under one of the following conditions.
un
pt
an
d
itte
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• "Ignition on", engine stationary, oil pressure switch closed
rm
ab
pe
• Engine speed above 1500 rpm, oil pressure switch open
ility
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h re
Notes:
hole
spec
If the oil pressure switch is closed, the warning lamp will remain switched on if the engine speed is above 5000
es, in part or in w
t to the co
rpm. The warning lamp will be switched off again if the engine speed is below 5000 rpm.
satelettronica
If the oil pressure switch is open for 0.3 ... 3.0 seconds when the engine speed is above 1500 rpm, it will be
rrectness of i
stored in the combi-processor in the dash panel insert. If this condition occurs three times when the engine is
running, the oil pressure warning will be activated and will not be cancelled even below 1500 rpm.
l purpos
The oil pressure warning will be cancelled when the oil pressure switch is closed for longer than 5 seconds at
an engine speed above 1500 rpm or when the ignition is switched off. nform
mercia
Test conditions
a
com
tion in
r
• Engine oil level OK, checking => Page 88

te o
thi
• Oil pressure warning lamp (K3) must light up for approx. 3 seconds when ignition is switched on
s
iva
do
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• Engine oil temperature at least 80 °C (radiator fan must have run once)
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cum
fo
en
ng
t.
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Test sequence
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Remove oil pressure switch (F1) and screw into tester.
- Screw tester into the cylinder head in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 B using aux. cables from V.A.G 1594 A to battery positive (+) and oil
pressure switch.
- If the LED lights up, renew oil pressure switch (F1) .
If the LED does not light up:
- Start engine and increase speed slowly.

At
0.3...0.6 bar
94 17 - Lubrication
Polo 1995 ➤
the LED must light up; otherwise renew oil pressure switch.
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed 7.0 bar.
satelettronica
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
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itte
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erm
ab
ility
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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
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Prote AG.
1.4 - Checking oil pressure and oil pressure switch 95

Polo 1995 ➤
19 - Cooling system
1 - Removing and installing parts of cooling system

AG. Volkswagen AG d
agen oes
ksw
1.1 - Removing and installing parts of cooling system ol not
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rise nte
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Notes: s
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e
nl
pt
du
an
◆ When the engine is warm the cooling system is under pressure. If necessary release pressure before com‐
itte
y li
mencing repair work. erm
ab
ility
◆ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
ot p
wit
◆ V.A.G 1921 or VAS 5024 pliers are recommended when installing spring-type clips.
, is n
h re
hole
spec
Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/3 and
es, in part or in w
V.A.G 1274/4.
t to the co
Parts of cooling system body side =>Page 97 .
satelettronica
rrectness of i
Parts of cooling system engine side => 100 .
l purpos
Coolant hose connection diagram =>Page 104 .
nform
ercia
Draining and filling with coolant=> Page 105 .

m
at
om
io
Coolant mixture ratios => Page 105 , draining and filling with coolant
n
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.
96 19 - Cooling system
Polo 1995 ➤
1.2 - Parts of cooling system body side
satelettronica
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
1 Radiator
=>Page 107
rrectne
◆ After replacing renew entire coolant

2 Lock carrier
ss o
3 Radiator fan
cial p
f inform
4 10 Nm
mer
5 Bracket
atio
om
◆ For electric fan

n
c
i
or
n thi
6 Connector
te
sd
va
7 Lower coolant hose

i
o
pr
cum
r
fo
◆ Coolant hose connection diagram =>Page 104

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 - Parts of cooling system body side 97

Polo 1995 ➤
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
satelettronica
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
8 To ATF cooler
thi
s
iva
◆ Only on vehicles with automatic gearbox
do
r
rp
c
um
fo
en
ng
9 Upper coolant hose

t.
yi Co
op py
◆ Coolant hose connection diagram =>Page 104 t. C rig
gh ht
yri
10 Expansion tank
p by
o Vo
by c lksw
cted
◆ Carry out leak test of cooling system with cooling system tester V.A.G 1274 and adapter V.A.G1274/3
agen
Prote AG.
11 Cap
◆ Check with V.A.G 1274 and 1274/4
◆ Test pressure 1.4...1.6 bar
12 Cover
13 From thermostat housing
Polo 1995 ➤
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
satelettronica
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
ht. rig
rig ht
py by
co Vo
by lksw
cted
14 From ATF cooler
agen
Prote AG.

15 To thermostat housing
16 Thermo-switch (F18), 35 Nm
◆ For electric fan
◆ Switching temperatures:
Stage 1
on: 92...97 °C
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C
1.2 - Parts of cooling system body side 99

Polo 1995 ➤
1.3 - Parts of cooling system engine side
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
satelettronica
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.
1 Retainer
◆ For connectors
2 From bottom of radiator
3 Self-tapping bolt, 10 Nm
◆ max. rotational speed if using power tools: 350 rpm
4 Connection
5 O-ring
◆ Renew
6 Coolant thermostat
◆ Checking operation: heat-up thermostat in water the thermo element pin must move out
◆ Temperature check: Opening starts (approx. 84 °C) and ends (approx. 98 °C) cannot be checked.

Polo 1995 ➤
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
rm
ab
pe
ility
ot
satelettronica
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
7 To expansion tank en
ng
t.
yi Co
op
◆ Coolant hose connection diagram =>Page 104 C py
ht. rig
8 To heat exchanger
rig ht
py by
co Vo
9 From expansion tank
by lksw
cted agen
Prote AG.
10 Retaining clip
11 From heat exchanger
12 Coolant pump housing on cylinder block
13 Seal
◆ Renew
14 Coolant pipe
15 Thermostat housing
16 10 Nm
1.3 - Parts of cooling system engine side 101

Polo 1995 ➤
satelettronica
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
17 Coolant temperature sender (G62)

es, in part or in w
t to the co
◆ With coolant temperature gauge sender (G2)

18 Sealing plug
19 To top of radiator
rrectness of i

l purpos
20 Self-tapping bolt
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 1995 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
satelettronica
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
t to the co
rrectness o
cial p
f inform
mer
Coolant pump side
atio
om
n
c
i
or
n
1 Coolant pump thi
te
sd
a
◆ With integrated seal

iv
o
pr
◆ Seal must not be separated from coolant pump

um
r
fo
en
◆ Replace damaged or leaking coolant pump together with seal

ng
t.
yi Co
◆ Check for ease of movement t. Cop py
rig
2 Toothed belt guard - coolant pump
gh ht
pyri by
Vo
o
3 20 Nm
c by lksw
cted agen
Prote AG.
5 12 Nm
◆ Renew
7 Toothed belt
◆ Check for wear
◆ Do not kink
=> Page 57
1.3 - Parts of cooling system engine side 103

Polo 1995 ➤
1.4 - Coolant hose connection diagram
satelettronica
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
rrectne
1 Coolant pump
ss
2 Intake manifold
o
cial p
f in
3 Heating system heat exchanger

form
mer
4 Expansion tank
atio
m
5 ATF cooler
o
n
c
i
or

thi
te
sd
a
6 Upper coolant hose

iv
o
pr
cum
7 Radiator
r
fo
en
ng
t.
8 Lower coolant hose
yi Co
op py
9 Thermostat housing
. C rig
ht ht
rig by
py
10 Cylinder block co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
1.5 - Draining and filling cooling system
◆ -> V.A.G 1306 Drip tray
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
◆ -> V.A.G 1921 Pliers for spring-typess clips or VAS 5024 assembly tool for spring-type clips
a ac
◆ Anti-freeze tester
ce
le
un
pt
an
d
itte
y li
Draining
rm
ab
pe
- Remove cap from coolant expansion tank. ility

ot
wit
, is n
- Drain coolant from bottom radiator hose. h re

hole
spec
Note:
es, in part or in w
t to the co
Observe disposal regulations!

Filling
rrectness of i
Notes:
l purpos
◆ Only use coolant additive G 12 in accordance with TL VW 774 F.

Distinguishing feature: coloured violet
nform
ercia
◆ G 12 violet (in accordance with TL VW 774 F) can be mixed with the previous coolant additive G 12 red!
m
◆ G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage,
com
tio
scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with
n in
r
frost and corrosion protection additives.

te o
thi
s
iva
do
r
rp
◆ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in
um
fo
countries with tropical climates.

en
ng
t.
yi
◆ Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).
Co
Cop py
◆ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer
t. rig
gh ht
yri
countries. The anti-freeze ratio must be at least 40 %. p by
co Vo
by lksw
◆ If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only
Prote
cted AG.
agen
up to 60 % (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling
effectiveness is also reduced.
1.5 - Draining and filling cooling system 105

Polo 1995 ➤
◆ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Recommended mixture ratios:
Frost protection Anti-freeze amount G 121) Water1)

to
-25 °C 40 % 2.25 l 3.35 l
-35 °C 50 % 2.8 l 2.8 l
1) The quantity of coolant can vary depending upon the vehicle equipment.
satelettronica
- -> Fill with coolant up to max. mark on expansion tank.
- Fit expansion tank cap.
- Start engine and maintain an engine speed of about 2000 rpm for approx. 3 minutes.
- Run engine until radiator fan cuts-in.
- Check coolant level and replenish as necessary. When the engine is at normal operating temperature, the
coolant level must be on the max. mark, when the engine is cold, between the min. and max. marks.
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
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.

Polo 1995 ➤
1.6 - Removing and installing radiator
satelettronica
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
◆ V.A.G 1921 Pliers for spring-type clips or VAS 5024 assembly tool for spring-type clips
◆ Anti-freeze tester
nf
ercia
Removing
rm
m
atio
m
- Remove front bumper cover and bumper carrier:

o
n in
or c
thi
te
sd
a
=> General body repairs, exterior; Repair group 63; Front bumper; Assembly overview Front bumper Assembly
iv
o
r
overview
rp
cu
o
m
f
en
ng
t.
yi Co
- Drain coolant => Page 105 . Cop py
- Pull coolant hoses off radiator.
t. rig
gh ht
yri
- Pull connectors off thermo-switch.
p by
co Vo
by lksw
- Remove radiator securing bolts and take out radiator downwards. Prote
cted AG.
agen
Vehicles with air conditioning system:
1.6 - Removing and installing radiator 107

Polo 1995 ➤
- Observe additional information and removal work => Page 108 .
Installing
Installation is carried out in the reverse order, when doing this note the following:

- Electrical connections and routing:
=> Current flow diagrams, Electrical fault finding and Fitting locations
Additional information and removal work on vehicles with air conditioner
Warning!
The air conditioning system refrigerant circuit must not be opened.
Note:
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
not stretched, kinked or bent.
satelettronica
- Remove retaining clamp(s) from refrigerant pipes.
- Unbolt condenser from radiator and secure to lock carrier.
- Pull radiator out carefully, downwards.
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
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

by lksw
cted agen
Prote AG.
Polo 1995 ➤
20 - Fuel supply system
1 - Removing and installing parts of fuel supply system

1.1 - Removing and installing parts of fuel supply system
lkswage es n
o ot g
yV ua
Notes: ir se
d b ran
tee
tho
u or
◆ Always replace clamp-type
ss clips with spring or screw-type clips.
a ac
◆ Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw-
ce
le
un
pt
type clips is not permissible.
an
d
itte
◆ V.A.G 1921 or VAS 5024 pliers are recommended when installing spring-type clips.
y li
rm
ab
pe
ility
Observe safety precautions=> Page 115 .
ot
wit
, is n
h re
hole
Observe rules for cleanliness => Page 116 .
spec
es, in part or in w
t to the co
satelettronica
Observe crash fuel shut-off => Page 116 .
Removing and installing fuel tank with attachments and fuel filter => Page 110 .
rrectness of i
Servicing parts of electronic accelerator control (EPC) => Page 127 .
l purpos
Servicing parts of the activated charcoal filter system => Page 134 .
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.
1.1 - Removing and installing parts of fuel supply system 109

Polo 1995 ➤
1.2 - Removing and installing fuel tank with its attachments and fuel filter
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
satelettronica
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
o
by c lksw
1 Cap Prote
cted AG.
agen
2 Retaining ring
3 Tank flap unit
=> General body repairs; Repair group 55; Removing and installing fuel flap unit Removing and installing fuel
flap unit
4 Gravity/overflow valve
◆ To remove, release locking lug and unclip valve upwards out of filler neck
◆ Check valve for through-flow
valve vertical: open,
valve tilted 90 °: closed
110 20 - Fuel supply system

Polo 1995 ➤
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
satelettronica
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
5 Earth connection
o
m
f
en
ng
t.
yi
6 10 Nm
Co
Cop py
7 Return pipe
t. rig
gh ht
yri by
◆ Blue cop Vo
by lksw
◆ From fuel manifold
cted agen
Prote AG.
8 Union nut
◆ Remove and install with 3217
9 Fuel delivery unit
=> Page 116
◆ Checking fuel pump
=> Page 119
◆ Note fitting position on fuel tank => Fig. 1
1.2 - Removing and installing fuel tank with its attachments and fuel filter 111
Polo 1995 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
10 Fuel gauge sender
ce
le
un
pt
◆ Removing and installing => Page 117

an
d
itte
y li
◆ Adjusting:
erm
ab
ility
ot p
=> Electrical system self-diagnosis; Repair group 01; Self-diagnosis of dash panel insert for vehicles 10.99 ▸;
wit
is n
Checking fuel gauge (adaption) Self-diagnosis of dash panel insert for vehicles 10.99 ▸ Checking fuel gauge
h re
ole,
(adaption)
spec
t to the co
11 Sealing ring
◆ Coat with fuel when installing
rrectne
12 Fuel filter
◆ Fitting position: Arrow points in direction of flow
ss o
13 Supply pipe
cial p
f in
◆ Black
form
mer
◆ To fuel manifold
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.

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
Polo 1995 ➤
d
4-Cyl.orisinjection
e engine (2 valve, roller rocker nte
eo
finger), Mechanics - Edition 10.1999
th
au 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
satelettronica
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
14 3 Nm
15 Fuel tank
=> Page 118
◆ Press clamping washer from heat shield tightly onto pins on vehicle floor
16 25 Nm
17 Vent pipe
◆ To activated charcoal filter
=>Page 135 , item 5
18 Sealing boot
◆ After installing filler pipes fit over fuel tank connections, having turned boot inside out
19 Filler pipes
◆ With non-return valve
Polo 1995 ➤
satelettronica
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
20 Vent valve
ility
ot p
◆ Checking =>Fig. 2
wit
, is n
h re
◆ To remove pull locking latch lightly to inside -arrow- and pull valve out
hole
=>Fig. 2 -arrow-
spec
es, in part or in w
21 O-ring
t to the co
22 Cup
rrectness of i
◆ For filler pipes

l purpos
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 1995 ➤
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
-> Fig. 1 Installation position of fuel delivery unit flange
rrectness of i
Marking on the flange must align with marking on the fuel tank.
l purpos
nf
ercia
orm
m
atio
satelettronica
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
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
-> Fig. 2 Checking vent valve
Lever in rest position: Closed
Lever pushed in direction of arrow: Open
1.3 - Safety precautions when working on the fuel supply system
When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel
tank the following must be observed:
Warning!
◆ Before commencing work, switch on exhaust extraction system and place an extraction hose close to the
sender opening in the fuel tank to extract escaping fuel fumes.
If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displace‐
ment greater than 15 m3/h can be used.
◆ Prevent skin contact with fuel! Wear fuel-resistant gloves!
◆ For safety reasons fuse No. 40 must be removed from fuse holder before opening the fuel system, otherwise
the fuel pump can be activated by the door contact switch in driver's door.
Polo 1995 ➤
1.4 - Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
1.5 - Crash fuel shut-off
Function
Vehicles with an airbag are fitted with a crash fuel shut-off system. It reduces the danger of a fire in a crash as
the fuel pump is switched off via the fuel pump relay.
Simultaneously this system provides improved starting characteristics for the engine.
When the door is opened the fuel pump is activated for 2 seconds to build-up the pressure in fuel system.
When opening the fuel system:
satelettronica
- Check fuel pump relay:
1.6 - Removing and installing fuel delivery unit
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◆ -> 3217 Union nut spanner
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mer
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Polo 1995 ➤
Removing
- Note safety precautions before starting work => Page 115


- Fold rear seat forwards.
- Remove floor cover.
Warning!
satelettronica
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- -> Pull connector ir se-2- supply pipe -3-, and return pipe -1- aoff
d r n flange.
tee
- Disconnect supply
utho
pipe -4- and breather pipe -5-. or
- Place all pipes
ss
a
outside of well. ac
- Place the spanner 3217 on the three rounded-off ribs on the union nut and unscrew union nut from flange.
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- Pull delivery unit and seal out of the opening in fuel tank.
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Note:
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If the delivery unit is to be renewed then drain old delivery unit before disposal.
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Installing
es, in part or in w
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- Installation of the fuel delivery unit is carried out in the reverse order.
rrectness of i
Notes:
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◆ When inserting the fuel delivery unit ensure that the fuel gauge sender is not bent.
◆ Coat flange seal with fuel when fitting.
nform
ercia
◆ Fitting position of fuel delivery unit flange => Page 115 , Fig. 1 .
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ion
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1.7 - Removing and installing fuel gauge sender

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- Remove fuel delivery unit
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=> Page 116 .
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1.6 - Removing and installing fuel delivery unit 117

Polo 1995 ➤
AG. Volkswagen AG d
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- -> Release and pull off the terminals for wiresris-3-
ed and -4-.
ara
nte
- Lift retaining tabs -1- and -2- with a screwdriver
ut
ho and pull fuel gauge sender out downwards e o -arrows-.
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s a c
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Installing
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- Insert fuel gauge sender in the guides on the fuel delivery unit and push up until it engages.
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1.8 - Removing and installing fuel tank
hole
satelettronica
spec
es, in part or in w
t to the co
Removing
rrectness of i
l purpos

- Remove cover in luggage boot floor.
nf
ercia
orm
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- -> Pull fuel return pipe -1- and connector -2- off flange.
- Disconnect fuel supply pipe -4- and breather pipe -5- at hose connections.
- Drain fuel tank.

lkswage es n Polo 1995 ➤
Vo ot g
4-Cyl. injection engine (2 evalve,d by roller rocker finger), Mechanics ua
ran - Edition 10.1999
ir s tee
tho
- -> Remove support bracket
au -1- from body. or
ac
- ss
Remove all rear exhaust system mountings from body. Then lower the exhaust system slightly and secure
ce
le
to body with wire.
un
pt
an
d
- Remove rear right wheel.
itte
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- Detach filler pipe from body.
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ility
- Take filler cap off filler neck and detach filler neck from cup.
ot p
- Remove gravity/overflow valve => Page 110 , item 4 and attach with breather pipe to fuel tank.
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is n
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- Remove filler neck.
ole,
- Now the fuel tank can be detached from body and removed together with the heat shield.
spec
t to the co
Installing
Installing is basically in the reverse order but note following:
rrectne
◆ Install breather and fuel pipes kink-free.
s
◆ Do not interchange supply and return pipes (return pipe blue or with blue markings, supply pipe black).
s o
cial p
f inform
mer
atio
1.9 - Checking fuel pump
om
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1.8 - Removing and installing fuel tank 119

Polo 1995 ➤
◆ 3217 Spanner for union nut
◆ V.A.G 1318 Pressure gauge
◆ V.A.G 1318/1 Adapter
◆ V.A.G1318/7 Adapter
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◆ V.A.G1318/17 Adapter
◆ V.A.G 1348/3 A Remote control
nform
ercia
◆ V.A.G 1348/3-2 Adapter cable

m
◆ V.A.G 1527 B Diode test lamp

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Polo 1995 ➤
AG. Volkswagen AG d
agen oes
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◆ -> V.A.G 1715 Multimeter
es, in part or in w
t to the co
◆ Measuring container
◆ Current flow diagram
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Note:
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Observe functional description of crash fuel shut-off=> Page 116 .
nf
ercia
Test sequence
or
satelettronica
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Test conditions
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• Battery voltage at least 11.5 V

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• -> Fuse SB40 OK.
Checking function and voltage supply
Note:
Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
must be disconnected. Obtain radio code first if necessary.

- Remove floor cover.
- Briefly operate starter. Fuel pump must be heard to run briefly -approx. 1 second-.
If the fuel pump does not run:
- Switch off ignition.

- Remove cover in front of fuse holder.
- Pull fuse SB40 out of fuse holder.
1.9 - Checking fuel pump 121

Polo 1995 ➤
- -> Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to contact 40b -arrow- to fuel
pump and battery positive (+).
- Operate remote control.
Fuel pump runs:
- Check activation of fuel pump relay:
satelettronica
Fuel pump does not run:
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- -> Pull 4-pin connector -1- off fuel tank flange -2-.
du
an
itte
- Connect diode test lamp V.A.G 1527 using aux. cables from V.A.G 1594 to the outer contacts of the con‐
y li
erm
ab
nector.
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- Operate remote control.

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LED must light up

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LED does not light up:

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- Locate and eliminate open circuit using current flow diagram
LED lights up (voltage supply OK.):

rrectness of i
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- Fit spanner 3217 on the three rounded ribs of union nut and unscrew union nut from flange.
- Check that the electrical wires between flange and fuel pump are connected.
nform
ercia
If not open circuit can be found:

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- Renew fuel delivery unit.

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Checking delivery rate

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Test conditions
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• The voltage supply for the fuel pump OK.
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Polo 1995 ➤
AG. Volkswagen AG d
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• Remote control V.A.G 1348/3A is still connected.
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Test sequence tho
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- Remove filler cap from fuel tank filler neck.
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es, in part or in w
t to the co
rrectness of i
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Warning!
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n in
c
satelettronica
or
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- -> Pull fuel supply hose (white marking) off fuel supply pipe -1-.
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- Connect pressure gauge V.A.G 1318 with adapter /1 to fuel supply pipe. Cop py
- Screw adapter hose /13 with adapter /7 to pressure gauge and hold hose in measuring container.
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- Open the pressure gauge shut-off tap. The lever then points in the direction of flow -A-. cted agen
Prote AG.
- Operate remote control V.A.G 1348/3A and slowly close cut-off tap, until pressure gauge shows
3 bar.
From this point on do not move position of cut-off tap.
- Empty the measuring container.
- The fuel pump delivery range is dependent upon battery voltage. Therefore connect the multimeter with
adapter cables from V.A.G 1594 to the vehicle battery.
- Operate remote control for
30 seconds
and measure battery voltage
- -> Compare the quantity of fuel delivered with specification.
*) Minimum delivery cm3/30 seconds
**) Voltage at fuel pump with engine stopped and pump running (approx. 2 volts less than battery voltage).
Example:

Polo 1995 ➤
During the test, a voltage of 12.5 volts is measured at the battery. As the voltage at the pump is approx. 2 volts
less than the battery voltage, this will equate to a minimum delivery of 540 cm3/30 s.
If the minimum delivery rate is not attained:
- Check the fuel pipes for possible restrictions (kinks) or blockages.

- -> Pull supply hose -1- off inlet to fuel filter.
- Connect pressure gauge V.A.G 1318 with adapter 1318/17 to fuel supply pipe.
- Repeat delivery rate check.
satelettronica
If the minimum delivery rate is now attained:
- Replace the fuel filter.
If the minimum delivery rate is again not attained:
- Remove the fuel delivery unit and check the strainer filter for soiling.
Only when up to now no fault has been detected:

AG. Volkswagen AG d
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- Replace the fuel delivery by V unit.
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If the delivery rateauhas
th been attained but nevertheless you suspect eo
r aa fuel supply system fault (e.g. intermittent
failure of fuel supply
ss system): c
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pt
du
- Check the current draw of the fuel pump as follows:

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itte
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ility
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es, in part or in w
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nform
mercia
at
- Reconnect all disconnected fuel pipes.

om
ion
- -> Connect the multimeter V.A.G 1715 using the current clamp to the red/yellow wire from wiring harness.
c
in t
or
- Start the engine and run at idling speed.

his
ate
- Measure the current draw of the fuel pump.

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Specification: max. 8 amps.

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Polo 1995 ➤
Note:
If the fuel system malfunction is intermittent, you can perform the check during a test drive with the help of a
2nd person.
If the current draw is exceeded:

. Volkswagen AG
- Replace the fuel
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Test conditions
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• Remote control V.A.G 1348/3A is still connected.
ab
ility
• Pressure gauge V.A.G 1318 is still connected.
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Test sequence
hole
spec
es, in part or in w
Note:
t to the co
With this check the fuel supply pipe connections from the fuel delivery unit to the point at which the pressure
gauge V.A.G 1318 is connected will be checked for leaks at the same time.
rrectness of i
satelettronica
l purpos
- Close pressure gauge cut-off tap (lever at right angle to direction of flow).
- Operate remote control at short intervals until a pressure of
3 bar nf
ercia
has built up.

orm
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Warning!
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Danger of spray when opening the shut-offtap, hold container over the free connection of the pressure gauge.
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- If pressure builds up too high, lower excess pressure by carefully opening the shut-off tap.
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- Watch pressure drop. After 10 minutes the pressure must not drop below
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If the pressure drops further: Prote
cted AG.
agen
- Check pipe connections for leaks.
If no fault is detected in the wiring:
- Replace the fuel delivery unit.
2 - Electronic power control (EPC)

2.1 - Electronic power control (EPC)
2.2 - Function of EPC system
With the EPC system the throttle valve is not operated by a cable. There is no mechanical connection between
accelerator and throttle valve.
The position of the accelerator is transmitted to the engine control unit by two accelerator position senders
(variable resistors together in a housing) which are connected to the accelerator pedal.

Polo 1995 ➤
The position of the accelerator (drivers requirement) is the main input value for the engine control unit.
The throttle valve is operated over the complete revolution and load range by an electric motor (throttle valve
positioner) in the throttle valve control part.
The throttle valve is operated by the throttle valve positioner which is controlled by the engine control unit.
When the engine is not running and the ignition is switched on the engine control unit moves the throttle valve
exactly as prescribed by the accelerator pedal position sender. This means that when the accelerator is de‐
pressed halfway the throttle valve positioner opens athe n throttle
AG. Volksvalve by
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oes same amount, the throttle is then
w ge
approximately half open. y Volks not
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When the engine is running (under load) th the engine
o control unit can open or close theorthrottle valve independ‐
ently of the accelerator pedal positionau
ss sender.
ac
ce
le
un
pt
This means that the throttle valve can already be completely open even though the accelerator pedal is de‐
an
d
itte
pressed half way.
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ab
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This also gives vastly improved consumption and exhaust emission levels at certain load conditions.
ot
wit
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The torque required by the engine can be produced by the engine control unit by optimising the combination
spec
of throttle valve cross-section and charge pressure.
es, in part or in w
t to the co
satelettronica
It is incorrect to believe that the "EPC" is comprised of one or two components only. The EPC is a system,
which is comprised of all components which have an influence, control or monitor the position of the throttle
rrectness of i
valve, e.g. the accelerator pedal position sender, the throttle valve control unit, the EPC warning lamp, the
engine control unit.
l purpos
nform
ercia

m
a
com
tion in
Checking electronic accelerator warning lamp => Page 128 .
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Polo 1995 ➤
2.3 - Servicing parts of electronic power control (EPC)
satelettronica
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spec
1 Bracket
t to the co
=> Brake systems; Repair group 24; Brake pedal overview Brake pedal overview
rrectne
2 Connector
ss
◆ Black, 6-pin
o
cial p
f in
3 Accelerator pedal position sender (G79 and G185)

form
mer
◆ Not adjustable
atio
m
◆ The accelerator pedal position passes the position of the pedal on to the engine control unit
o
n
c
◆ Remove footwell cover to remove sender

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or
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◆ Checking =>Page 130

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2.3 - Servicing parts of electronic power control (EPC) 127

Polo 1995 ➤
2.4 - Checking electronic accelerator warning lamp
Note:
The electronic accelerator warning lamp -K132 is known also as the EPC warning lamp.
◆ Test box V.A.G 1598/22

◆ Hand multimeter V.A.G 1526 agen
or
AGmultimeter
. Volkswagen AV.A.G
G do 1715
◆ Adapter set V.A.G 1594 Volksw es n
ot g
sed by ua
ran
ri tee
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Check conditions
ss
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• The fuses must be OK.
an
d
itte
• The battery voltage must be at least 11.5 V.
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ility
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Checking function of warning lamp
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spec
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t to the co
rrectness o
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- Switch on ignition.
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-> The EPC warning lamp must light up.

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- Start engine and run at idling speed.
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The EPC warning lamp must cted agen
Prote AG.
go out
when no EPC fault has been stored.
Electronic accelerator warning lamp does not light up
- Remove wiper arms and cowl panel:

Polo 1995 ➤
=> Electrical system; Repair group 92; Servicing windscreen wiper system Servicing windscreen wiper system
- -> Connect test box V.A.G 1598/22 to control unit wiring harness.
- Bridge test box sockets 2 + 30 with aux. cables from V.A.G 1594.
- Switch ignition on.

The fault lamp must light up
If the fault lamp does not light up:

- Remove dash panel insert and check the bulb and its voltage supply.:
=> Electrical system; Repair group 90; Dash panel insert; Removing and installing dash panel insert Dash panel
insert Removing and installing dash panel insert n AG. Volkswagen AG age does
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If no fault is found: ed
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- Check wiring for open circuit between testau box socket 30 and dash panel insert using current ra
c flow diagram:
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un
pt
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If no wiring fault is detected:
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ility
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- Renew engine control unit:
h re
ole,
spec
=> Repair group 24; Engine control unit; Renewing engine control unit Engine control unit Renewing engine
t to the co
control unit
Electronic accelerator fault lamp lights up continuously
rrectness o
cial p
f inform
mer
atio
om
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- -> Connect test box V.A.G 1598/22 to control unit wiring harness. cted agen
Prote AG.
- Check wiring for short to earth between test box socket 30 and dash panel insert using current flow diagram:
If no wiring fault is detected:
control unit
2.4 - Checking electronic accelerator warning lamp 129

Polo 1995 ➤ n AG. Volkswagen AG do
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yV
o rocker finger), Mechanics
lks ot g - Edition 10.1999
b ua
ed ran
ris
2.5 - Checking accelerator pedal position
tho sender tee
or
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le
un
pt
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d
itte
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ility
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t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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satelettronica
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cum
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fo
en
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t.
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Cop py
t. rig
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by
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Prote AG.
◆ V.A.G 1526 Hand multimeter

◆ V.A.G 1598/22 Test box
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
Function
Both accelerator pedal position senders -G79- and -G185- on the accelerator pedal pass the driver's require‐
ments on to the engine control unit independently of one another. Both senders are installed together in a
housing.
Check conditions
• The fuses must be OK.

• The battery voltage must be at least 11.5 V.

Polo 1995 ➤
Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics control
unit with the "Address word" 01:
=> Repair group 01; General to self-diagnosis; Connecting fault reader V.A.G 1551 and selecting engine control
unit General to self-diagnosis Connecting fault reader V.A.G 1551 and selecting engine control unit
-> Indicated on display:
Rapid data transfer HELP
Select function XX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

Read measured value block
Input display group number XXX
- Press keys 0, 6 and 2 for the "Display group number 62" and confirm entry with Q key.

(1...4 = Display zones)
Read measured value block 62 AG. Volkswagen AG d
1 2 3 4 agen oes
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- Check specifications of sender
rised 1 (G79) at idling stop in display zonente 3.
Specification: 12...97tho
% eo
au r
- Check specificationsssof sender 2 (G185) at idling stop in display zone 4.ac
Specification: 4...49 %
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Note:
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ility
The engine control unit calculates the voltage values of the angle sender in percent relative to 5 Volt and displays
ot p
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these as a percentage figure (5 Volt supply voltage equates to 100 %).
is n
h re
ole,
- Operate the accelerator pedal slowly until fully depressed and observe the angle sender figures in display
spec
zones 3 and 4:
The percent figures in display zone 3 must rise evenly. The tolerance range of 12...97 % is not covered t to the co
completely.
rrectne
The percent figures in display zone 4 must rise evenly. The tolerance range of 4...49 % is not covered
completely.
ss
Note:
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cial p
f in
The figure displayed in display zone 3 must always be approximately double that displayed in display zone 4.
form
mer
End specification value not achieved:

atio
om
- Press the ⇒key.

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or
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- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
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- Check accelerator pedal position sender voltage supply and wiring connections =>Page 131 .
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2.5 - Checking accelerator pedal position sender 131

Polo 1995 ➤
4-Cyl. injection engine (2 valve, roller rocker
en AG. Vfinger),
olkswagen AMechanics
G - Edition 10.1999
ag does
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Vol
- Remove cover in footwell (driver's side). ed b y gu
ara
- Disconnect 6-pin connector for accelerator ris pedal position sender. nte
tho eo
- Switch ignition on. au ra
c
- ss
-> Connect multimeter to measure voltage at the following contacts of the connector:
ce
e
Contact 1 + earth
nl
pt
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Contact 1 + 5
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Contact 2 + earth
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Contact 2 + 3
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Specification: minimum 4.5 V
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- Remove wiper arms and cowl panel:

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=> Electrical system; Repair group 92; Servicing windscreen wiper system Servicing windscreen wiper system
t.
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- -> Check wiring for open circuit between test box and 6-pin connector (connector to control unit) using current
flow diagram.
Contact 1+socket 6
Contact 2+socket 8
Contact 3+socket 7
Contact 4+socket 33
Contact 5+socket 19
Contact 6+socket 45
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
Specification: ∞ω
If voltage supply is OK and no wiring fault is detected:
- Renew accelerator pedal position sender

=> Page 127 , item 3
If voltage supply is not OK and no wiring fault is detected:

Polo 1995 ➤
control unit
3 - Activated charcoal filter system

3.1 - Activated charcoal filter system
3.2 - Function
Depending upon the air pressure and ambient temperature, fuel vapour will form above the level of fuel in the
tank. agen
AG. Volkswagen AG d
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The activated charcoal
ris
ed filter system prevents these HCaremissions
an
tee
escaping to the atmosphere.
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In limited quantities,
ss fuel vapours pass through a gravity valveac(which closes at an angle of 32 °) located at the
highest point in the tank and through a breather valve into the activated charcoal filter.
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nl
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The activated charcoal stores these vapours like a sponge.
erm
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When the Lambda control is active when driving (engine warm), the tank venting valve (N80), also known as
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the regeneration valve), is activated (pulsed) from engine control unit depending upon load and engine speed.
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hole
The opening period is dependent on the input signals.

spec
es, in part or in w
t to the co
Intake manifold vacuum draws fresh air through the vent opening on the underside of the activated charcoal
filter during the purging procedure (regenerating the activated charcoal). The fuel vapours stored in the activated
charcoal and fresh air are pulse-fed for combustion.
rrectness of i
The breather valve prevents fuel vapours from being drawn from the tank when the tank venting valve is open
l purpos
and intake manifold vacuum is present. It therefore ensures that the evacuation of the activated charcoal filter
has priority.
nform
ercia
No voltage (e.g. wiring open circuit) the tank venting valve is closed. The activated charcoal filter will not be
m
at
purged.
om
ion
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in t
or
Notes:
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ate
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◆ Hose connections are secured with either spring-type or clamp-type clips.

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for
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◆ Always replace clamp-type clips with spring-type clips.

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◆ V.A.G 1921 or VAS 5024 pliers are recommended when installing spring-type clips. Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
2.5 - Checking accelerator pedal position sender 133

Polo 1995 ➤
olksw
roller rocker finger), Mechanics - Edition 10.1999
AG. V agen AG
agen does
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3.3 - Servicing parts dofby Vthe activated
ol
charcoal filternot
gusystem
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ris
tho eo
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un
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an
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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
satelettronica
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.
1 Retaining ring
2 Bracket
◆ On body front right
3 Tank venting valve for activated charcoal filter (N80)
◆ Valve closed with ignition switched off
◆ When the engine is warm the valve will be activated from the engine control unit (pulsed)
◆ Check tank venting valve => Page 135
◆ Check activation of tank venting valve:
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐
forming final control diagnosis
4 Connector

AG. Volkswagen AG d
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agen Polooes1995 ➤
not
ol
4-Cyl. injection engine (2 valve, roller rocker finger),d by V Mechanics - Edition 10.1999 gu
ara
ise nte
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aut ra
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itte
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erm
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ility
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spec
es, in part or in w
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rrectness of i
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Cop py
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rig ht
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by lksw
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Prote AG.
5 Breather pipe
◆ From gravity/overflow valve on fuel tank
=> Page 113 , item 17
6 Throttle valve control part
7 Activated charcoal filter
◆ Location: in front right wheel housing
◆ Connection "MOTOR" to solenoid valve 1 item - 3 -
◆ Connection "TANK" with vacuum non-return valve
◆ To remove, release securing tab -arrow- and push container out upwards
3.4 - Checking tank venting valve
Note:
Tank venting valve is closed when no current is supplied.
Checking activation:
3.3 - Servicing parts of the activated charcoal filter system 135

Polo 1995 ➤
Test conditions
• Fuse No. 1 must be OK.

• Coolant temperature must be at least 80 °C, =>display group 04, display zone 3.
Functional check
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select the engine control unit with the
"Address word" 01. Connecting fault reader and selecting engine control unit:
AG. Volkswagen AG d
agen oes
-> Indicated on display: olksw not
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Rapid data transfer HELP ise nte
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Select function XX h
satelettronica
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- Press keys 0 and 4 for the function "Initiating basic settings" and confirm entry with Q key.
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Basic setting
wit
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hole
spec
- Press keys 0, 7 and 0 for "Display group number 70" and confirm entry with Q key.
es, in part or in w
t to the co
rrectness of i
System in basic setting 70
1 2 3 4
l purpos
Note:
nform
ercia
The engine must not be loaded during this diagnosis because the diagnosis will be interrupted and will not be
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at
started again until the engine is revved-up.

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ion
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in t
or
When the diagnosis is initiated by the engine control unit the display in display zone 4 jumps from "Test OFF"
his
ate
to "Test ON"
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- Run engine at idling speed until the

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op
Specification "TVV OK" C py
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is displayed in display zone 4. gh ht
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If the display indicates as described:
agen
Prote AG.
- Press ⇒key.
If the display does not indicate as described:
- Press ⇒key.
- Introduce final control diagnosis and activate tank venting valve (N80):

Polo 1995 ➤
3.5 - Checking fuel

ksw
agtank
en AG. breather
Volkswagen AG
does
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spec
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satelettronica
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◆ -> V.A.G 1368 Vacuum tester

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ercia
orm
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
◆ -> V.A.G 1390 Hand vacuum pump
Test conditions
• Ignition must be switched off
3.4 - Checking tank venting valve 137

Polo 1995 ➤
Test sequence
olkswagen AG
satelettronica
en AG. V
- -> First pull vent hose -1- from activated charcoal filter off tank venting ksw valve -2-.
ag does
not
Vol
- Connect hand vacuum pump V.A.G 1390 and vacuum tester ed bV.A.G 1368 as shown to hose -1-.guar
y
an
- Set vacuum tester to -A/B- position. ris tee
tho
- Operate hand vacuum pump V.A.G 1390 several times. au or
ac
Vacuum must not ss
ce
le
build up.
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pt
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If vacuum builds up:
rm
ab
pe
ility
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- Check breather connection -3- located on bottom of activated charcoal filter -4- for soiling, clean if necessary.
wit
, is n
h re
hole
spec
If vacuum does not build up:
es, in part or in w
t to the co
- Temporarily seal breather connection -3- and operate vacuum pump again several times.
A vacuum must build up.
(Vacuum non-return valve in activated charcoal filter must close).
rrectness of i
l purpos
- Renew activated charcoal filter.
nform
ercia
Checking lines to fuel tank and fuel cap

m
a
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tion in
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te o
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fo
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Pull vent hose -1- from fuel tank off activated charcoal filter -2-.
- Connect hand vacuum pump V.A.G 1390 and vacuum tester V.A.G 1368 as shown to hose -1-.
- Set vacuum tester to -A/B- position.
- Remove fuel filler cap from filler neck.
- Operate V.A.G 1390 several times. Vacuum must

Polo 1995 ➤
not build-up.
If vacuum builds-up:
- Check gravity/overflow valve => Page 110 , item 4

- Check line -1- from fuel tank for blockage.
- Refit fuel filler cap.

- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not
build up.
Note: agen
AG. Volkswagen AG d
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olksw not
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If the fuel level in the tank is low
rise the hand vacuum must be operated at
d b ara
nteleast 20...30 times.
tho eo
u ra
If vacuum builds up: ss a c
ce
le
un
pt
- Replace fuel tank cap.
an
d
itte
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rm
ab
pe
ility
satelettronica
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
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rp
cum
fo
en
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t.
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Cop py
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Vo
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cted agen
Prote AG.
3.5 - Checking fuel tank breather 139

lkswage es n
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Polo 1995 hor ➤
is tee
t or
4-Cyl.s auinjection engine (2 valve, roller rocker finger), ac Mechanics - Edition 10.1999
s
ce
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26 - Exhaust system nl
pt
du
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itte
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erm
ab
ility
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wit
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spec
1 - Removing and installing parts of exhaust system
es, in part or in w
t to the co
1.1 - Removing and installing parts of exhaust system
rrectness of i
Notes:
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◆ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient
nf
ercia
clearance to the bodywork. If necessary, loosen double clamp(s) and align silencer and exhaust pipe so
or
that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
m
m
atio
m
◆ Renew self-locking nuts.

o
n in
c
◆ Components marked with * will be checked by self-diagnosis:

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satelettronica
- Check catalyst => Page 147 . C py
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Prote AG.
140 26 - Exhaust system

Polo 1995 ➤
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments
satelettronica
AG. Volkswagen AG d
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1 Warm air collector plate

hole
spec
2 10 Nm
es, in part or in w
t to the co
◆ Note tightening sequence

Page => 145 , Fig. 1
3 Exhaust manifold
rrectness of i
◆ With integrated pre-catalyst only engine codes AKP, AUC or AUD

l purpos
4 Gasket
◆ Renew
nform
ercia
5 Lock nut, 25 Nm
m
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tion in
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments 141
Polo 1995 ➤
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
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nl
pt
du
an
itte
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erm
ab
satelettronica
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
6 Lambda probe 2 after catalyst (G130)*, 50 Nm

um
for
en
g
◆ Only engine codes AKP, AUC, AUD

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t.
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op
◆ Checking: C py
t. rig
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=> Repair group 24; Check functions; Check Lambda probe and Lambda regulation after catalyst Check func‐
co Vo
by lksw
cted
tions Check Lambda probe and Lambda regulation after catalyst
agen
Prote AG.
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
body
7 To silencer
8 Marking
9 Connector
◆ Only engine codes AKP, AUC, AUD
◆ For Lambda probe 2 after catalyst (G130) and Lambda probe heating (Z29)
◆ Black, 4-pin

Polo 1995 ➤
en AG . rocker
Volkswagefinger),
n AG Mechanics - Edition 10.1999
ag does
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b ara
ed nte
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th
au ra
c
ss
ce
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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
nform
mercia
a
com
tion in
r
te o
thi
satelettronica
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.
10 Front exhaust pipe with catalyst

◆ Check catalyst (engine codes AKP, AUC, AUD) => Page 147
◆ Only engine code AKK with ECE standard: uncoated catalyst
11 Mounting
12 Locating nut, 40 Nm
13 Connector
◆ For Lambda probe 1 before catalyst (G39) and Lambda probe heating (Z19)
Engine codes AKK, ALD:
◆ Black,4-pin
Engine codes AKP, AUC, AUD:
◆ Black, 6-pin
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments 143
Polo 1995 ➤
satelettronica
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
rrectne
14 Lambda probe 1 before catalyst (G39)*, 50Nm

◆ Checking:
ss o
=> Repair group 24; Check functions; Check Lambda probe and Lambda regulation before catalyst Check
cial p
f in
functions Check Lambda probe and Lambda regulation before catalyst

form
mer
atio
m
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
o
n
c
body
i
or
n thi

te
sd
a
◆ Check Lambda probe dynamics

iv
o
pr
(only engine code AKP, AUC, AUD) => Page 147 , Checking catalyst
um
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fo
en
ng
◆ Only engine code AKK with ECE standard: lead resistant Lambda probe
t.
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Cop py
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15 Bracket
gh ht
pyri by
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o
◆ For electric wiring of Lambda probe 1 before catalyst
c by lksw
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Prote AG.
Note:
Tighten warm air collector plate in sequence as illustrated to ensure it is installed free of stress.

Polo 1995 ➤
-> Fig. 1 Tightening sequence, warm air collector plate on exhaust manifold.
1.3 - Silencer with mountings
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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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
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nf
ercia
orm
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1 Front exhaust pipe with catalyst

thi
te
sd
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2 Marking
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◆ Three times on circumference

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Cop py
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Prote
145
AG.
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments
Polo 1995 ➤
3 Double clamp
4 Dimension-a- = ca. 5 mm
5 Mushroom head screw
6 23 Nm
7 Front silencer1)
◆ Insert in double clamp to marking
8 Mounting
satelettronica
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, is n
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hole
spec
es, in part or in w
t to the co
9 Connecting piece
rrectness of i
10 15 Nm
l purpos
11 Mounting
nform
ercia
12 20 Nm + 1/4 turn (90 °) further

m
13 Rear silencer1)
at
om
ion
c
14 Marking
in t
or
his
e
◆ Visible from below

at
do
riv
◆ For repair double clamp -item 16 -

p
cum
or
15 Separating point
f
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ng
t.
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◆ For repair cases1) t. Cop py
rig
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by
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise Polo 1995
nte ➤
eo
h
4-Cyl. injection engine (2 valve, roller s arocker finger), Mechanics - Edition 10.1999
ut ra
c
s
ce
le
◆ Marked by impressions on connecting pipe
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.
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op
satelettronica
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
16 Repair double clamp

◆ Must be slid onto the markings - 14 -
1) Front and rear silencers are installed as a single component as standard. In repair cases the front and
rear silencers are supplied individually and a repair double clamp item 16 is supplied as a joint. Cut through
connecting pipe at separating point - 15 - with a body saw e.g. V.A.G 1523.
1.4 - Checking catalyst
Only engine codes AKP, AUC, AUD
1.3 - Silencer with mountings 147

lkswage es n
o ot g
byV ua
d ran
ir se
Polo 1995 th ➤
o tee
or
u
4-Cyl.ssinjection engine (2 valve, roller rocker finger),
a ac
Mechanics - Edition 10.1999
ce
e
nl
pt
Test conditions
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
• -> Fuse No. 1 must be OK.
at
om
io
• Vehicle stationary
n
c
in t
r
• All electrical consumers, e.g. lights and rear window heating must be switched off.
o
his
e
• If the vehicle is equipped with an air conditioning system, this must be switched off.
at
do
riv
• Exhaust system between catalyst and cylinder head must be free of leaks
p
cum
or
• Coolant temperature must be at least 80 °C, =>display group 04, display zone 3.
f
en
ng
t.
• Intake air temperature less than 60°C
yi Co
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=>display group 04, display zone 4
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satelettronica
t. C rig
gh ht
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co
Functional check
by lksw
cted agen
Prote AG.
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select the engine control unit with the
"Address word" 01. Connecting fault reader and selecting engine control unit:
Lambda probe dynamics diagnosis

Rapid data transfer HELP
Select function XX
- Press keys 0 and 4 for the "Introduce basic setting" function and confirm entry with Q key.

Basic setting

1 2 3 4
- Depress brake pedal.
The engine speed is increased to

approx. 1100...1300 rpm
by the engine control unit
- Allow engine to run at increased engine speed until

display zone 4 jumps from "Test OFF" to "Test ON". The catalyst temperature in
display zone 2 must be a minimum of 400 °C.

Polo 1995 ➤
Note:
This process can take a few minutes.
- Check the amplitude quality in display zone 3:

Specification: 0.7... 2.00
- Allow engine to continue to run at increased engine speed until
display zone 4 displays the specification "B1-P1 OK.".
- Press C key.
The engine speed drops to idling speed.
Catalyst diagnosis
satelettronica
AG. Volkswagen AG d
agen
Note: Volksw
oes
not
by gu
d ara
ise nte
The diagnosis will
thor only be terminated if the Lambda probe dynamics
eo diagnosis is first successfully completed.
au ra
ss c
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un
pt
an
d
Basic setting
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ility
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hole

spec

es, in part or in w
t to the co

1 2 3 4
rrectness of i
- Depress brake pedal.

l purpos
The engine speed is increased to

approx. 1100...1300 rpm
nform
ercia
by the engine control unit

m
a
com
ti
- Allow engine to run at increased engine speed until

on in
display zone 4 jumps from "Test OFF" to "Test ON". The catalyst temperature in
r
te o
thi
display zone 2 must be a minimum of 400 °C.

s
iva
do
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rp
cum
fo
- Check the amplitude ratio in display zone 3:

en
ng
t.
Specification: max. 0.50 op
yi Co
- Allow the engine to continue to run at increased engine speed until
C py
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gh
display zone 4 displays "Cat B1 OK."
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pyri by
Vo
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by
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Prote AG.
1.4 - Checking catalyst 149

Polo 1995 ➤
- Press ⇒key.
The engine speed drops to idling speed.
2 - Exhaust gas recirculation system

2.1 - Exhaust gas recirculation system
Notes:
◆ The function/control of the exhaust gas recirculation system is checked by the self-diagnosis of the Motronic
control unit (J220).
◆ Pulsed control makes every conceivable valve position possible.
◆ Checking exhaust gas recirculation valve (N18).
satelettronica
◆ The cone shaped plunger in the (electric) EGR valve ensures that various cross sectional openings are
possible at different plunger lifts.
◆ Components marked with an * are checked via the self-diagnosis.
AG. Volkswagen AG d
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=> Repair group 01; Fault memory; olksInterrogating and erasings nfault
w e
ot g memory of engine control unit Fault memory
yV
Interrogating and erasing fault
sed memory of engine control unit
b ua
ran
ri tee
ho
ut or
◆ Components marked
ss with
a ** are checked via the final control diagnosis.ac
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
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or c
thi
te
sd
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Polo 1995 ➤
2.2 - Servicing parts of exhaust gas recirculation system
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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
Only engine code AUC

en
ng
t.
yi Co
Cop py
1 Intake manifold ht. rig
rig ht
py by
2 Oil seal co Vo
by lksw
cted agen
◆ Renew if damaged Prote AG.
3 Connecting pipe
4 Self-tapping bolt, 8 Nm
5 EGR valve (N18)*/** with potentiometer for exhaust gas recirculation (G212)*
◆ Check EGR valve (N18):
◆ Check potentiometer for exhaust gas recirculation (G212) =>Page 153
2.2 - Servicing parts of exhaust gas recirculation system 151

Polo 1995 ➤
AG. Volkswagen AG d
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satelettronica
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aut ra
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pt
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
6 10 Nm
7 8 Nm
nf
ercia
8 Gasket
rm
m
atio
◆ Renew
om
n in
c
9 Breather pipe
or
thi
e
10 Connection to intake manifold

t
sd
iva
o
r
11 Cylinder head
rp
cu
o
m
f
en
ng
12 6-pin connector yi
t.
Co
Cop py
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Prote AG.

Polo 1995 ➤
2.3 - Checking potentiometer for exhaust gas recirculation (G212)
lkswage es n
o ot g
byV ua
d ran
ir se tee
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u or
a ac
ss
ce
le
un
pt
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d
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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
satelettronica
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
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gh ht
pyri by
Vo
co lksw
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Prote AG.
Only engine code AUC
◆ V.A.G 1526 Hand multimeter

◆ V.A.G 1598/22 Test box
2.3 - Checking potentiometer for exhaust gas recirculation (G212) 153

Polo 1995 ➤
Test conditions
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• -> Fuses 30, 31 and 36 must be OK. s au ra
c
s
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nl
Test sequence
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
rrectness of i
l purpos
nform
ercia
- -> Pull off 6-pin connector -1- (grey) from EGR valve.
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
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cted agen
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- -> Connect multimeter to contacts 2 and 4 of 6-pin connector for voltage measurement.
- Switch on ignition.
Specification: min. 4.5 V

Polo 1995 ➤
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- -> Check wiring for open circuit
thor between test box and 6-pin connector using
eo current flow diagram.
Contact 2 and test box
s au socket 62 ra
c
s
Contact 4 and test box socket 54 ce
le
Contact 6 and test box socket 69

un
pt
an
d
Wire resistance: max. 1.5 ω

itte
y li
rm
- Additionally check wiring for short to one another, and for short to positive or earth.
ab
pe
ility
- Depending on conditions, renew following components:
ot
wit
, is n
h re
Voltage supply and wiring OK:

hole
spec
es, in part or in w
- Renew EGR valve (N18) with potentiometer (G212).

t to the co
- Erase learnt values and re-adapt engine control unit
=> Repair group 24; Engine control unit; Adapting engine control unit to throttle valve control part Engine control
rrectness of i
unit Adapting engine control unit to throttle valve control part

l purpos
If no wiring fault is detected and voltage supply is not OK:

nform
ercia
- Renew engine control unit.

m
a
com
tio
n in
r
control unit
te o
thi
s
iva
do
r
rp
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2.3 - Checking potentiometer for exhaust gas recirculation (G212) 155

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AG.

4-Cyl. injection engine (2 valve, roller rocker finger),

Service Department. Technical Information

10 - Removing and installing engine

15 - Cylinder head, Valve gear

20 - Fuel supply system

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg 00050207920

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

1.2 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

1.4 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

1.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

1.7 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

2.5 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

3.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

3.3 Servicing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

the gearbox end below the thermostat housing.

1.3 - Engine data

Code AKK ALD AUC AUD, AKP1)

Code AKK ALD AUC AUD, AKP1)

1.1 - Technical data 1

Code AKK ALD AUC AUD, AKP1)

3) In exceptional circumstances min. 91 RON, however with reduced performance

4) Additionally with integrated pre-catalyst in exhaust manifold

10 - Removing and installing engine

1 - Removing and installing engine

◆ 2024 A Lifting tackle

1.1 - Removing and installing engine 3

◆ -> V.A.G 1332 Torque wrench (40...200 Nm)

must be disconnected. Obtain radio code first if necessary.

- The engine is removed forwards together with the gearbox.

- With ignition switched off disconnect battery earth strap.

- Remove battery and battery retainer.

- Loosen or separate the following components:

- The hose from intake manifold to activated charcoal filter system

- The vacuum hose from inlet manifold at brake servo

4 10 - Removing and installing engine

- Disconnect clutch cable:

- Disconnect selector mechanism from gearbox.

selector mechanism Dismantling and assembling selector mechanism

Continuation for all vehicles

- Drain coolant => Page 105 .

- Remove securing clamps for power steering pressure pipe.

Vehicles with air conditioner

- Removing air conditioner compressor: