Volkswagen Polo [90-94] Haynes Service And Repiar Manual.pdf

Contents

LIVING WITH YOUR VW POLO

Introduction

Page 0.4

Safety first!

Page 0.5

Roadside repairs

Introduction

Page 0.6

If your car won’t start

Page 0.6

Jump starting

Page 0.7

Wheel changing

Identifying leaks

Towing

Page 0.8

Page 0.9

Weekly checks

Introduction

Page 0.10

Underbonnet check points

Engine oil level

Page 0.10

Page 0.11

Coolant level

Page 0.11

Brake fluid level

Page 0.12

Screen washer fluid level

Page 0.12

Wiper blades

Battery

Tyre condition and pressure

Bulbs and fuses

Page 0.13

Page 0.14

Page 0.15

Lubricants, fluids and tyre pressures

Page 0.16

MAINTENANCE

Routine maintenance and servicing

Page 1.1

Maintenance schedule

Page 1.3

Maintenance procedures

Page 1.5

Contents

REPAIRS & OVERHAUL

Engine and associated systems

Petrol engine in-car repair procedures

Page 2A.1

Engine removal and overhaul procedures

Cooling, heating and ventilation systems

Fuel/exhaust systems - single-point petrol injection models

Fuel/exhaust systems - multi-point petrol injection models

Page 2B.1

Page 3.1

Page 4A.1

Page 4B.1

Exhaust and emission control systems

Page 4C.1

Engine electrical - starting and charging systems

Engine electrical - Ignition system

Page 5A.1

Page 5B.1

Transmission

Clutch

Page 6.1

Manual transmission

Page 7.1

Driveshafts

Page 8.1

Brakes and suspension

Braking system

Page 9.1

Suspension and steering

Page 10.1

Body equipment

Bodywork and fittings

Body electrical systems

Page 11.1

Page 12.1

Wiring diagrams

Page 12.12

REFERENCE

Dimensions and weights

Page REF.1

Conversion factors

Page REF.2

Buying spare parts and vehicle identification

General repair procedures

Jacking and vehicle support

MOT test checks

Page REF.3

Page REF.4

Page REF.5

Fault finding

Glossary of technical terms

Page REF.12

Page REF.19

Index

Page REF.24

0.4 Introduction

The updated VW Polo range was introduced in November of A wide range of standard and optional equipment is available within

1990, with a choice of 1.05 litre (1043 cc) or 1.3 litre (1272 cc) petrol the Polo range to suit most tastes, including a sliding sunroof, tinted

engines, with either single-point or multi-point fuel injection. During glass, alloy wheels and remote adjustable door mirrors.

Spring 1991, the G40 model was launched, equipped with a Provided that regular servicing is carried out in accordance with the

supercharged version of the 1.3 litre engine. Three body shells are manufacturer’s recommendations, the VW Polo should prove reliable

available - a three-door hatchback, a two-door saloon and a three- and very economical. The engine compartment is well-designed, and

door Coupe.

most of the items requiring frequent attention are easily accessible.

All engines are derived from the well-proven units which have

appeared in previous versions of the VW Polo. The engine is of four-

cylinder overhead camshaft design, mounted transversely, with the

transmission mounted on the left-hand side. All models have a four or

five-speed manual transmission.

Your Polo manual

The aim of this manual is to help you get the best value from your

vehicle. It can do so in several ways. It can help you decide what work

must be done (even if you choose to get it done by a garage). It will

also provide information on routine maintenance and servicing, and

give a logical course of action and diagnosis when random faults

occur. However, it is hoped that you will use the manual by tackling the

work yourself. On simpler jobs it may even be quicker than booking the

car into a garage and going there twice, to leave and collect it. Perhaps

most important, a lot of money can be saved by avoiding the costs a

garage must charge to cover its labour and overheads.

All models have fully-independent front suspension and employ coil-

over-damper struts, transverse lower arms and an anti-roll bar. The

rear suspension is semi-independent, utilising coil-over-damper struts

and incorporating trailing arms located by a torsion beam axle. A rear

anti-roll bar is fitted to certain models.

The WV Polo Team

Haynes manuals are produced by dedicated and

enthusiastic people working in close co-operation. The

team responsible for the creation of this book included:

The manual has drawings and descriptions to show the function of

the various components so that their layout can be understood. Tasks

are described and photographed in a clear step-by-step sequence.

This manual is not a direct reproduction of the vehicle

manufacturer’s data, and its publication should not be taken as

implying any technical approval by the vehicle manufacturers or

importers.

Authors

Andy Legg

Spencer Drayton

Carole Turk

Bob Jex

Pete Shoemark

Sub-editor

Editor & Page Make-up

Acknowledgements

Thanks are due to Champion Spark Plugs, who supplied the

illustrations showing spark plug conditions. Special thanks to Loders

of Yeovil who provided several of the project vehicles used in the

origination of this manual. Thanks are also due to Sykes-Pickavant

Limited, who provided some of the workshop tools, and to all those

people at Sparkford and Newbury Park who helped in the production

of this manual.

We take great pride in the accuracy of information given in this

manual, but vehicle manufacturers make alterations and design

changes during the production run of a particular vehicle of which

they do not inform us. No liability can be accepted by the authors

or publishers for loss, damage or injury caused by any errors in, or

omissions from, the information given.

Workshop manager

Photo Scans

Paul Buckland

John Martin

Paul Tanswell

Steve Tanswell

Cover illustration & Line Art

Roger Healing

Wiring diagrams

Matthew Marke

We hope the book will help you to get the maximum

enjoyment from your car. By carrying out routine

maintenance as described you will ensure your car’s

reliability and preserve its resale value.

VW Polo Boulevard

WV Polo GT Coupe

Safety first! 0.5

Working on your car can be dangerous.

This page shows just some of the potential

risks and hazards, with the aim of creating a

safety-conscious attitude.

General hazards

Mains voltage is also dangerous. Make

sure that any mains-operated equipment is

correctly earthed. Mains power points should

be protected by a residual current device

(RCD) circuit breaker.

Special hazards

Hydrofluoric acid

This extremely corrosive acid is formed

when certain types of synthetic rubber, found

in some O-rings, oil seals, fuel hoses etc, are

exposed to temperatures above 400°C. The

rubber changes into a charred or sticky

substance containing the acid. Once formed,

the acid remains dangerous for years. If it

gets onto the skin, it may be necessary to

amputate the limb concerned.

When dealing with a vehicle which has

suffered a fire, or with components salvaged

from such a vehicle, wear protective gloves

and discard them after use.

The battery

Batteries contain sulphuric acid, which

attacks clothing, eyes and skin. Take care

when topping-up or carrying the battery.

The hydrogen gas given off by the battery

is highly explosive. Never cause a spark or

allow a naked light nearby. Be careful when

connecting and disconnecting battery

chargers or jump leads.

Air bags

Air bags can cause injury if they go off

accidentally. Take care when removing the

steering wheel and/or facia. Special storage

instructions may apply.

Diesel injection equipment

Diesel injection pumps supply fuel at very

high pressure. Take care when working on

the fuel injectors and fuel pipes.

Fume or gas intoxication

Exhaust fumes are

poisonous; they often

contain carbon

monoxide, which is

Scalding

Don’t remove the radiator or expansion

tank cap while the engine is hot.

. Engine oil, automatic transmission fluid or

power steering fluid may also be dangerously

hot if the engine has recently been running.

rapidly fatal if inhaled.

Never run the

engine in a

confined space

such as a garage

with the doors shut.

Fuel vapour is also

Burning

Beware of burns from the exhaust system

and from any part of the engine. Brake discs

and drums can also be extremely hot

immediately after use.

poisonous, as are the vapours from some

cleaning solvents and paint thinners.

Crushing

Poisonous or irritant substances

Avoid skin contact with battery acid and

with any fuel, fluid or lubricant, especially

antifreeze, brake hydraulic fluid and Diesel

fuel. Don’t syphon them by mouth. If such a

substance is swallowed or gets into the eyes,

seek medical advice.

When working under or near

a raised vehicle,

Prolonged contact with used engine oil can

cause skin cancer. Wear gloves or use a

barrier cream if necessary. Change out of oil-

soaked clothes and do not keep oily rags in

your pocket.

Air conditioning refrigerant forms a

poisonous gas if exposed to a naked flame

(including a cigarette). It can also cause skin

burns on contact.

venture

under a car which

is only supported by a jack.

Take care if loosening or tightening high-

torque nuts when the vehicle is on stands.

Initial loosening and final tightening should

be done with the wheels on the ground.

Fire

Asbestos

A ! Warning: Never expose the hands,

Fuel is highly flammable; fuel vapour is

explosive.

Don’t let fuel spill onto a hot engine.

Do not smoke or allow naked lights

(including pilot lights) anywhere near a

vehicle being worked on. Also beware of

creating sparks

(electrically or by use of tools).

. Fuel vapour is heavier than air, so don’t

work on the fuel system with the vehicle over

an inspection pit.

Another cause of fire is an electrical

overload or short-circuit. Take care when

repairing or modifying the vehicle wiring.

Keep a fire extinguisher handy, of a type

suitable for use on fuel and electrical fires.

Asbestos dust can cause cancer if inhaled

or swallowed. Asbestos may be found in

gaskets and in brake and clutch linings.

When dealing with such components it is

safest to assume that they contain asbestos.

face or any other part of the body

to injector spray; the fuel can

penetrate the skin with potential/y fatal

results.

Electric shock

Ignition HT

voltage can be

dangerous,

especially to

people with heart

problems or a

pacemaker. Don’t

work on or near the

ignition system with

the engine running or

the ignition switched on.

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