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

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Page 0.4
Safety first!
Page 0.5
Roadside repairs
Page 0.6
If your car won’t start
Page 0.6
Jump starting
Page 0.7
Wheel changing
Identifying leaks
Page 0.8
Page 0.9
Page 0.9
Weekly checks
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
Tyre condition and pressure
Bulbs and fuses
Page 0.13
Page 0.13
Page 0.14
Page 0.15
Lubricants, fluids and tyre pressures
Page 0.16
Routine maintenance and servicing
Page 1.1
Maintenance schedule
Page 1.3
Maintenance procedures
Page 1.5
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
Page 6.1
Manual transmission
Page 7.1
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
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
Page REF.5
Fault finding
Glossary of technical terms
Page REF.12
Page REF.19
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
Andy Legg
Spencer Drayton
Carole Turk
Bob Jex
Pete Shoemark
Editor & Page Make-up
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
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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
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
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.
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.
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.
A ! Warning: Never expose the hands,
Fuel is highly flammable; fuel vapour is
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
Electric shock
Ignition HT
voltage can be
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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