11

Service
Polo Estate 1996 ➤

4-cyl. injection engine Mechanics (1.6 l engine)
Engine ID AEH AKL APF AUR
Edition 12.1999
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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 Estate 1996 ➤ y Volksw
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00 - Technical data hole
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10 - Removing and installing engine
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 © 2011 Volkswagen AG, Wolfsburg 00056408120

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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
spec
1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
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1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
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1.7 Renewing bonded rubber bushes on subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

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1.8 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . . .14
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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2 Removing and installing sealing flange and pressure plate/drive plate . . . . . . . . . . . . . . . .28
2.1 Removing and installing sealing flange and pressure plate/drive plate . . . . . . . . . . . . . . . .28
2.2 Renewing crankshaft oil seal -belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.3 Removing and installing front sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.2 Colour markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
1.2 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
1.3 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
1.5 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2.3 Replacing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
2.5 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
2.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
2.7 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
2.8 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Contents i
4-cyl. injection engine Mechanics (1.6 l engine) - Edition 12.1999
1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
1.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
1.2 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
1.3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.4 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
1.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
1.8 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
1.2 Removing and installing fuel tank with its attachments and fuel filter . . . . . . . . . . . . . . . . . .124
1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .130
satelettronica
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
1.5 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
1.6 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
1.7 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
1.8 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
1.9 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
2 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
2.1 Accelerator mechanism . . w. a.g.en. A. G. ..V.o.lk.sw. a.g.e.n A. G
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2.2 Servicing acceleratorbymechanism
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2.3 Adjusting throttleorcable
ise . . . . . . . . . . . . . . . . . . . . . . . . . . .ra. n.te.e . . . . . . . . . . . . . . . . . . . . . . . .145
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3 Checking electronic
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3.1 Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
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3.2 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

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3.3 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

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3.4 Adjusting pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

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4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

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4.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

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4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

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4.3 Servicing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

4.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
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1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . . . . . .161
1.3 Checking catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
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2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

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2.1 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

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2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

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2.3 Removing and installing parts of the secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . .174
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2.4 Checking secondary air pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
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2.5 Checking combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
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2.6 Checking secondary air inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
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3 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
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3.1 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

3.2 Servicing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
ii Contents
3.3 Checking exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186

3.4 Checking potentiometer for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
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iv Contents
00 - Technical data
1 - Technical data
1.1 - Technical data
1.2 - Engine number
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-> The engine number ("Code letters" and "Serial number") can be found on the joint between engine/gearbox.
The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters)
makes up the "engine code", and the second part (6 characters), the "serial number". If more than 999,999
engines with the same engine code are produced, the first of the six characters is replaced with a letter.
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1.3 - Engine data

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Manufactured 10.99 ▸ 10.99 ▸ 01.00 ▸ 05.00 ▸

Exhaust emissions fulfil MVEG II standard D3 standard D4 standard EURO IV
Emissions warning lamp No No No Yes
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Capacity ltr. 1.6 1.6 1.6 1.6

Output kW at rpm 74/5600 74/5600 74/5600 74/5600
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Torque Nm at rpm 145/3800 145/3800 145/3800 145/3800

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Bore ø mm 81.0 81.0 81.0 81.0

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Stroke mm 77.4 77.4 77.4 77.4

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Compression 10.2 10.2 10.2 10.2

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RON min. 95 unleaded 95 unleaded 95 unleaded 95 unleaded

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Injection, ignition SIMOS 2.1 SIMOS 2.1 SIMOS 3.3 SIMOS 3.3
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Knock control Yes Yes Yes Yes

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1.1 - Technical data 1


Lambda control Yes Yes Yes1) Yes1)

Catalyst Yes Yes Yes Yes
Exhaust gas recirculation No No Yes Yes
Charging No No No No
Secondary air system No No Yes Yes
Variable intake manifold Yes Yes Yes Yes
Camshaft adjustment No No No No
1) With 2 Lambda probes
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2 00 - Technical data

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

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◆ VW 313 Support clamp
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◆ VW 540 Engine and gearbox support t. C rig
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◆ V.A.G 1202 A Workshop crane
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◆ V.A.G 1306 Drip tray
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1.1 - Removing and installing engine 3

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◆ V.A.G 1331 Torque wrench (5...50 Nm)
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◆ VAS 5024 Assembly tool for spring-type clip
◆ G 000 100 Grease (vehicles with manual gearbox) nf
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◆ Cable tie
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1.2 - Notes on removing

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- The engine is removed forwards together with the gearbox.

- All cable ties which are opened or cut open when removing engine, must be replaced in the same position
when installing engine.
- With the ignition switched off disconnect battery earth strap.
- Remove engine cover.
- Remove battery.
- Unscrew power steering reservoir and tie-up.
4 10 - Removing and installing engine

- Remove intake hose between air mass meter (G70) and throttle valve control part (J338).
- Remove air cleaner.
Warning!
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release
pressure by carefully loosening the connection.
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- -> Pull off or supply pipe/hose -1- (with white marking)ntand
is ee return pipe/hose -2- (with blue marking) and collect
fuel thatu leaks out with a cloth.
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Note:
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Press buttons on hose couplings to do this.
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- Seal the pipes so that the fuel system is not contaminated by dirt etc.
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- Observe rules for cleanliness => Page 131 .

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- Pull hose -3- off activated charcoal filter solenoid valve 1.

hole
spec
- Remove noise insulation tray.

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- Remove ribbed belt => Page 26 .

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- Remove front exhaust pipe from exhaust manifold => Page 161 , exhaust manifold, front exhaust pipe and
catalyst with attachments.
rrectness of i
- Disconnect drive shafts at gearbox:

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=> Running gear, Axles, Steering; Repair group 40; Removing and installing drive shaft Removing and installing
drive shaft
nf
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- Unscrew pipes for power steering from engine carrier.

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- Open and close the expansion tank sealing cap to release pressure in cooling system.
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- Drain coolant => Page 114 .

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- Pull connectors off thermo-switch and radiator fan.

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- Pull radiator coolant hoses off engine using spring-type clip pliers V.A.G 1921 or VAS 5024.
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- Removing lock carrier with attachments:

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=> General body repairs, exterior; Repair group 50; Body, front; Removing and installing lock carrier with at‐
C py
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tachments. Body, front Removing and installing lock carrier with attachments.
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Vehicles with air conditioner: Prote
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- Observe additional information and removal instructions => Page 14 .
- In preparation for the further dismantling work, depending on equipment, disconnect the connectors from
the following components:
ignition transformer (N152)
Hall sender (G40)
injectors (N30... N33,)
coolant temperature sender (G62)
engine speed sender (G28)
knock sensor 1 (G61)
EGR valve (N18) with potentiometer for
exhaust gas recirculation (G212)
secondary air pump motor (V101)
1.2 - Notes on removing 5

oil pressure switch (F1)
air mass meter (G70)
throttle valve control part (J338)
- Disconnect all electric wires from gearbox, alternator and starter and move clear.
- Pull off/disconnect all other electrical connections as necessary from engine
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- Pull vacuum and breather hoses off engine. Volksw not
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- Disconnect selector mechanism from gearbox.
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=> 5-Speed manual gearbox 02K; Repair group 34; Servicing selector mechanism Servicing selector mecha‐
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- Remove hydraulic clutch slave cylinder:
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=> 5-Speed manual gearbox 02K; Repair group 30; Servicing clutch control Servicing clutch control
es, in part or in w
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Note:
Clutch pedal must not be depressed.
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Vehicles with automatic gearbox
satelettronica
- Remove selector lever cable from gearbox:
nform
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=> Automatic gearbox 01M; Repair group 37; Servicing shift mechanism; Dismantling and assembling shift
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mechanism Servicing shift mechanism Dismantling and assembling shift mechanism
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Continuation for all vehicles
- Remove power assisted steering vane pump with bracket and lay to side; hoses remain connected.
=> Running gear, Axles, Steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes
Assembly overview: vane pump, reservoir, hydraulic pipes
- -> Attach lifting tackle 2024 A as follows and lift slightly with workshop crane V.A.G 1202 A:
Pulley end:
4th hole in hook at position 1
Flywheel end:

4th hole in hook at position 8
Warning!
The hooks and locating pins must be secured with locking pins -arrows-.
Notes:
◆ The positions marked 1...4 on the bar must be towards the pulley end.
◆ The holes in the hook rails are counted up from the hook.
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- -> Remove securing bolts -1- from assembly mounting.
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- Pull assembly out forwards. When doing this, if necessary turn assembly and lower slightly.
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When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the
engine and gearbox bracket VW 540 and supplementary set VW 540/1B.
Work sequence
- Remove gearbox.

- Secure torque converter against "falling out" after separating engine from gearbox.
1.2 - Notes on removing 7

- -> Attach lifting tackle 2024A as follows .
Pulley end:
3rd hole in hook rail at position 2
Flywheel end:
4th hole in hook rail at position 8
Warning!
The hooks and locating pins must be secured with locking pins.
Notes:
◆ The positions marked 1...4 on the bar must be towards the pulley end.
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- Secure engine to support clamp VW 313 using engine and gearbox bracket VW 540 and supplementary set
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VW 540/1B. Fitting pins must be removed.
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1.4 - Notes on installing
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Installation is carried out in the reverse sequence, when doing this note the following:
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- Insert in the cylinder block new dowel sleeves for centralising engine and gearbox.
- -> Fit intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
Vehicles with manual gearbox
- Lightly grease input shaft splines with G 000 100.

- Check clutch and clutch operating mechanism, then install.
=> 5-Speed manual gearbox 02K; Repair group 30; Servicing clutch control Servicing clutch control
- When installing the assembly, ensure sufficient clearance to drive shafts.
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- -> When installing the assembly, take note that the bonded rubber bush lugs rear left, rear front and right
locate in the inserts on the consoles -arrows-.
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- Align engine mountings stress-free by rocking.
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Assembly mounting tightening torques

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=> Page 11 .
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- Install gear selector mechanism: cted agen
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- If necessary, adjust gear selector mechanism:
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- Install selector cable on gearbox, adjust if necessary:
=> Automatic gearbox 01M; Repair group 37; Servicing shift mechanism; Dismantling and assembling shift
mechanism Servicing shift mechanism Dismantling and assembling shift mechanism
- Electrical connections and routing:
1.4 - Notes on installing 9

=> Electrical system; Repair group 97
- Installing lock carrier with attachments:
Vehicles with air conditioner
- Installing air conditioner compressor:
=> Heating, Air conditioning; Repair group 87; Removing and installing compressor bracket Removing and
installing compressor bracket
- Install drive shafts:
=> Running gear, Axles, Steering; Repair group 40; Removing and installing drive shaft Removing and installing
drive shaft n AG. Volkswagen A G do
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- Fit front exhaust pipe to exhaust manifold => Page ed
by V 161 , exhaust manifold, front exhaust
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ran pipe and catalyst
with attachments. ris tee
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- Installing P.A.S. vane pump: au
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=> Running gear, Axles, Steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes
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Assembly overview: vane pump, reservoir, hydraulic pipes

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- Install ribbed belt => Page 26 .
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- Install noise insulation tray.
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spec
- Tighten power steering reservoir nuts/bolts.
es, in part or in w
t to the co
- Fill with coolant => Page 114
- Check headlight adjustment and adjust if necessary:
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=> Maintenance booklet
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Vehicles without EPC (AEH, AKL)

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- Adjusting accelerator cable =>Page 144 , Servicing accelerator mechanism.

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- Match engine electronics control unit to throttle valve control part:

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=> Repair group 24; Engine control unit; Matching engine control unit to throttle valve control part Engine control
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unit Matching engine control unit to throttle valve control part

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=> Repair group 24; Engine control unit; Erasing learnt values and adapting engine control unit to throttle valve
control part and EGR valve Engine control unit Erasing learnt values and adapting engine control unit to throttle
valve control part and EGR valve
- On vehicles with automatic gearbox the gearbox control unit must be matched additionally:
=> Self-diagnosis for automatic gearbox 01M; Repair group 01; Performing self-diagnosis; Initiating basic set‐
tings Performing self-diagnosis Initiating basic settings

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- Carry out a test drive and interrogate fault memory:
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=> Repair group 01; Fault memory; Interrogating and erasing fault memory of engine control unit Fault memory
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Interrogating and erasing fault memory of engine control unit
hole
spec
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1.5 - Tightening torques
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Bolted connection Tightening torque
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Bolts, nuts M6 10 Nm
M8 20 Nm
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M10 45 Nm
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M 12 60 Nm
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Exhaust pipe to manifold 40 Nm
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Engine carrier to body 50 Nm
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Assembly mounting tightening torques C py
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=> Page 11 .
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1.6 - Assembly mountings
Tightening torques
(Bolts oiled)
-> Front assembly mounting
A = 55 Nm
B = 45 Nm
C = 55 Nm
1.4 - Notes on installing 11

-> Rear right assembly mounting
A = 25 Nm
B = 60 Nm
C = 30 Nm
-> Rear left assembly mounting (vehicles with manual gearbox).
satelettronica
A = 60 Nm
B = 35 Nm
C = 30 Nm
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-> Rear left assembly mounting (vehicles with automatic gearbox).

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A = 60 Nm
B = 35 Nm
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C = 30 Nm
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◆ 10-222A Support device with legs 10-222A/1

◆ 3302 Peening tool
◆ VW 432 Thrust piece
Work sequence
- Fit engine support bracket 10-222A with legs 10-222A/1.
1.7 - Renewing bonded rubber bushes on subframe 13

- Locate support bracket in lifting eye on left of cylinder head and take-up weight of engine.
- Remove engine carrier.
- -> Lever off washers from the spacer sleeves with pliers wage (replace any washers
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- Pull out spacer sleeves and detach rubber ir semounting.
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- Fit new rubber mounting and insert spacer
utho sleeves as far as possible. or
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- -> Fit washers -1- over peening tool 3302 onto the rubber mounting -2-.
- Fit press sleeve of peening tool 3302 and using a press, press the washers onto the spacer sleeves and
nform
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peen. Use VW 432 as packing.

- Remove any resulting protrusion/burr on the peening.
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1.8 - Additional information and removal instructions for vehicles with air conditioner
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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.
To facilitate removing and installing the engine without opening the refrigerant circuit:
- Remove retaining clamp(s) from refrigerant pipes.
- Unscrew cooler and cooler fan from lock carrier.
- Unscrew condenser from cooler.

- Removing air conditioner compressor:
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket removing and in‐
stalling compressor bracket
- Remove air conditioner compressor and condenser and position to one side so that the refrigerant hoses
are not stressed.
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1.8 - Additional information and removal instructions for vehicles with air conditioner
15
13 - Crankshaft group
1 - Dismantling and assembling engine

1.1 - Dismantling and assembling engine
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Note:
If large amounts of metal shavings or quantities of small metal particles or wear are discovered during engine
repair work, this can originate from damage to the crankshaft or conrod bearings. To prevent any further damage
from occurring, carry out the following once the repair procedure is complete:
- Thoroughly clean oil channels

- Renew oil spray jets
- Renew oil cooler
16 13 - Crankshaft group
- Renew oil filter
I =>Page 17
II =>Page 21
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Part I
AG.
1 25 Nm
2 Bracket
◆ various designs possible
3 Toothed belt guard - upper part
4 Toothed belt guard - centre section
5 20 Nm
6 Washer
7 Tensioner
◆ Checking semi-automatic toothed belt tensioning roller
=> Page 58
1.1 - Dismantling and assembling engine 17

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◆ Removing, installing and tensioning

=> Page 55
9 Rear toothed belt guard
10 O-ring
◆ Renew
11 Coolant pump
◆ Check for ease of movement
◆ Note installation position
◆ Removing and installing
=> Page 119
12 15 Nm
13 Crankshaft toothed belt sprocket
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◆ Threads and shoulder must be free of oil and grease
agen
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◆ Counter-hold with 3415 to loosen and tighten
15 Toothed belt guard - lower part
16 10 Nm
17 Pulley
◆ For power assisted steering pump
18 25 Nm
19 Ribbed belt
◆ Mark direction of rotation before removing
=> Page 26

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20 Belt pulley/vibration damper
C py
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◆ Can only be installed in one position. Holes are off-set py by
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◆ Note position when installing toothed belt
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=> Page 55 , Removing, installing and tensioning toothed belt
AG.
21 Tensioning device for ribbed belt

◆ Turn using a 16 mm open jaw spanner to slacken ribbed belt => Page 26 , Removing and installing
ribbed belt
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Part II
1 Knock sensor 1 (G61)

◆ Checking:
=> Repair Group 01; Fault memory; Interrogating and erasing engine control unit fault memory Fault memory
Interrogating and erasing engine control unit fault memory
2 20 Nm
◆ Tightening torque influences the function of the knock sensor
3 Coolant pipe
4 Dipstick
◆ The oil level must not be above the max. mark!
◆ Markings=> Page 92 , Fig. 1
5 Bracket
◆ For ignition coils
6 10 Nm

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7 Securing screw
◆ Engine codes AEH, AKL tighten to 20 Nm
◆ Engine codes APF, AUR tighten to 10 Nm
8 Bracket
◆ various designs possible
9 Securing screw
◆ Engine codes AEH, AKL tighten to 10 Nm
◆ Engine codes APF, AUR tighten to 6 Nm
10 Oil filter bracket with attached parts
◆ Dismantling and assembling
=> Page 89
11 15 Nm + 1/4 turn (90 °) further
◆ Renew
12 Gasket
◆ Renew
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13 10 Nm
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14 Engine speed sender
◆ Checking: ss o
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inform

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15 Connection
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16 15 Nm
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17 O-ring
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◆ Renew if damaged
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19 Coolant thermostat
es, in part or in w

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=> Page 121

◆ Observe installation position,
=> Page 121 Removing and installing thermostat
rrectness of i
◆ Checking: heat-up thermostat in water

l purpos
◆ Opening commences approx. 85 °C

◆ Ends approx. 105 °C
◆ Opening lift min. 7 mm
nf
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20 45 Nm
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21 Compact bracket
om
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◆ For ribbed belt tensioning roller, alternator, P.A.S. vane pump and air conditioner compressor
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◆ Removing and installing sealing flange and pressure plate/drive plate C py
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=> Page 28
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◆ Removing and installing crankshaft => Page 39
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◆ Dismantling and assembling pistons and conrods
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=> Page 44
23 O-ring
◆ Renew

1.2 - Removing and installing ribbed belt
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Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
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◆ Retaining pin T10060
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◆ Spanner 15 mm AF
hole
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Work sequence
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satelettronica
- Remove noise insulation tray:
- Remove windscreen washer reservoir.
rrectness of i
- Mark direction of rotation of ribbed belt.
l purpos
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- -> To slacken ribbed belt turn tensioning element with a 16 mm spanner in direction of arrow.
- -> Lock tensioning element with retaining pin T10060.

- Remove ribbed belt.
Installing ribbed belt
- Install in reverse order.
Notes:
◆ Ensure, before installing ribbed belt, that all ancillaries (alternator, air conditioner compressor, power as‐
sisted steering vane pump) are secured tightly.
◆ When fitting the ribbed belt observe belt direction of rotation and that the belt is seated correctly in the belt
pulleys.
◆ For vehicles without air conditioning, put ribbed belt over alternator last.
◆ For vehicles with air conditioning, put ribbed belt over air conditioning compressor last.
After completing repairs always:
- Start engine and check belt running.
satelettronica
-> Belt drive without air conditioner compressor
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AG.
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2 - Removing and installing sealing flange and pressure plate/drive plate yV
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2.1 - Removing and
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Note:
For repairs to the clutch:
=> 5-Speed manual gearbox 02K; Repair group 30; Servicing clutch Servicing clutch
1 15 Nm
2 Oil seal
◆ Renewing => Page 31
3 Front sealing flange
◆ Must be located on dowel sleeves
=> Page 34
◆ To remove and install remove sump
4 Threaded pin, 10 Nm
◆ Renew
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5 Cylinder block C py
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◆ Removing and installing crankshaft => Page 39
rig ht
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◆ Dismantling and assembling pistons and conrods by c lksw
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=> Page 44
Prote AG.
6 Oil seal
◆ Fitted permanently on -item 7 -
7 100 Nm
8 60 Nm + 1/4 turn (90 °) further
◆ Renew
9 Plate
◆ Observe fitting position
10 Pressure plate/drive plate
◆ To remove and install lock pressure plate with VW 558
◆ Removing and installing drive plate =>Page 36
2.1 - Removing and installing sealing flange and pressure plate/drive plate 29
satelettronica
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11 Intermediate plate
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◆ Do not damage/bend when assembling

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12 Sealing flange with oil seal

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◆ Only renew complete

◆ Use protective sleeve supplied when installing
◆ To remove and install remove sump
rrectness of i
◆ Do not additionally oil or grease the oil seal sealing lip

◆ Before installing, remove oil remains from crankshaft journal with a clean cloth
l purpos
◆ Remove protective sleeve first after sealing flange has been slid onto crankshaft journal
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2.2 - Renewing crankshaft oil seal -belt pulley end
satelettronica
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◆ 3203 Oil seal extractor

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2.2 - Renewing crankshaft oil seal -belt pulley end
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Removing
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- Remove toothed belt => Page 55 .
wit
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- -> Remove crankshaft toothed belt sprocket. To do this counter-hold sprocket with 3415.
hole
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- -> To guide seal extractor, screw centre bolt into crankshaft onto stop by hand.
fo
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- Unscrew inner part of oil seal extractor 3203 nine turns (approx. 20 mm) out of the outer part and lock with
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knurled screw. Cop py
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- -> Lubricate threaded head of oil seal extractor 3203, place it in position and exerting firm pressure screw
it as far as possible into oil seal.
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.
Installing
Note:
Gradual introduction of PTFE oil seal (identifying characteristics: no annular spring, sealing lip wider). The
sealing lip of this oil ring must not be oiled or lubricated. A plain encased seal of older construction (with annular
spring) may be replaced with a PTFE oil seal, but not vice versa.
- Before installing, remove oil remains from crankshaft journal with a clean cloth.
- -> Fit guide sleeve T10053/1 onto crankshaft journal.
- Slide oil seal over guide sleeve onto crankshaft stub.
satelettronica
AG. Volkswagen AG d
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- -> Pressrise in oil seal onto stop using press sleeve
d ara
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- -> Install crankshaft sprocket and counter-hold with 3415.

Tightening torque: 90 Nm + 1/4 turn (90 °) further
nform
ercia
Note:
m
at
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io
Thread and shoulder must be free of oil and grease.

n
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Installing toothed belt and adjusting valve timing => Page 55 .

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2.2 - Renewing crankshaft oil seal -belt pulley end 33

2.3 - Removing and installing front sealing flange
AG. Volkswagen AG d
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◆ 3415 Counter-hold tool
◆ T10053 Assembly device
◆ Hand drilling machine with plastic brush insert
◆ D176404 A2 Silicone sealant
◆ Flat scraper
Removing

- Remove toothed belt => Page 55 .
- -> Remove crankshaft toothed belt sprocket. To do this counter-hold sprocket with 3415.
- Drain engine oil.
- Remove sump => Page 92 .
- Unbolt front sealing flange.
- Take off sealing flange, release using light blows with a rubber headed hammer if necessary.
satelettronica
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- Remove sealant residue on cylinder block with a flat scraper.

, is n
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- Cover seal with a clean rag.

hole
spec
- -> Remove sealant remains on sealing flange with a rotating plastic brush (wear protective goggles).
es, in part or in w
- Clean sealing surface, must be free of oil and grease.

t to the co
Installing
rrectness of i
Notes:
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◆ Note the use by date of the sealant.

◆ The sealing flange must be installed within 5 minutes of applying the silicone sealant.
nform
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at
om
ion
c
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or
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ate
do
priv
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for
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- -> Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
2.3 - Removing and installing front sealing flange 35

- Apply silicone sealing compound, as shown, to clean sealing surface of the sealing flange. Sealing com‐
pound bead must be:
Notes:
◆ Thickness of sealing bead -arrows-: 2 ... 3 mm
◆ The sealing bead must not be thicker, otherwise excessive sealant may drip into the oil sump, the intake
pipe oil strainer may be blocked and it could also drip onto the sealing surface of crankshaft seal.
◆ Cover the sealing surface of the oil seal with a clean cloth before applying the sealant.
- Fit sealing flange immediately and lightly tighten all bolts.
Note:
Use guide sleeve T10053/1 to fit sealing flange with the oil seal already installed.
- Tighten sealing flange securing bolts using alternate sequence.
Tightening torque:15 Nm
- Remove excess sealant
- Install sump => Page 92 .
Note:
G. Volkswagen
After installing, the sealant must be allowed
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AG do
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- -> Install crankshaft sprocket and counter-hold with 3415.

rrectne
Tightening torque: 90 Nm + 1/4 turn (90 °) further

ss
Note:
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Thread and shoulder must be free of oil and grease.

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◆ VW 558 Counter-hold tool

◆ Hexagon bolt M8x45 and two M10 hexagon nuts
◆ Depth gauge n AG. Volkswagen AG do
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Loosening and tightening drive plate o
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- -> Secure counter-hold tool VW 558 to the drive plate with a hexagon bolt M8x45. Place two M10 hexagon
satelettronica
nuts between counter-hold tool and drive plate.
nform
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Position of counter-hold tool:

m
a
A - To loosen
com
tion in
B - To tighten
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Installing drive plate
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- -> Locate drive plate and packing plate with recesses -1-.
- Fit new bolts -3- and tighten to
30 Nm.
- -> Check dimension -a- at three points and calculate average.
2.4 - Removing and installing drive plate 37

Specification: 19.5...21.1 mm
AG. Volkswagen AG d
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Measured through hole
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- -> Remove drive plate again and fit shim -2-. Again tighten bolts -3- to
m
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m
30 Nm.
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- Tighten bolts to 60 Nm and turn

or
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4-cyl. injection
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3 - Removing and installing crankshaft ris
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3.1 - Removing andss installing crankshaft
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Notes:
◆ Before removing the crankshaft, prepare a suitable surface so that the sender wheel (item 8 ) is not making
contact with anything and is not damaged.
◆ When stripping and assembling the engine it should be secured to the engine frame with engine and gearbox
bracket VW 540 and supplementary set VW 540/1B.
1 Oil pump
=> Page 84
2 15 Nm
3 Chain sprocket
◆ For oil pump drive
3.1 - Removing and installing crankshaft 39

AG. Volkswagen AG d
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4 Bearing shells 1, 2, 3, 4 and 5

◆ Classification for ordering spare parts =>Page 42 , Fig. 1
◆ For bearing cap without oil groove
◆ For cylinder block with oil groove
◆ Do not interchange used bearing shells (mark)
5 40 Nm + 90 ° (1/4 turn) further
◆ Renew
◆ Threaded along complete length (screw)
◆ Tighten to 40 Nm when measuring radial clearance
6 Bearing cap
◆ Bearing cap 1: Pulley end
◆ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
AG. Volkswagen AG d
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◆ => Item 4
◆ Do not interchange used bearing shells (mark)
8 Sender wheel
◆ For engine speed sender (G28)
◆ Can only be installed in one position. Holes are off-set
9 10 Nm + 1/4 turn (90 °) further
◆ Renew
10 Crankshaft
◆ Axial clearance new: 0.07...0.23 mm
Wear limit: 0.30 mm
◆ Check radial clearance with Plastigage
New: 0.01...0.04 mm
Wear limit: 0.15 mm
◆ Do not rotate the crankshaft when checking the radial clearance
◆ Crankshaft dimensions
=> Page 43

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11 Thrust washer
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◆ For cylinder block, bearing 3

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-> Fig. 1 Upper crankshaft bearing identification

pr
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- The upper bearing shell is classified at the factory and marked as shown on the cylinder block.
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A = Marking for bearing 1
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B = Marking for bearing 2
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C = Marking for bearing 3

D = Marking for bearing 4
E = Marking for bearing 5
3.2 - Colour markings
S = black
R = red
G = yellow
B = blue
- The lower crankshaft bearing shells are always supplied as a spare part with the colour marking "yellow".
3.3 - Crankshaft dimensions
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Basic -0.017 -0.022
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1st undersize -0.017 -0.022
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-0.037 -0.042
2nd undersize -0.017 -0.022
53.50 47.30
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-0.037 -0.042
3rd undersize -0.017 -0.022
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4 - Dismantling and assembling pistons and conrods

4.1 - Dismantling and assembling pistons and conrods
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1 Piston ring
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Prote AG.
◆ Offset gaps by 120 °

◆ Remove and install with piston ring pliers
◆ "TOP" faces towards piston crown
◆ Checking ring gap=> Fig. 1
◆ Checking ring to groove clearance
=> Fig. 2
◆ 2 or 3 part oil scraper ring, mixed installations permissible
2 Piston
◆ Checking => Fig. 3
◆ Mark installation position and cylinder number
◆ Arrow on piston crown points to pulley end
◆ Install using piston ring clamp
lkswage es n Polo Estate 1996 ➤
Vo ot g
4-cyl.edinjection engine Mechanics (1.6
by ua l engine) - Edition 12.1999
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Cop py
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Prote AG.
3 Conrod
◆ Only renew as a set
◆ Mark cylinder number -B-
◆ Installation position:
Marking -A- faces towards pulley end
4 Conrod bearing cap
◆ Note installation position
5 30 Nm + 1/4 turn (90 °) further
◆ Alternative: Bolt
◆ Oil threads and contact surface
◆ To measure radial clearance tighten to 30 Nm but not further
6 Pressure relief valve, 27 Nm
◆ Opening pressure: 1.3...1.6 bar
7 Oil spray jet
◆ For piston cooling
4.1 - Dismantling and assembling pistons and conrods 45

AG. Volkswagen AG d
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◆ Ensure retaining lugs fit tightly in recesses
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◆ Axial clearance
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Prote AG.
New: 0.05...0.31 mm
Wear limit: 0.37 mm
◆ Check radial clearance with Plastigage:
New: 0.01...0.06 mm
Wear limit: 0.12 mm
Do not rotate crankshaft when checking radial clearance
9 Cylinder block
◆ Checking cylinder bores
=>Fig. 4
◆ Piston and cylinder dimensions
=>Page 50
10 Conrod bolt
satelettronica
AG. Volkswagen AG d
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11 Circlip
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12 Piston pin
spec
◆ If difficult to remove, heat piston to 60 °C

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◆ Remove and install with VW 222a

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-> Fig. 1 Checking piston ring gap
Special tools, workshop equipment, testers,

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and auxiliary items required
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◆ Feeler gauges ris
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- Push ring squarely from
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Piston ring Gap

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Compression rings mm 0.20...0.40 0.8
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Oil scraper ring mm 0.25...0.50 0.8
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-> Fig. 2 Checking ring to groove clearance
◆ Feeler gauges
Clean groove before check.
Piston ring Clearance

New Wear
limit
Compression rings mm 0.06...0.09 0.20
Oil scraper ring mm 0.03...0.06 0.15
AG. Volkswagen AG d
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4-cyl. injection engine Mechanicsrised
(1.6 l engine) - Edition 12.1999 nte
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-> Fig. 3 Checking piston
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◆ Micrometer 75...100 mm
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Measure pistons approx. 10 mm from the lower edge of skirt, at 90 ° to the piston pin axis.
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Deviation from nominal dimension C py
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-> Fig. 4 Checking cylinder bores
◆ Internal dial gauge 50...100 mm

◆ Measure bores at 3 locations in both directions -A- across the engine and -B- in line with crankshaft.
◆ Deviation from nominal dimension
max. 0.08 mm
Note:
Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with
adapter bracket VW 540, as incorrect measurements would then be possible.

4.2 - Piston and cylinder dimensions
Honing Piston-ø Cylinder bore-ø

dimension
Basic dimen. mm 80.9651) 81.01
1) Dimension without graphite coating (thickness 0.02 mm)

the graphite coating wears away.
AG. Volkswagen AG d
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15 - Cylinder head, Valve gear
1 - Removing and installing cylinder head

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1.1 - Removing and y Vinstalling cylinder head
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Checking compressions=>
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Notes:
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◆ When installing an exchange cylinder head with fitted camshaft, the contact surfaces between the bucket
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◆ If the cylinder head is replaced, all the coolant in the system must also be renewed.
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◆ Removing and installing intake manifold:
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=> 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

1 Cap
2 Gasket
3 Gasket
4 Breather housing
◆ To remove turn breather housing clockwise
5 10 Nm
6 Bracket
7 Sealing plug - 15 Nm
◆ Renew
8 Oil seal
◆ Renew
9 10 Nm
satelettronica
AG. Volkswagen AG d
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11 O-ring
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12 Lifting eye co Vo
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13 20 Nm Prote AG.
14 Cylinder head gasket
52 15 - Cylinder head, Valve gear

◆ Renew
◆ After replacing renew the complete coolant
15 15 Nm
17 Cylinder head
◆ Check for distortion => Fig. 1
◆ Reworking sealing surface
=> Page 68 , Fig. 1
=> Page 59
◆ After replacing renew the complete coolant
satelettronica
AG. Volkswagen AG d
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18 Cylinder head bolt
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◆ Renew Prote AG.
◆ Removing and installing Polydrive cylinder head bolt with 3452 or T10070
◆ Observe sequence when loosening and tightening => Page 59 , Removing and installing cylinder head
19 Oil deflector
20 Cylinder head cover gasket
◆ Before fitting gasket, coat transition between bearing cap/cylinder head with "D 454 300 A2"
21 Cylinder head cover
22 Reinforcing strip
23 Toothed belt guard

AG. Volkswagen AG d
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24 O-ring
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25 Breather connection
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◆ To expansion chamber
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◆ Only for engine code APF

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n AG. Volkswagen AG do Polo Estate 1996 ➤
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4-cyl. injection y Vo engine Mechanics (1.6
lks olt gengine) - Edition 12.1999
db ua
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-> Fig. 1 Checking cylinder head
thor for distortion tee
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Max. permissible distortion: 0.1 mm
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1.2 - Removing, installing and tensioning toothed belt
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(Adjusting valve timing)
◆ T 10020 Two-hole pin wrench

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

AG. Volkswagen AG d
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V gu
Polo Estate 1996 ➤ d by ara
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Removing
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nf
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- Remove toothed belt guard - upper part.
rm
- Remove ribbed belt => Page 26 . m
atio
m
- Remove tensioning element for ribbed belt. o
n in
or c
- -> Turn crankshaft to TDC No. 1 cylinder.
thi
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- Mark D.O.R. of toothed belt.
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- -> Remove vibration damper/belt pulley.

- Remove toothed belt guard centre and lower parts.
- Release tensioner and take off toothed belt.
- Turn crankshaft back slightly.
Installing
Note:
When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
A - Toothed belt completely removed
If toothed belt has only been removed from camshaft => Page 57
Conditions
• The pistons must not be positioned at TDC.
Work sequence

- -> Bring mark on camshaft into line with the mark on toothed belt guard.
- Place toothed belt on crankshaft pulley and coolant pump (observe DOR).
- Install toothed belt guard centre and lower parts.
- Install vibration damper/belt pulley
Tightening torque: 25 Nm
- -> Turn crankshaft to TDC No. 1 cylinder.

- Place toothed belt on tensioning rollerGand
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swagen sprocket and tension => Page 57 .
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B - Toothed belt only taken doff by camshaft sprocket
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- -> Bring mark on camshaft into line with the mark on toothed belt guard.
- Turn crankshaft to TDC No. 1 cylinder.
l purpos
- Place toothed belt on the camshaft sprocket and tension => Page 57 .
nf
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Tensioning toothed belt

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Conditions
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• The engine must not be more than warm to the touch.

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• Engine is at TDC No. 1 cylinder.

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• Before tensioning toothed belt turn tensioning roller on eccentric with a pin wrench T10020 five times in both
iv
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Work sequence . Cop py
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1.2 - Removing, installing and tensioning toothed belt 57

- -> Tension toothed belt. Do this by turning eccentric to left (direction of arrow) with 2-hole pin wrench T
10020 onto stop.
- Then release the toothed belt until the notch -1- and indicator -2- align (use mirror).
- Tighten securing nut to 20 Nm.
- Turn crankshaft two turns in engine direction of rotation until the engine is again at TDC No. 1 cylinder. When
doing this it is important that the last 45° (1/8 turn) is performed without stopping.
- Check toothed belt tension again
Specification: indicator and notch align
Continuation, installing toothed belt

- Install upper toothed belt guard.
- Install ribbed belt tensioner.
- Install noise insulation tray.
- Install engine cover
1.3 - Checking semi-automatic toothed belt tensioning roller
satelettronica
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Installation position d byV ua
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• -> The angled retainer -arrow- must locatedauin cut-out on cylinder head.
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Conditions
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- Set the engine to TDC No. 1 cylinder.

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- -> Press hard with thumb on toothed belt. The indicator -2- must move.
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- Release toothed belt and turn crankshaft two turns in engine direction of rotation until the engine is again
Co
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- The tensioning roller must return to its original position. (Notch -1- and indicator -2- are again aligned).
Note:
For checking use a mirror.
1.4 - Removing and installing cylinder head
AG. Volkswagen AG d
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Special tools, workshop equipment, test and measuring appliances and auxiliary items required Prote AG.

◆ VAS 5024 Assembly tool for spring-type clip
◆ 3450/2A Guide pins
◆ 3450/3 Removal tool
Engines with Polydrive cylinder head bolts:
◆ 3452 Tool or T10070 socket insert
1.3 - Checking semi-automatic toothed belt tensioning roller 59

Prerequisites
• The engine must be no more than warm to touch.
Work sequence
- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
satelettronica
Warning!
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Fuel system is under pressure!sBefore
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does place a cloth around the connection. Then release
pressure by carefully loosening
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- -> Pull off supplyutpipe/hose
ho -1- (with white marking) and return pipe/hose
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ra -2- (with blue marking) and collect
fuel that leakssout
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with a cloth. c
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Note:
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- Seal the pipes so that the fuel system is not contaminated by dirt etc.
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- Observe rules for cleanliness => Page 131 .

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- Pull hose -3- off activated charcoal filter solenoid valve 1.

hole
spec
- Remove intake manifold upper part:

es, in part or in w
t to the co
rrectness of i
Note:
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Seal the intake ports in the intake manifold lower part with a clean cloth.
- If necessary, remove exhaust gas recirculation connection pipe.
- If necessary, remove intake and pressure pipes for the secondary air pump.
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- If necessary, unbolt and remove secondary air pump motor and bracket.
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atio
- Unbolt coolant connecting piece.

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- Remove front exhaust pipe with catalyst from exhaust manifold.

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- -> Set camshaft sprocket to TDC No. 1 cylinder by turning the crankshaft. Mark on camshaft sprocket must
align with arrow on toothed belt guard.
- Release tensioning roller and take toothed belt off camshaft sprocket.
- Remove cylinder head cover.
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- -> Loosen cylinder head bolts in the sequence given and then remove completely.
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Note:
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spec
Use tool 3452 or socket insert T10070 for Polydrive cylinder head bolts.
t to the co
- Carefully lift cylinder head off.
Installing
rrectne
Notes:
ss o
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◆ There must be no oil or coolant in the cylinder head bolt pockets in the cylinder block.
inform
◆ Only remove the new cylinder head gasket from its packing immediately before installing.
mer
◆ Handle the new gasket with extreme care. Damaging will lead to leaks.
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- Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and n thi
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piston.
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- Also prevent dirt and emery cloth particles from getting into the coolant.
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- Carefully clean cylinder head and cylinder block sealing surfaces. Thereby ensuring that no scoring or
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scratches are formed (when using abrasive paper the grade must not be less than 100).
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- If the crankshaft has been turned in the mean time, set No. 1 cylinder piston to top dead centre and then
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turn crankshaft back slightly.
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- -> To centralize, screw guide pins from 3450/2A into front outer holes for cylinder head bolts.

Note:
The tolerance at the upper end of the centralizing holes has been reduced. Therefore, before fitting the cylinder
head check whether the guide pins can be removed upwards. If necessary, grind down the knurling on the
guide pins.
- Fit new cylinder head gasket. 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 hole using removal tool 3450/3. To do this, turn removal tool anti-clockwise
until the pins are free.
- Fit remaining cylinder head bolts and tighten hand-tight.
AG. Volkswagen AG d
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- -> Tighten cylinder head in tightening sequence as follows:
, is n
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- Pretighten all bolts to 40 Nm.
hole
- Then tighten all bolts a 1/4 turn (90 °) further using a rigid wrench. spec
es, in part or in w
- Then tighten all bolts again a 1/4 turn (90 °) further. t to the co
Note:
rrectness of i
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The rest of the assembly is basically a reverse of the dismantling sequence.

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Filling with new coolant => Page 114 .

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1.5 - Checking compression pressures
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◆ 3122 B Spark plug spanner

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◆ T10029 Assembly tool

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◆ V.A.G 1763 Compression tester

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◆ V.A.G 1922 Spark plug connector pliers

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1.5 - Checking compression pressures
Check conditions
• Engine oil temperature must be at least 30 °C.

• Voltage supply OK.
Work sequence
- -> Pull 4 pin connector off ignition transformer (N152) -arrow-.
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- -> Remove fuse 40 for fuel pump.
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- Pull connectors off outer injectors.
du
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- Pull off spark plug connectors on cylinders 1 and 4 using special tool T10029, and on cylinders 2 and 3 with
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spark plug connector pliers V.A.G 1922.

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- Remove spark plugs.

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- Have a second mechanic fully depress accelerator pedal and operate the starter.
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- Check compressions with compression tester V.A.G 1763 and adapter V.A.G 1763/6.
hole
spec
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Note:
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Using the compression tester => Operating instructions.

rrectness of i
- Operate starter until tester shows no further pressure increase.

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Compression pressure:
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New: 10...13 bar

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Wear limit: 7.5 bar

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Permissible difference between all cylinders: 3 bar

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- Finally, erase engine control unit's fault memory because pulling off injector connectors will have caused a
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Interrogating and erasing fault memory of engine control unit co Vo
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2 - Servicing valve gear

2.1 - Servicing valve gear
Notes:
◆ Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark
plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum
of 0.3 mm in width, or when no more than the first four spark plug threads are cracked.

◆ After installing new bucket tappets the engine must not be started for approx. 30 minutes (otherwise valves
will strike pistons), then turn crankshaft two rotations.
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◆ Use counter-hold tool 3415 to loosen and tighten
AG.
2 Camshaft sprocket
◆ With rotor for Hall sender
3 Oil seal
◆ Renew=> Page 72
4 Woodruff key
◆ Ensure tight fit
5 20 Nm
6 Bearing cap
◆ Installation position => Fig. 3
◆ Installation sequence
=> Page 75 , removing and installing camshaft
◆ Coat contact surfaces of bearing cap 1 lightly with sealant AMV 174 004 01
2.1 - Servicing valve gear 65

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7 Camshaft
◆ Checking axial clearance => Fig. 2
=> Page 75
◆ Checking radial clearance with plastigage
Wear limit: 0.1 mm
◆ Run-out: max. 0.01 mm
8 Bucket tappet
◆ Do not interchange
◆ With hydraulic valve clearance compensation
◆ Checking => Page 78
◆ Store with cam lobe contact surface downwards
◆ Before installing check camshaft axial clearance => Fig. 2
◆ Oil contact surface
9 Cotters

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10 Upper valve spring plate

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11 Valve spring
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◆ Removing and installing:

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Cylinder head
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removed: with 2037

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installed: => Page 81 , renewing valve stem seals

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12 Valve stem seal t. Cop py
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◆ Renewing=> Page 81
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13 Valve guide
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◆ Renewing => Page 80
◆ Service version with collar
14 Cylinder head
◆ Reworking valve seats
=> Page 70
15 Valves
◆ Do not rework only grinding-in is permitted
◆ Valve dimensions => Fig. 4

AG. Volkswagen AG d
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-> Fig. 1 Reworking cylinder head sealing surface
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Cylinder head reworking dimension:
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a = At least 132.6 mm
Note:
rrectness of i
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When the sealing surface has been reworked, the valves must be set deeper by the same amount (rework
valve seat inserts), otherwise valves will contact pistons. Ensure when doing this that the permissible minimum
dimension is maintained => Page 70 .
nform
mercia
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-> Fig. 2 Checking camshaft axial clearance
◆ Universal dial gauge bracket VW 387

◆ Dial gauge
Check with bucket tappets removed and with first and last bearing caps fitted.
Wear limit: max. 0.15 mm

AG. Volkswagen AG d
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4-cyl.s injection engine Mechanics (1.6 l engine) -c Edition 12.1999
s
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nl
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c
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ate
do
priv
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t.
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satelettronica
t. rig
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pyri by
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Prote AG.
-> Fig. 3 Fitting position of camshaft bearing caps
Note offset. Before installing camshaft fit bearing caps and determine fitting position.
-> Fig. 4 Valve dimensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

øa mm 39.5 ±0.15 32.9 ±0.15
øb mm 6.92 ±0.02 6.92 ±0.02
c mm 91.85 91.15
α <° 45 45

2.2 - Reworking valve seats
◆ Depth gauge
◆ Valve seat refacing tool
Notes:
◆ When repairing engines with leaking valves, it is not always sufficient to reface or renew valve seats and
valves. It is also necessary to check the valve guides for wear. This is particularly important on high mileage
engines.
◆ 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.
AG. Volkswagen AG d
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- -> Measure distance -a- between end of valve stem and upper edge of cylinder head.
- Calculate max. permissible reworking dimension from measured distance -a- and minimum dimension.
rrectness of i
Minimum dimension:
l purpos
Inlet valve 33.8 mm

Exhaust valve 34.1 mm
Measured distance minus minimum dimension
nf
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= max. permissible reworking dimension.

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Example:
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- Measured distance -a- 35.1 mm

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Minimum dimension 34.1 mm

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= max. perm. rework dimension* 1.0 mm

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*) The max. permissible reworking dimension is shown on illustrations for reworking valve seats as yi
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dimension "b". t. Cop py
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-> Reworking inlet valve seat
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Dim. Inlet valve seat byV
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45° Valve seat angle
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30° Upper correction angle
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-> Reworking exhaust valve seat
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Dim. Exhaust valve seat . C rig
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c mm approx. 2.4
Z Cylinder head lower edge
45° Valve seat angle
30° Upper correction angle
2.2 - Reworking valve seats 71

2.3 - Replacing camshaft oil seal
AG. Volkswagen AG d
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◆ T10071 Puller
◆ 2085 Oil seal extractor
◆ 3415 Counter support
Removing

4-cyl. injection engine Mechanics
AG. Volk(1.6
sw l
agen engine) - Edition 12.1999
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- -> Remove camshaft sprocket. When loosening camshaft sprocket bolt, counter-hold with 3415 (first remove
bolts -arrows-).
- Remove woodruff key from the camshaft.
- Screw camshaft sprocket securing bolt fully into camshaft.
- Unscrew inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock in
position 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.
- Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.
- Clamp flats of oil seal extractor in vice. Remove oil seal with pliers.
Installing
Conditions
2.3 - Replacing camshaft oil seal 73

Note:
Gradual introduction of PTFE oil seal (identifying characteristics: no annular spring, sealing lip wider). The
sealing lip of this oil ring must not be oiled or lubricated. A plain encased seal of older construction (with annular
spring) may be replaced with a PTFE oil seal, but not vice versa.
- Position oil seal with guide sleeve T10071 and press in with press sleeve T10071/1 and bolt T10071/2.
- Insert woodruff key in camshaft.
satelettronica
- -> Install the camshaft sprocket. Counter-hold with 3415 to tighten the camshaft sprocket securing bolt (first
remove bolts -arrows-).
Note:
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Installing toothed ri belt and
se adjusting valve timing => Pageante55 .
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c
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lkswage
4-cyl. injection engine Mechanics (1.6 l engine)es n - Edition 12.1999
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2.4 - Removing and installing camshaft
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◆ 3415 Counter support

◆ AMV 174 004 01 Sealant
Removing
2.4 - Removing and installing camshaft 75

AG. Volkswagen AG d
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=> Repair group 24; Servicing injection system;
orise
Removing and installing parts of injection
nte
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th
injection system Removing and installingauparts of injection system ra
ss c
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Note:
un
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- Remove toothed belt guard upper part.
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- -> Remove camshaft sprocket. When loosening camshaft sprocket bolt, counter-hold with 3415 (first remove rig ht
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- Remove woodruff key from camshaft. Prote AG.
- First remove bearing caps 5, 1 and 3. Then loosen bearing caps 2 and 4 alternately and diagonally.

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◆ When installing the camshaft No. 1 cylinder cams must point upwards.
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◆ -> When installing the bearing cap note offset, before installing camshaft fit bearing caps and determine Cop py
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fitting position. opyri
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Work sequence
agen
Prote AG.
- Oil the camshaft contact surfaces.

- Fit camshaft.
- Tighten bearing caps 2 and 4 alternately and
diagonally to
20 Nm.
- Coat contact surfaces of bearing cap 1 lightly with sealant AMV 174 004 01.
- Install bearing caps 3, 1 and 5 and tighten to
20 Nm.
- Position oil seal with guide sleeve T10071 and press in with press sleeve T10071/1 and bolt T10071/2.
2.4 - Removing and installing camshaft 77

- Insert woodruff key in camshaft.
- -> Install the camshaft sprocket. Counter-hold with 3415 to tighten the camshaft sprocket securing bolt (first
remove bolts -arrows-). agen
AG. Volkswagen AG d
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Tightening torque: 100 olksw
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Note:
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When new tappets have been installed the engine must not be started for about 30 minutes. Hydraulic com‐
spec
pensation elements must settle (otherwise valves will strike pistons).
t to the co
2.5 - Checking hydraulic bucket tappets
rrectness
o
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◆ Feeler gauge
form
satelettronica
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◆ Wood or plastic wedge
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Notes:
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◆ Renew defective tappet complete (cannot be adjusted or repaired).

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◆ Irregular valve noises when starting engine are normal.
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Test sequence Cop py
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- Start engine and run until the radiator fan has switched on once. p by
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- Increase engine speed to about 2500 rpm for approx. 2 minutes.
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If the hydraulic tappets are still noisy, locate defective tappets as follows:
Note:
- Rotate crankshaft clockwise, until cam of the tappet to be checked is pointing upwards.
- Determine play between cam and bucket tappet.
- If the play is in excess of 0.2 mm, renew bucket tappet. If the play is less than 0.1 mm or no play, proceed
with check as follows:

AG. Volkswagen AG d
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ara Polo Estate 1996 ➤
ise nte
tho4-cyl.
r injection engine Mechanics (1.6 e or l engine) - Edition 12.1999
s au ac
- -> Push bucket tappet down lightly with a wooden or plastic wedge. If when the bucket tappet is pushed
s
ce
e
nl
down a 0.2 mm thick feeler gauge can be pushed between the camshaft and bucket tappet, the bucket
pt
du
an
tappet is to be replaced.
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Note:
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After installing new tappets the engine must not be started for approx. 30 minutes. Hydraulic compensation
hole
spec
elements must settle (otherwise valves will strike pistons).
es, in part or in w
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2.6 - Checking valve guides
rrectness of i
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◆ VW 387 Universal dial gauge bracket

◆ Dial gauge
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:
Inlet valve guide = 1.0 mm
Exhaust valve guide = 1.3 mm
2.5 - Checking hydraulic bucket tappets 79

2.7 - Renewing valve guides
◆ 3120 Reamer and cutting fluid

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◆ 3121 Drift
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Removing
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- Clean and check cylinder head. Cylinder heads in which the valve seats can no longer be reworked, or
cylinder heads which have already been machined to the minimum dimension, should not have the valve
guides replaced.
nform
ercia
The permissible minimum dimension must be maintained =>Page 68 , Fig. 1

m
- Press out worn valve guides with 3121 from the camshaft side (valve guides with shoulder - repair version
at
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- from the combustion chamber side).

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Installing
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- Press in new guides, moistened with oil, from camshaft side onto shoulder in cold cylinder head using drift
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3121.
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When the shoulder on guide makes contact, the pressure must not exceed 1.0 t otherwise shoulder may break
off.
- Ream guides out with hand reamer 3120 using plenty of cutting fluid.
- Rework valve seats => Page 70 .

2.8 - Renewing valve stem seals
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◆ VW 541/1A Valve lever
◆ VW 541/5 Thrust piece
◆ VW 653/3 Pressure hose
◆ 2036 Assembly appliance
◆ 3047A Puller
2.8 - Renewing valve stem seals 81

◆ 3129 Fitting tool
satelettronica
◆ 3122 B Plug spanner
Removing AG. Volkswagen AG d

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- Remove camshaft => ss a Page 75 . ra
c
- Remove the bucket tappets and place them with the contact surface downwards. When doing this ensure
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that the tappets are not interchanged.

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- Remove spark plugs.

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- Set piston of appropriate cylinder to "bottom dead centre".

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- -> Fit assembly tool 2036 and adjust mountings to height of studs.
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- Screw pressure hose VW 653/3 into the spark plug thread.

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

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6 bar.
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- Remove valve springs with lever VW 541/1A and press piece VW 541/5.
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Note:
Tight cotters can be loosened by tapping lightly on the lever.
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- -> Pull off valve stem seals with 3047A.
erm
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Installing
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- -> Place the plastic sleeve -A- supplied on the appropriate valve stem. This will prevent the new valve stem
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seal -B- being damaged.

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- Insert new valve stem seal in fitting tool 3129.

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- Oil valve stem seal sealing lip and press carefully onto the valve guide.
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2.8 - Renewing valve stem seals 83

17 - Lubrication
1 - Removing and installing parts of the lubrication system

AG. Volkswagen AG d
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1.1 - Removing and installing parts of the lubricationbysystem
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◆ If when repairing an engine, metal shavings or a large quantity of small metal particles are found, this could
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indicate that the crankshaft and conrod bearings are damaged. To prevent consequential damage perform
rm
ab
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the following repairs:
ot
- Thoroughly clean oil passages
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- Replace oil spray jets
hole
- Replace oil cooler
spec
- Replace oil filter
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◆ The oil level must not be above the max. mark - danger of damage to catalyst!
Marking => Page 92 , Fig. 1
satelettronica
rrectness of i
Checking oil pressure => Page 94
l purpos
Oil system capacity1):
nform
ercia
with oil filter 4.5 ltrs.

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1) Up-to-date figures:
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=> Exhaust emissions test binder
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Engine oil specifications:
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op py
Use engine oils to VW standard 500 00, 501 01 or 502 00. Only in exceptional cases: Multi-grade oils corre‐ . C rig
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sponding to ACEA A2/A3.
rig by
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84 17 - Lubrication
AG. Volkswagen AG d
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Part I cted agen
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Part II Dismantling oil filter bracket
=> Page 89
1 Oil pump
◆ With pressure relief valve of 12 bar
◆ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder head are fitted
◆ Renew if running surfaces and gears are scored
2 Chain sprocket
3 20 Nm
4 Chain
1.1 - Removing and installing parts of the lubrication system 85

AG. Volkswagen AG d
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satelettronica
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5 Sealing flange
nform
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=> Page 34
m
◆ Insert with silicone sealant

com
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D 176 404 A2
n in
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=> Page 34
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◆ Renewing crankshaft oil seal - pulley end => Page 31

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6 15 Nm
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7 Chain tensioner with tensioning rail, 15 Nm

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◆ When installing, pretension spring and fit
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8 Dipstick
py by
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◆ The oil level must not be above the max. mark!
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◆ Markings=> Page 92 , Fig. 1
86 17 - Lubrication
AG. Volkswagen AG d
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Cop py
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9 Guide
◆ Pull off to extract oil
10 Guide tube
11 Dowel sleeves
12 O-ring
◆ Renew
13 Suction pipe
◆ Clean strainer if soiled
14 Baffle plate
15 Sump
◆ Clean sealing surface before installing
◆ Install with silicone sealant
D 176 404 A2
=> Page 92

AG. Volkswagen AG d
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16 Seal
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17 Oil drain plug, 30 Nm

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◆ Renew plug with attached seal

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Cop py
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88 17 - Lubrication
satelettronica
AG. Volkswagen AG d
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Part II
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1 Sealing plug, 40 Nm
ss
◆ Renew
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2 Seal
inform
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◆ Fits firmly on item 1

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3 Spring
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◆ For pressure relief valve, approx. 4 bar

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4 Piston
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◆ For pressure relief valve, approx. 4 bar

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5 Gasket
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◆ Renew
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6 Non-return valve, 8 Nm py by
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7 Seal cted agen
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◆ Fit onto sealing cap shoulder -item 8 -

AG. Volkswagen AG d
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satelettronica
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Cop py
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8 Sealing cap
9 Retaining clip
10 Sealing plug, 15 Nm
11 Seal
◆ If sealing ring is leaking nip open and replace.
12 1.4 bar oil pressure switch (F1), 25 Nm
◆ Black
13 Seal
◆ If sealing ring is leaking nip open and replace.
14 Oil filter bracket
15 15 Nm + 1/4 turn (90 °) further
◆ Renew
90 17 - Lubrication
satelettronica
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16 Gasket t to the co
◆ Renew
◆ Fit into groove on oil cooler
rrectness of i
17 Oil cooler
◆ Ensure clearance to adjacent components
l purpos
◆ See note
=> Page 84
nform
ercia
18 25 Nm
19 Oil filter
m
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◆ Loosen with strap wrench

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◆ Tighten by hand
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◆ Observe installation instructions on oil filter

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AG. Volkswagen AG d
-> Fig. 1 Markings on oil dipstick agen oes
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1- max. mark horis nte
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2- min. mark s aut ra
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a- Area above hatched field up to max. mark: Do not replenish with engine oil! s
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b- Oil level within hatched field: can be replenished with engine oil
nl
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c- Area from min. mark up to hatched field: replenish with max. 0.5 ltr. of engine oil!
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satelettronica
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1.2 - Removing and installing sump
h re
hole
spec
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◆ Hand drill with plastic brush
rrectness of i
◆ Silicone sealant D176404 A2
l purpos
Removing
nform
ercia

- Drain engine oil.
m
at
om
- Remove sump, it may be necessary to release sump by tapping lightly with a rubber head hammer.
on
c
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or
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
- Remove sealant residue on cylinder block with a flat scraper.

- -> 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.
92 17 - Lubrication
◆ Sump must be installed within 5 minutes of applying silicone sealing compound.
- -> 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-.
Note:
satelettronica
The sealing compound bead must not be thicker, otherwise excess sealing compound will enter the sump and
may block the oil suction pipe strainer. en AG. V
olkswagen AG
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tion in
- -> Apply silicone sealing bead as shown to the clean sealing surface of the sump. (The illustration shows
r
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the position of the sealant bead on the cylinder block).

thi
s
iva
- Install sump immediately and tighten bolts as follows:

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1- Tighten all bolts sump/cylinder block very lightly and diagonally.

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2- Lightly tighten three bolts sump/gearbox. Cop py
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3- Lightly tighten all bolts sump/cylinder block diagonally.
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4- Tighten three bolts sump/gearbox to 25 Nm. cop Vo
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5- Tighten all bolts sump/cylinder block diagonally to 15 Nm. cted agen
Prote AG.
Notes:
◆ When installing the sump on an engine which is out of vehicle, ensure that the sump is flush with cylinder
block on flywheel end.
◆ The sealant must be allowed to drive approx. 30 minutes after fitting the sump. Only then can the engine
be filled with engine oil.
1.2 - Removing and installing sump 93

1.3 - Checking oil pressure and oil pressure switch
AG. Volkswagen AG d
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satelettronica
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do
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Cop py
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◆ V.A.G 1342 Oil pressure tester
◆ V.A.G 1527 B Diode test lamp
◆ V.A.G 1594 A Adapter set
Function of the dynamic oil pressure warning indicator

When not under pressure, the oil pressure switch is open and will close when the operating pressure is attained.
The oil pressure warning will be activated
approx. 10 seconds
after switching the ignition on.
Switch-in delay of oil pressure warning
approx. 3 seconds.
Switch-off delay of oil pressure warning
94 17 - Lubrication
AG. Volkswagen AG d
agen oes
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ho 4-cyl. injection engine Mechanics eo
ra
(1.6 l engine) - Edition 12.1999
s a c
s
approx. 5 seconds.
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Note:
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Functional check and servicing the optical and acoustic oil pressure warning:
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=> Current flow diagrams, Electrical fault finding and Fitting locations
ole,
spec
Checking warning lamp
t to the co
After switching on the ignition and engine not started the oil pressure warning lamp in dash panel insert must
light for
rrectne
approx. 3 seconds
and then go out. The test will be terminated if the engine is running.
ss o
Test conditions
cial p
f inform
mer
• Engine oil level OK, checking => Page 92
atio
• Oil pressure warning lamp (K3) must light up for approx. 3 seconds when ignition is switched on
om
• Engine oil temperature at least 80 °C (radiator fan must have run once)
n
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Test sequence
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satelettronica
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 oil filter bracket in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 B using auxiliary cables from V.A.G 1594 A to battery positive (+) and
oil pressure switch.
LED must not light up.
- If the LED lights up, renew 1.4 bar oil pressure switch (F1) .
If the LED does not light up:

- Start engine and increase speed slowly.
At
1.2...1.6 bar
the LED must go out, otherwise renew oil pressure switch.
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C, the oil pressure should be between 2.7 ... 4.5 bar.
At higher engine speeds the oil pressure must not exceed

7.0 bar
If the specifications are not obtained:
- Rectify mechanical damage, e.g. bearing damage.
- Replace oil filter bracket with pressure relief valve => Page 90 , item 14 or replace oil pump.
If the specification is exceeded:

- Check oil galleries.
- If necessary, replace oil filter bracket with pressure relief valve
1.3 - Checking oil pressure and oil pressure switch 95

=> Page 90 , item 14
AG. Volkswagen AG d
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do
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
96 17 - Lubrication
19 - Cooling system
1 - Removing and installing parts of cooling system

1.1 - Removing and installing parts of cooling system
Notes:
◆ When the engine is warm the cooling system is under pressure. If necessary release pressure before com‐
mencing repair work.
◆ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
◆ Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended for fitting spring-type clips.
◆ When installing coolant hoses route stress-free, so that they do not come into contact with other components
(observe markings on coolant connection and hose).
Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/3 and
V.A.G 1274/4.
satelettronica
Parts of cooling system body side =>Page 98 .
wage es n
Parts of cooling system engine y Vside => 101 .
olks ot g
ua
d b ran
ir se tee
Coolant hose connection uth diagram =>Page 111 .
o
or
a ac
ss
Draining and filling with coolant=> Page 114 .
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un
pt
an
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Coolant mixture ratios => Page 114 , draining and filling with coolant
rm
ab
pe
ility
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es, in part or in w
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1.1 - Removing and installing parts of cooling system 97

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PoloauEstate 1996 ➤
th or
ac
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- Edition 12.1999
ce
le
un
pt
1.2 - Parts of cooling system body side
an
d
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rm
ab
pe
ility
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spec
es, in part or in w
t to the co
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nform
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a
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tion in
r
te o
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Cop py
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satelettronica
t
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pyri by
Vo
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by
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Prote AG.
1 Clamp
2 10 Nm
3 Radiator
=>Page 117
◆ After replacing renew entire coolant
4 Lock carrier
5 Air ducting
6 Rubber washer
7 Upper coolant hose
◆ Coolant hose connection diagram =>Page 111
8 Radiator fan
=>Page 117
98 19 - Cooling system
satelettronica
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9 Connector ss
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10 Additional fan
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◆ Only vehicles with optional equipment

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11 Fan ring
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12 Connector
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◆ For radiator fan

hole
spec
13 Bracket
es, in part or in w
◆ For radiator fan connector

t to the co
14 Cover
15 Expansion tank
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◆ Carry out leak test of cooling system with cooling system tester V.A.G 1274 and adapter V.A.G1274/3
l purpos
16 To coolant pipe
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1.2 - Parts of cooling system body side 99
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17 From upper coolant hose

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mer
18 Cap
atio
m
◆ Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/4
o
n
c
◆ Test pressure 1.4...1.6 bar

i
or
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19 Connector
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◆ For thermo-switch
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20 Thermo-switch (F18), 35 Nm
t.
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◆ For electric fan C py
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◆ Switching temperatures:
ht
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Stage 1
co Vo
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on: 92...97 °C Prote AG.
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C
21 Lower coolant hose

1.3 - Parts of cooling system engine side
AG. Volkswagen AG d
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mer
atio
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Engine codes: AEH, AKL

o
n
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Engine codes: APF, AUR

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=>Page 106
i
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pr
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1 To top of expansion tank

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. C rig
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rig
2 To heat exchanger
py by
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agen
Prote AG.
3 Connector
◆ 4-pin
4 Coolant temperature sender (G62)
◆ For engine control unit
◆ If necessary release pressure in cooling system before removing
◆ Checking:
1.3 - Parts of cooling system engine side 101

◆ With coolant temperature gauge sender (G2)
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5 O-ring
m
at
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◆ Renew
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6 Retaining clip his

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◆ Check seated securely

p
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7 10 Nm
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t.
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8 From heat exchanger
Co
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9 40 Nm
co Vo
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10 Coolant pipe
Prote AG.

11 From bottom of expansion tank
12 ATF cooler
◆ Only on vehicles with automatic gearbox

satelettronica
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13 To top of radiator
ility
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14 Connection
hole
spec
15 O-ring
es, in part or in w
◆ Renew
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16 To bottom of radiator
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17 Oil cooler
l purpos

=>Page 91 , Item 17
18 15 Nm
nform
ercia
19 Connection
m
at
om
◆ For thermostat
ion
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AG. Volkswagen AG d
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Polo Estate 1996 ➤ rise
d b ara
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4-cyl. injection engine Mechanics
autho
(1.6 l engine) - Edition 12.1999 eo
ra
ss c
ce
le
un
pt
an
d
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erm
ab
ility
ot p
wit
is n
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spec
t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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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.
=> Page 121
21 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
=> Page 55
22 Coolant pump
◆ If damaged or leaking renew complete
=> Page 119

AG. Volkswagen AG d
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24 20 Nm
m
at
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25 Throttle valve control part

n
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◆ Heated by coolant
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AG. Volkswagen AG d
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1 From cylinder head breather pipe

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2 Coolant pipe
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◆ Clipped to bulkhead t. C rig
gh ht
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3 To heat exchanger
p by
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4 To top of expansion tank
5 10 Nm
6 O-ring
◆ Renew
7 From heat exchanger

AG. Volkswagen AG d
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8 From bottom of expansion tank

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9 40 Nm
n
t.
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10 Coolant pipe
C py
t. rig
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◆ Coolant hose connection diagram =>Page 111 p by
o Vo
by c lksw
11 Retaining clip cted agen
Prote AG.
◆ Check seated securely
12 Coolant temperature sender (G62)
◆ For engine control unit
◆ If necessary release pressure in cooling system before removing
◆ Checking:
◆ With coolant temperature gauge sender (G2)

satelettronica
AG. Volkswagen AG d
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ab
13 Connector
ility
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◆ 4-pin
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14 To top of radiator
hole
spec

es, in part or in w
t to the co
15 To bottom of radiator
16 Oil cooler
rrectness of i

l purpos
=>Page 91 , Item 17
17 15 Nm
nform
ercia
18 Connection
◆ For thermostat
m
at
om
ion
c
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do
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t.
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Cop py
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rig ht
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AG. Volkswagen AG d
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not 1996 ➤
yV gu
4-cyl. injection engine Mechanicsised b (1.6 l engine) - Edition 12.1999
ara
nte
or eo
h
aut ra
ss c
ce
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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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
satelettronica
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
=> Page 121
20 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
=> Page 55

satelettronica
AG. Volkswagen AG d
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d by ara
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or eo
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21 Coolant pump
erm
ab

ility
ot p
◆ If damaged or leaking renew complete

wit
, is n

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hole
=> Page 119

spec
es, in part or in w

t to the co
23 20 Nm
rrectness of i
◆ Heated by coolant
25 Connection
l purpos
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1.4 - Coolant hose connection diagram
satelettronica
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=> page 113

h re
ole,
spec
1 Intake manifold
t to the co

3 Heating system heat exchanger
4 Expansion tank
rrectne
5 ATF cooler
◆ Only on vehicles with automatic gearbox
ss o

cial p
f inform
7 Radiator
mer
atio
8 Oil cooler
om
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c

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111
Prote AG.
1.4 - Coolant hose connection diagram
AG. Volkswagen AG d
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10 Coolant pump/coolant thermostat

te o
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11 Coolant pipe
do
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12 Cylinder head/cylinder block

fo
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satelettronica
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1 Intake manifold
hole
spec

es, in part or in w
t to the co
3 Heating system heat exchanger

4 Expansion tank
rrectness of i
6 Radiator
l purpos
7 Oil cooler
nform
ercia
9 Coolant pump/coolant thermostat

m
10 Coolant pipe
at
om
ion
11 Cylinder head/cylinder block

c
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1.4 - Coolant hose connection diagram 113

1.5 - Draining and filling cooling system
AG. Volkswagen AG d
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satelettronica
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Cop py
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Prote AG.
◆ T10007 Refractometer
◆ VAS 5024 Assembly tool for spring-type clamps
Not illustrated:
◆ VAS 6096 Cooling system charging
Draining
Warning !
Steam can be released when removing the cap from the expansion tank. Cover cap with a cloth and open
carefully.
- Open cap on coolant expansion tank.


- Pull off lower coolant hose at radiator using assembly tool for spring-type clamps VAS 5024.
- -> To drain coolant from engine also remove coolant hose from oil cooler -arrow-.
Note:
Observe disposal regulations!
Filling AG. Volkswagen AG d
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Notes: byV gu
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◆ Only use coolant additive G 12 in
ss aaccordance with TL VW 774 F. ra
c
Distinguishing feature: coloured violet
ce
le
un
◆ G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage,
pt
an
d
scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with
itte
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frost and corrosion protection additives.
ab
ility
◆ G 12 violet (in accordance with TL VW 774 F) can be mixed with the previous coolant additive G 12 red!
ot p
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◆ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in
is n
h re
countries with tropical climates.
ole,
spec
◆ Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).
◆ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer
t to the co
countries. The anti-freeze ratio must be at least 40 %.
◆ If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only
up to 60 % (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling
rrectne
effectiveness is also reduced.
◆ The refractometer T10007 is recommended for determining the current anti-freeze density.
◆ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
ss o
cial p
f in
Recommended mixture ratios:

form
mer
atio
m
Frost pro- tec‐ Anti-freeze G 121) Water1)

o
n
c
tion to amount
i
or
n thi
te
-25 °C 40 % 2.2 ltr. 3.3 ltr.

sd
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-35 °C 50 % 2.75 ltr. 2.75 ltr.

p
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1) The quantity of coolant can vary depending upon the vehicle equipment. ht. Cop py
rig
rig ht
py by
- Secure lower coolant hose on connecting piece of radiator. co Vo
by lksw
- Connect the coolant hose to oil cooler.
cted agen
Prote AG.
With cooling system charging unit VAS 6096
- Screw adapter V.A.G 1274/3 onto expansion tank.

- Fill coolant circuit using cooling system charging unit VAS 6096.
=> Operating instructions for cooling system charging unit VAS 6096
1.5 - Draining and filling cooling system 115

lkswage es n
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byV ua
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Not using cooling system charging
au unit VAS 6096
t or
ac
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- -> Fill with coolant up to max. mark on expansion tank.

un
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With and without cooling system charging unit VAS 6096
ab
pe
ility
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- Fit expansion tank cap.
h re
- Turn off heater control.
hole
spec
satelettronica
- Start engine and maintain an engine speed of about 2000 rpm for approx. 3 minutes.
es, in part or in w
- Run engine until radiator fan cuts-in.
t to the co
Warning !
rrectness of i
Steam can be released when removing the cap from the expansion tank. Cover cap with a cloth and open
carefully.
l purpos
- Check coolant level and top-up if necessary. When the engine is at normal operating temperature, the
nform
ercia
coolant level must be on the MAX. marking and between the MIN. and MAX. marking when the engine is
cold.
m
a
com
- Install noise insulation tray. tion in

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by
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1.6 - Removing and installing radiator
AG. Volkswagen AG d
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inform
mer
atio
om
n
c
i
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sd
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t.
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Cop py
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Vo
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Prote AG.
◆ VAS 5024 Assembly tool for spring-type clips
Removing

- Pull coolant hoses off radiator.
- Pull connectors off thermo-switch and radiator fan.
- Remove radiator fan together with fan ring.
Vehicles with air conditioning system:
- Observe additional information and removal work => Page 118 .
- Remove radiator securing bolts and take out radiator.
1.6 - Removing and installing radiator 117

Installing
AG. Volkswagen AG d
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Installation is carried by out in the reverse order, when doing
Vol
gu
ara
this note the following:
ed
ris nte
- Filling with tho eo
au coolant => Page 114 ra
- Electricals connections and routing:
s c
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ab
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Additional information and removal work on vehicles with air conditioner
ot
wit
, is n
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hole
spec
Warning!
es, in part or in w
t to the co
The air conditioning system refrigerant circuit must not be opened.
rrectness of i
Note:
l purpos
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
not stretched, kinked or bent.
nform
mercia
- Remove retaining clamp(s) from refrigerant pipes.
satelettronica
com
tio
n in
r
te o
thi
s
=> General body repairs; Repair group 50; Body, front; Removing and installing lock carrier with attachments.
iva
do
r
Body, front Removing and installing lock carrier with attachments.

rp
cum
fo
en
ng
t.
yi Co
- Remove radiator securing bolts. Cop py
- Remove condenser from cooler.
t. rig
gh ht
yri
- Remove air conditioner compressor and position to one side with lock carrier so that the refrigerant hoses
p by
o Vo
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are not stressed.
Prote
cted AG.
agen
- Check headlight adjustment and adjust if necessary:
=> Maintenance

. Volkswagen AG Polo Estate 1996 ➤
gen AG
4-cyl.
Vo lkinjection
swa engine Mechanics
does
not (1.6 l engine) - Edition 12.1999
by gu
ara
ed
1.7 - Removing andthoris installing coolant pump nte
eo
au ra
c
ss
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
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orm
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or c
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sd
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f
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
Notes:
◆ Always renew seals and gaskets.
◆ The lower part of the toothed belt guard need not be removed.
◆ The toothed belt should be left in position on the crankshaft sprocket.
◆ Cover toothed belt with a cloth to protect it from coolant before removing coolant pump.
- Drain coolant => Page 114

- Remove windscreen washer reservoir.
- Remove tensioning element for ribbed belt.
- Remove upper and centre toothed belt guard.
1.7 - Removing and installing coolant pump 119

- Take toothed belt off coolant pump toothed belt sprocket => Page 55 , Removing, installing and tensioning
toothed belt.
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- -> Remove securing bolt -1- from rear toothed belt guard -2-. un
pt
- Unscrew coolant pump securing bolts -5- and remove coolant pump -4-.
an
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Installing
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Installation is carried out in the reverse sequence, when doing this note the following:
ole,
satelettronica
spec
- Moisten new O ring -3- with coolant.
t to the co
- Insert coolant pump -4- into cylinder block and tighten securing bolts -5-.
rrectne
Note:
s
The coolant pump plug faces downwards.
s o
cial p
f inform
- Tighten securing bolt -1- for rear toothed belt guard -2- to cylinder head.
mer
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- Install upper and centre toothed belt guard.
pr
cum
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- Install ribbed belt tensioning element.
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op
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- Remove windscreen washer system reservoir.
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pyri by
Vo
o
- Fill with coolant => Page 114 by c lksw
cted agen
Prote AG.

1.8 - Removing and installing thermostat
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Removing
Note:
◆ Always renew seals and gaskets.
- Drain coolant => Page 114
1.8 - Removing and installing thermostat 121

Polo Estate 1996 ➤ . Volkswagen AG
gen AG does
4-cyl. injection engine Mechanicsol swa l engine) - Edition
k(1.6 n12.1999
ot g
V y ua
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es, in part or in w
t to the co
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- -> Pull coolant hose off connecting flange -3-.
- Unbolt securing bolts -4- of connecting flange -3- and remove connecting flange -3- with thermostat -1-.
l purpos
Installing
nform
ercia
Installation is carried out in the reverse order, when doing this note the following:
m
a
com
tion in
- Moisten new O-ring -2- with coolant.
r
te o
thi
- Fit connecting flange -3- with thermostat -1- into engine block.
s
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Note:
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op py
The brace on the thermostat must be almost vertical. t. C rig
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- Tighten securing bolts -4-.
by lksw
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Prote
AG.
- Fill with coolant => Page 114

20 - Fuel supply system
1 - Removing and installing parts of fuel supply system

1.1 - Removing and installing parts of fuel supply system
Notes:
◆ Hose connections are secured with either spring-type or clamp-type clips.

◆ Always replace clamp-type clips with spring-type
lkswage clips. es n
◆ Fuel hoses in engine compartment dmustby
Vo only be secured with spring-typeot g
ua clips. The use of clamp or screw-
ran
type clips is not permissible. orise tee
◆ Assembly tool VAS 5024 or hoseau
th clip pliers V.A.G 1921 are recommended for or fitting spring-type clips.
a
ss c
ce
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Observe safety precautions=> Page 130 .

un
pt
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Observe rules for cleanliness => Page 131 .
erm
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satelettronica
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Removing and installing fuel tank with its attachments and fuel filter => Page 124 .
is n
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ole,
spec
Servicing accelerator mechanism => Page 144
t to the co
Adjusting throttle cable => Page 145
Checking electronic accelerator control (E-Gas) => Page 147 .
rrectne
Servicing parts of the activated charcoal filter system => Page 156 .
ss o
cial p
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1.1 - Removing and installing parts of fuel supply system 123

1.2 - Removing and installing fuel tank with its attachments and fuel filter
satelettronica
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1 Cap
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2 Seal
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3 Retaining ring
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4 Cup
m
at
◆ For filler pipes

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5 Gravity valve
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◆ To remove valve unclip upwards out of support

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◆ Check valve for through-flow

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valve vertical: open,

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valve tilted 45 °: closed

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6 O-ring . C rig
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124 20 - Fuel supply system

satelettronica
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7 Earth connection
◆ Check securely seated
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8 4 Nm
9 Return line
s
◆ Blue
s o

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◆ Clipped onto fuel tank

form
mer
◆ To remove from flange press release button on connecting piece

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◆ From fuel manifold

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10 Union nut, 75 Nm
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◆ Remove and install with spanner 3217
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1.2 - Removing and installing fuel tank with its attachments and fuel filter 125
satelettronica
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11 Fuel delivery unit spec


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=> Page 131

◆ Checking fuel pump
=> Page 136
rrectne
◆ Clean strainer if soiled

◆ Note fitting position on fuel tank => Fig. 1
ss
12 Sealing ring
o
cial p
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nform
◆ Coat with fuel when installing

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13 Fuel filter
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◆ Fitting position: Arrow points in direction of flow

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14 Supply line
◆ Black
◆ To remove from flange press release button on connecting piece
◆ To fuel manifold
15 3 Nm
16 Fuel tank
◆ Support with engine and gearbox jack V.A.G 1383 A when removing
=> Page 134
17 Clamping washer
◆ Press clamping washer from heat shield tightly onto pins on vehicle floor
satelettronica
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18 Heat shield
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◆ For fuel tank

h re
hole
19 Securing strap
spec
es, in part or in w
20 25 Nm
t to the co
21 Connecting piece
◆ With exhaust system mounting
rrectness of i
22 Vent pipe
◆ To activated charcoal filter
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nf
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23 Sealing boot
orm
◆ After installing filler pipes fit over fuel tank connections, having turned boot inside out
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24 Filler pipes
n in
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◆ With non-return valve

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25 Vent valve
pt
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◆ Checking =>Fig. 2
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◆ To remove pull locking latch lightly to inside -arrow- and pull valve out
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26 Tank flap unit

wit
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spec
=> General body repairs, Exterior; Repair group 55; Tank flap unit Tank flap unit
t to the co
27 Securing screw
rrectness o
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-> Fig. 1 Installation position of fuel delivery unit flange

AG. Volkswagen AG d
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Marking on sender must align with the marking
rise
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on fuel tank -arrows-. ara
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Blue or blue marked return pipe -1-ssto
a
connection with identification -R-. c
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Black supply pipe -2- to connection with identification -V-.
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Note:
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After installing fuel delivery unit flange, check that the supply, return and breather pipes are still clipped onto
h re
hole
the fuel tank.
spec
es, in part or in w
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rrectness of i
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Lever in rest position: Closed Prote AG.
Lever pushed in direction of arrow: Open
Note:
Before installing vent valve remove fuel tank cap.
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!
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.
◆ 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!
1.4 - Rules for cleanliness agen

AG. Volkswagen AG d
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When working on the fuel supply/injection system,
ut
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pay careful attention to the following "5 rules": eo
ra
s a c
s
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
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le
un
pt
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
an
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◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
rm
ab
◆ Only install clean components:
pe
ility
Only unpack replacement parts immediately prior to installation.
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Do not use parts that have been stored loose (e.g. in tool boxes etc.).
satelettronica
h re
◆ When the system is open:
hole
spec
Do not work with compressed air if this can be avoided.
es, in part or in w
Do not move vehicle unless absolutely necessary.
t to the co
rrectness of i
1.5 - Removing and installing fuel delivery unit
l purpos
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mercia
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com
tion in
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1.3 - Safety precautions when working on the fuel supply system 131
◆ 3217 Ring nut spanner
Removing
- Note safety precautions before starting work => Page 130 .

- Fold rear seat bench forwards.
- Remove floor cover.
When the floor cover is removed:
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- -> Pull off connector -1-.

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Warning!
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spec
es, in part or in w
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- Pull off/separate supply and return pipes -3 and 4- to fuel rail.

- Pull off/separate supply pipe -2- to fuel filter and bleeder pipe -5-.
rrectness of i
Note:
l purpos

nform
mercia
at
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ion
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ate
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Prote AG.
- -> Remove union nut with spanner 3217.

- Pull fuel delivery unit and seal out of opening in the fuel tank.
Note:
If the delivery unit is to be renewed then drain old delivery unit before disposal.
Installing
- Installation of the fuel delivery unit is carried out in the reverse order.

Notes:
◆ Do not bend fuel sender when installing.

◆ Coat flange seal with fuel when fitting.
◆ Ensure fuel hoses are seated securely.
◆ After installing fuel delivery unit, check that the supply, return and vent pipes are still clipped onto fuel tank.
◆ -> Note installation position of fuel delivery unit flange:

The marking on flange must align with marking on fuel tank -arrows-.
satelettronica
1.6 - Removing and installing fuel gauge sender
Removing
- Removing fuel delivery unit

=> Page 131 .
AG. Volkswagen AG d
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es, in part or in w
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- -> Release and pull off the terminals for wires -3- and -4-.
- Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge sender out downwards -arrows-.
rrectness of i
l purpos
Installing
- Insert fuel gauge sender in the guides on the fuel delivery unit and push up until it engages.
nf
ercia
- Installing fuel delivery unit

rm
m
=> Page 131 .

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1.5 - Removing and installing fuel delivery unit 133

1.7 - Removing and installing fuel tank
AG. Volkswagen AG d
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mercia
at
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c
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priv
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Cop py
◆ V.A.G 1383 A Engine/gearbox jack ht. rig
rig ht
py by
co Vo
by lksw
Removing cted agen
Prote AG.
- Note safety precautions before starting work

=> Page 130
- -> Pull off connector -1-.

Warning!
- Pull off/separate supply and return pipes -3 and 4- to fuel rail.

- Pull off/separate supply
swa
gepipe
n AG.-2- to fuel filter
Volkswagen AG
doeand
s
bleeder pipe -5-.
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satelettronica
Note:
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ercia
- Drain fuel tank.

m
- -> Remove rear connecting support -1-. at

om
ion
- Remove all rear exhaust system mountings -2- from body and secure the slightly lowered exhaust system
c
in t
or
with wire to body.

his
ate
- Remove rear right wheel.

do
priv
- Unbolt filler neck from body.

um
for
- Take filler cap off filler neck and unclip neck from cup.
en
ng
t.
yi Co
- Pull off breather hoses at filler neck. Cop py
- Remove clamping disc for fuel tank heat shield. ht. rig
rig ht
by
- Unbolt fuel tank from body and lower tank slightly using engine/gearbox jack V.A.G 1383 A.
copy Vo
by lksw
- Remove filler neck. Prote
cted AG.
agen
- Take out fuel tank together with heat shield.
Installing
Install in reverse order but note following:
◆ Breather and fuel hoses are to be installed kink-free.

◆ Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).
◆ Ensure fuel hoses are seated securely.
◆ Clip supply, return pipe and breather pipe onto fuel tank.
1.8 - Crash fuel shut-off
Function
Vehicles with airbags 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.
When opening the fuel system:
- Check fuel pump relay:
1.7 - Removing and installing fuel tank 135

=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐
forming final control diagnosis
1.9 - Checking fuel pump
satelettronica
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◆ 3217 Union nut spanner

s
◆ V.A.G 1318 Pressure tester

s o
◆ V.A.G 1318/1 Adapter

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◆ V.A.G1318/17 Adapter
atio

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◆ V.A.G 1348 Fuel quantity comparison meter
◆ V.A.G 1466 Test system
◆ V.A.G 1715 Multimeter
◆ Measuring container
◆ Current flow diagram
Check conditions
• Battery voltage at least 11.5 V
1.9 - Checking fuel pump 137

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• -> Fuse No. 40 OK. is n
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spec
Checking function and voltage supply
t to the co
Note:
rrectne
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.
ss o
satelettronica
- Switch ignition on.
cial p
f in
Fuel pump must be heard to run briefly.
form
mer
atio
om
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Prote AG.
If the fuel pump does not run:
- Switch off ignition.

- Remove cover in front of fuse holder.
- -> Pull fuse No. 40 out of fuse holder.
- Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to contact 40b to fuel pump and
battery positive (+).
- Operate remote control.
Fuel pump runs:
- Check activation of fuel pump relay:
Fuel pump does not run:


AG. Volkswagen AG d
agen Polonot Estate 1996 ➤
oes
olksw
yV gu
4-cyl. injection engine ed Mechanics (1.6 l engine) - Edition
b ara
nte
12.1999
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
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
- -> Pull 4-pin connector -1- off flange on fuel delivery unit.
l purpos
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ercia
orm
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om
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t.
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ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
- -> Connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 to the outer contacts of the
connector.
- Operate remote control.
LED must light up
LED does not light up:
- Locate and eliminate open circuit using current flow diagram:
LED lights up (voltage supply OK.):
- -> Remove union nut with spanner 3217.

- Check that the electrical wires between flange and fuel pump are connected.
If no open circuit can be found:
- Fuel pump defective, renew fuel delivery unit =>Page 131 , Removing and installing fuel delivery unit.

Checking delivery rate
Check conditions
• Voltage supply OK.
• Remote control V.A.G 1348/3A connected.
Test sequence
- Remove filler cap from fuel tank filler neck.
Warning!
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release
pressure by carefully loosening the connection.
satelettronica
- -> Pull off supply pipe/hose -1- and collect leaking fuel with a cloth.
Note:
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- -> Connect pressure gauge V.A.G 1318 with adapter 1318/23 and V.A.G 1318/17 to the fuel supply line.
thi
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- Push the hose V.A.G 1318/1 onto the adapter V.A.G 1318/11 on the pressure gauge and hold hose in a
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measuring container.
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- Open the pressure gauge shut-off tap. The lever then points in the direction of flow -A-.
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- Operate remote control V.A.G 1348/3A and slowly close cut-off tap, until pressure gauge shows
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3 bar.
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- Empty measuring container. by c lksw
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- 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
satelettronica
**) Voltage at fuel pump with engine stopped and pump running (approx. 2 volts less than battery voltage).
Example:
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 then this will equate to a minimum delivery of 200 cm3/30 s.
If the minimum delivery rate is not attained:
- Check the fuel pipes for possible restrictions (kinks) or blockages.
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- -> Pull supply hose -1- off fuel filter inlet.

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- Connect the pressure gauge V.A.G 1318 with adapter /17 on hose.
- Repeat delivery rate check.
rrectne
If the minimum delivery rate is now attained:

ss
- Renew the fuel filter.

o
cial p
f inform
If the minimum delivery rate is again not attained:

mer
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- Remove the fuel delivery unit and check the strainer filter for soiling.
o
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Only when up to now no fault has been detected:

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- Replace the fuel delivery unit.

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If the delivery rate has been attained but nevertheless you suspect a fuel supply system fault (e.g. intermittent
failure of fuel supply system):
- Check the current draw of the fuel pump as follows:

- Reconnect all disconnected fuel pipes.
- -> Connect the multimeter V.A.G 1715 using the current clamp to the 4-pin connector -contact 1- of wiring
harness.
- Start the engine and run at idling speed.
- Measure the current draw of the fuel pump.
satelettronica
Specification: max. 8 amps. agen
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Note: ris
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If the fuel system malfunction is intermittent, you canss aperform the check during a test drive with the helpac of a
2nd person.
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If the current draw is exceeded:
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Checking fuel pump non-return valve
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Test conditions
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• Remote control V.A.G 1348/3A is still connected.
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• Pressure gauge V.A.G 1318 is still connected.

Test sequence
Note:
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.
- -> Close pressure gauge shut-off tap (lever at right angles to throughflow direction - position -B-).
- Separate remote control at short intervals, until a pressure of
Approx. 3 bar
has built up.
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Danger of spray when opening the shut-offtap,
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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 on gauge. After 10 minutes the pressure must not drop below
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2.5 bar.
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If the pressure drops further:
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- Check pipe connections for leaks.
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If no fault is detected in the wiring:
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2 - Accelerator mechanism
2.1 - Accelerator mechanism
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2.2 - Servicing accelerator mechanism

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1 Accelerator cable
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◆ Adjusting => Page 145

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◆ Do not reuse damaged accelerator cable, replace

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2 Retaining clip
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◆ Adjusting throttle cable => Page 145 copy Vo
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3 Balance weight
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4 Accelerator pedal
5 Spacer sleeve
6 Bush
7 Washer
8 Stop bolt
9 20 Nm

2.3 - Adjusting throttle cable

◆ Pedal depressor en AG. V
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- Hook accelerator cablethinto or accelerator pedal and cam disk on throttle e o valve control part.
- Pull off retaining clip sfor
a accelerator cable core wire.
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- Depress accelerator pedal to full throttle position.
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Note:
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A second mechanic or a pedal depressor is required for this.
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- Adjust accelerator cable by moving the retainer at the support bracket, so that the full throttle position is
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attained at the throttle valve control part.
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◆ V.A.G 1526 A Hand multimeter
2.2 - Servicing accelerator mechanism 145

◆ V.A.G 1594 A Auxiliary test set
◆ Pedal depressor
Work sequence
- Hook accelerator cable into accelerator pedal and cam disk on throttle valve control part.
- Pull off retaining clip for accelerator cable core wire.
- Depress accelerator pedal to full throttle position.
Note:
A second mechanic or a pedal depressor is required for this.
- Adjust accelerator cable by moving the retainer at the support bracket, so that the full throttle position is
attained at the throttle valve control part and the kick-down
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- Release accelerator pedal or remove pedal depressor.
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- Pull 2-pin connector off kick-down switch (F8) in engine compartment (on the bulkhead).
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- -> Connect hand multimeter V.A.G 1526 A with aux. cables from V.A.G 1594 A to kick-down switch.
- Check resistance at switch.
nform
ercia
Specification: ∞ω
- Slowly move accelerator pedal in direction of full throttle.
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Shortly after the kick-down pressure point the resistance must drop to 0 ω.
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At this point the accelerator pedal must be just off the stop.
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3 - Checking electronic power control (EPC)

3.1 - Checking electronic power control (EPC)
AG. Volkswagen AG d
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1 Bracket
2 10 Nm
3 Accelerator pedal position sender (G79)
◆ The accelerator pedal position passes the position of the pedal on to the engine control unit
◆ To remove sender, remove footwell cover and trim below steering column
=> General body repairs, interior; Repair group 68; Removing shelves, covers and trims Removing shelves,
covers and trims
◆ Checking =>Page 150

◆ Adjusting =>Page 153
4 Cable cam
3.1 - Checking electronic power control (EPC) 147

satelettronica
AG. Volkswagen AG d
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5 Spring washer
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6 Adjustment bolt
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◆ Adjusting =>Page 153 t to the co

7 Accelerator pedal
8 20 Nm
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9 Hexagon bolt M8
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3.2 - Function of EPC system

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With the EPC system the throttle valve is not operated by a cable. There is no mechanical connection between
te o
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accelerator and throttle valve.

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The position of the accelerator is transmitted to the engine control unit by two accelerator position senders
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(variable resistors together in a housing) which are connected to the accelerator pedal.
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The position of the accelerator (drivers requirement) is the main input value for the engine control unit. p by
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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 the throttle valve by the same amount, the throttle is then
approximately half open.
When the engine is running (under load) the engine control unit can open or close the throttle valve independ‐
ently of the accelerator pedal position sender.
This means that the throttle valve can already be completely open even though the accelerator pedal is de‐
pressed half way.
After evaluating the torque requirements of various components (e.g. air conditioning, automatic gearbox, ABS/
ESP and so on), the engine control unit calculates the optimal throttle valve opening angle for the respective
situation.
This also gives vastly improved consumption and exhaust emission levels at certain load conditions.
EPC is a system comprising all components which contribute to determining, controlling or monitoring the
position of the throttle valve, e.g. accelerator pedal position sender, the throttle valve control part, the EPC
warning lamp, the engine control unit and so on.
3.3 - Checking accelerator pedal position sender
satelettronica
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3.2 - Function of EPC system 149

◆ V.A.G 1526 Hand multimeter

◆ V.A.G 1598/31 Test box
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
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.
Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics control
satelettronica
unit with the "Address word" 01:
=> Repair group 01; Self-diagnosis; Connecting fault reader V.A.G 1551 and selecting engine electronics con‐
trol unit Self-diagnosis Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
-> Indicated on display:

Rapid data transfer HELP
Select function XXX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.
-> Indicated on display: agen

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Input display group number XXX ed
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- Press keys 0, 6 and 2 for the "Display group number 62" and confirm entry with Q key.
ss
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(1...4 = Display zones)

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Read measured value block 62

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1 2 3 4
h re
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spec
- Check specification of sender 1 (G79) at idling speed limit stop in display zone 3.
es, in part or in w
Specification: 6...96 %
t to the co
- Check specification of sender 2 (G185) at idling speed limit stop in display zone 4.
rrectness of i
Note:
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The engine control unit calculates the voltage values of the angle sender in percent relative to 5 Volt and displays
these as a percentage figure (5 Volt supply voltage equates to 100 %).
nform
mercia
- Operate the accelerator pedal slowly until fully depressed and observe the angle sender figures in display
a
com
tio
zones 3 and 4:
n in
r
te o
thi
The percent figures in display zone 3 must rise evenly. The tolerance range of 6...96 % is not covered
s
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completely.
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Note:
The figure displayed in display zone 3 must always be approximately double that displayed in display zone 4.
End specification value not achieved:
- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Adjust accelerator pedal position sender
=>Page 153
Display does not change or is erratic:
- Check accelerator pedal position sender as follows:

- Press the ⇒key.
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- Remove cover in footwell
by
V(driver's
olk side) and the trim below
not steering column.
gu
ara
ed nte
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=> General body repairs,
tho
interior; Repair group 68; Removing shelves,
or covers and trims Removing shelves,
e
au ac
covers and trims ss
satelettronica
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- -> Disconnect 6-pin connector -1- for accelerator pedal position sender.
nform
mer
atio
om
n
c
i
or
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te
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- -> Measure sender resistance between connector contacts 1+3.

Specification:
Accelerator pedal in idling speed position: 1.0...1.5 kω
Accelerator pedal in full throttle position: 1.5...2.5 kω
- Measure sender resistance between connector contacts 4+6.
Specification
Accelerator pedal in idling speed position: 0.6...2.0 kω
Accelerator pedal depressed: 1.1...3.0 kω
3.3 - Checking accelerator pedal position sender 151

- Replace accelerator pedal position sender (G79)
=>Page 147 , item 3 .
If the specifications are obtained:

AG. Volkswagen AG d
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Checking voltage supply by
V and wiring to control unit
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- Switch ignition
aut
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- -> Connect
s multimeter to measure voltage at the following contacts of the connector:
satelettronica
s c
Contact 2 + earth
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Contact 2 + 3
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Contact 5 + earth
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Contact 5 + 4
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Specification: minimum 4.5 V

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s

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- -> Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains discon‐
t. rig
gh ht
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nected.
p by
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- -> Check wiring between test box and connector for open circuit according to current flow diagram.
Contact 1+ socket 51
Wire resistance: max. 1.5 ω
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
Specification: ∞ω
If no fault is detected in the wiring:
- Renew engine control unit:
=> Repair group 23; Renewing engine control unit, coding and matching; Renewing engine control unit Re‐
newing engine control unit, coding and matching Renewing engine control unit
3.4 - Adjusting pedal position sender
satelettronica
◆ Fault reader V.A.G 1551 (or vehicle system tester V.A.G 1552) with cable V.A.G 1551/3
Work sequence
(Accelerator pedal position sender removed)
Adjusting cable cam: AG. Volkswagen AG d

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- -> Install cable cam in position as illustrated.

rrectne
- Secure cable cam to sender so that the dimensions shown are adhered to when facing forwards.
a = 22 ±0.05 mm
s
b = 41±0.05 mm
s o
c = Forwards
cial p
f inform
mer
Note:
atio
om
n
c
The cable cam eye must be parallel to the forward direction.

i
or
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- Then secure accelerator position sender with preassembled cable cam to mounting block.
i
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cum
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- Reconnect sender 6 pin connector.

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op
Fine adjustment with sender installed:
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- Connect fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics control
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unit with the "Address word" 01:
AG.
3.3 - Checking accelerator pedal position sender 153

=> Repair group 01; Self-diagnosis; Connecting fault reader V.A.G 1551 and selecting engine electronics con‐
trol unit Self-diagnosis Connecting fault reader V.A.G 1551 and selecting engine electronics control unit

Select function XXX
- 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

Read measured value block 62
1 2 3 4
- Check specification of sender 1 (G79) at idling stop in display zone 3.

satelettronica
- Check specification of sender 2 (G185) at idling stop in display zone 4.
Note:
The figure displayed in display zone 3 must always be approximately double that displayed in display zone 4.
- Operate the accelerator pedal slowly until fully depressed and observe the angle sender figures in display
zones 3 and 4:
completely.
completely.
AG. Volkswagen AG d
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- -> Adjust accelerator pedal -2-, if necessary by turning the adjustment screw -1-, so that when accelerator
pedal is almost fully depressed
the following is displayed in
rrectness of i
display zone 3: 70... 96 %

and in
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display zone 4: 35... 48 %.

nform
ercia
Note:
m
at
om
Adjustment is to be carried out with accelerator pedal in full throttle position.

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4 - Activated charcoal filter system

4.1 - Activated charcoal filter system
4.2 - Function
Depending upon the air pressure and ambient temperature, fuel vapour will form above the level of fuel in the
tank.
The activated charcoal filter system prevents these HC emissions escaping to the atmosphere.
Fuel vapours pass through a gravity valve (which closes at an angle of 45 °) located at the highest point in the
tank and through a pressuregeretention
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The activated charcoaled b stores these vapours like a sponge.
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When the Lambda
ss
a control is active when driving (engine warm),
the solenoid valve (N80, also called regener‐
c
ation valve), is activated (pulsed) from engine control unit depending upon load and engine speed. The opening
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e
nl
satelettronica
pt
period is dependent on the input signals.
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Intake manifold vacuum draws fresh air through the vent opening on the underside of the activated charcoal
ility
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filter during the purging procedure (regenerating the activated charcoal). The fuel vapours stored in the activated
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charcoal and fresh air are pulse-fed for combustion.

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The pressure retention valve prevents fuel vapours from being drawn from the tank when the solenoid valve is spec
es, in part or in w
open and intake manifold vacuum is present. It therefore ensures that the evacuation of the activated charcoal
t to the co
filter has priority.
rrectness of i
No voltage (e.g. wiring open circuit) the solenoid valve is closed and the activated charcoal filter will not be
purged.
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Notes:
nform
ercia
◆ Hose connections are secured with either spring-type or clamp-type clips.

m
at
◆ Always replace clamp-type clips with spring-type clips.

om
io
◆ For fitting the spring-type clips, assembly tool VAS 5024 is recommended.
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Observe rules for cleanliness => Page 131 .

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4.1 - Activated charcoal filter system 155

4.3 - Servicing parts of the activated charcoal filter system
satelettronica
AG. Volkswagen AG d
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1 Breather connection
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◆ To atmosphere
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2 Pressure retention valve with connecting hose

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◆ Shuts-off the tank venting when the solenoid valve (N80) is open and intake manifold pressure is present
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3 Activated charcoal filter

spec
es, in part or in w
◆ Location: in engine compartment, right

t to the co
◆ Secured to body
4 Connector
◆ Black, 2-pin
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◆ For solenoid valve 1

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5 Solenoid valve1 (N80)
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◆ Valve closed with ignition switched off C py
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◆ When the engine is warm the valve will be activated from the engine control unit (pulsed)
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◆ Checking activation:
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6 Vent pipe
◆ From gravity valve on fuel tank
=> Page 124 , Item 5
◆ Vehicles with electronic power control without cable disc for accelerator cable
4.3 - Servicing parts of the activated charcoal filter system 157

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Polo Estate ut
h 1996 ➤
o eo
ra
a
4-cyl. injection
ss engine Mechanics (1.6 l engine) - Edition c 12.1999
ce
e
nl
pt
4.4 - Checking fuel tank breather
du
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itte
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ab
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nf
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m
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or c
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◆ V.A.G 1368 Vacuum tester

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Cop py
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ht. rig
rig ht
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co Vo
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Prote AG.
◆ V.A.G 1390 Hand vacuum pump
Test sequence
- -> Pull breather pipe/hose -2- from activated charcoal filter -1- off at throttle valve control part -3-.
- Connect hand vacuum pump V.A.G 1390 to pipe/hose -2-.
- Connect breather pipe/hose -5- from fuel tank to activated charcoal filter to vacuum tester V.A.G 1368 -
connection A-.
- Connect vacuum tester V.A.G 1368 -connection B- to breather pipe/hose -4-.
- Set vacuum tester to position -B-.
- Introduce final control diagnosis and select activated charcoal filter solenoid valve (N80):
- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not

build up.
If vacuum builds up:
- -> Check breather connection -6- on activated charcoal filter -1- for soiling and clean if necessary.
If vacuum does not build up:
satelettronica
- Remove fuel filler cap.
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- -> Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 -connection B-.
- Set vacuum tester to -A/B- position. rrectness of i
- Operate V.A.G 1390 several times. Vacuum must
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not build-up.
If vacuum builds-up:
nform
mercia
at
- Check gravity valve => Page 124 , Item 5 .

om
io
- Check pipe/hose -1- from fuel tank for blockage.

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If vacuum does not build up:

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- Refit fuel filler cap.

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- Operate hand vacuum pump V.A.G 1390 several times. Cop py
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Vacuum must not
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Note:
If the fuel level in the tank is low the hand vacuum must be operated at least 20...30 times.
If vacuum builds up:
- Replace fuel tank cap.
4.4 - Checking fuel tank breather 159

26 - Exhaust system
1 - Removing and installing parts of exhaust system

1.1 - Removing and installing parts of exhaust system
Notes:
◆ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient
clearance from the bodywork. If necessary, loosen double clamps and align silencer and exhaust pipe so
that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
◆ Renew self-locking nuts.
◆ Components marked with * will be checked by self-diagnosis:
=> Repair group 01; Fault memory; Interrogating and erasing

n AG. Volfault
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doesof engine control unit Fault memory
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Interrogating and erasing fault memory of engine
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satelettronica
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Cop py
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160 26 - Exhaust system

1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments
satelettronica
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=>Page 164
1 Heat shield
nf
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or
2 Washer
m
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3 25 Nm
o
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4 Bracket
thi
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5 4-pin connector
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◆ Brown
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◆ Contacts 3 and 4 gold plated

t.
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◆ For Lambda probe and Lambda probe heating Cop py
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Prote AG.
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments 161
AG. Volkswagen AG d
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6 Lambda probe (G39)*, 50 Nm

◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
nform
ercia
body
◆ Remove and install with Lambda probe open ring spanner set 3337
m
at
◆ Checking:
om
ion
c
in t
or
=> Repair group 24; Checking function; Checking Lambda probe and Lambda regulation Checking function
his
ate
Checking Lambda probe and Lambda regulation

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7 To front silencer
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8 Front exhaust pipe with catalyst C py
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◆ To remove, remove assembly mounting pyri by
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=> Running gear, axles, steering; Repair group 40; Servicing front suspension strut; Removing and installing
AG.
assembly mounting Servicing front suspension strut Removing and installing assembly mounting

AG. Volkswagen AG d
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➤ aut
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Polo Estate o1996 ra
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4-cyl. injection engine Mechanics (1.6 l engine) - Edition 12.1999 s
ce
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nl
pt
du
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ab
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Cop py
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satelettronica
rig ht
py by
co Vo
by lksw
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Prote AG.
9 40 Nm
10 Gasket
◆ Renew
11 Exhaust manifold
AG. Volkswagen AG d
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Cop py
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1 Heat shield
2 25 Nm
3 6-pin connector
◆ Black for Lambda probe 1 before catalyst (G39) and Lambda probe heater (Z19)
◆ Contacts gold plated
4 Lambda probe 1 before catalyst (G39)*, 50Nm
◆ Constantly operating Lambda probe
body
◆ Checking:
=> Repair group 24; Checking functions; Checking Lambda probe and Lambda control in front of catalyst
Checking functions Checking Lambda probe and Lambda control in front of catalyst

AG. Volkswagen AG d
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5 From combi-valve
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◆ Secondary air system =>Page 173

p
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6 Union, 35 Nm
f
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7 25 Nm
Co
Cop py
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8 Pipe
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9 25 Nm
Prote AG.
10 Flange
◆ For securing connecting pipe to EGR valve (N18)
11 25 Nm
◆ Renew
12 60 Nm
AG. Volkswagen AG d
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satelettronica
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Cop py
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13 4-pin connector
◆ For Lambda probe 2 after catalyst (G130) and Lambda probe heating (Z29)
◆ Contacts 3 and 4 gold-plated
14 Lambda probe 2 after catalyst (G130)*, 50 Nm
body
◆ Checking:
=> Repair group 24; Checking functions; Checking Lambda probe and Lambda regulation behind catalyst
Checking functions Checking Lambda probe and Lambda regulation behind catalyst
15 To front silencer

satelettronica
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16 Front exhaust pipe with catalystaut or
ac
ss
◆ To remove, remove assembly mounting
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=> Running gear, axles, steering; Repair group 40; Servicing front suspension strut; Removing and installing
y li
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assembly mounting Servicing front suspension strut Removing and installing assembly mounting
pe
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◆ Check catalyst
h re
=> Page 172

hole
spec
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17 40 Nm
t to the co
◆ Renew
18 25 Nm
rrectness of i
19 Support
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20 20 Nm
◆ Renew
nform
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21 Gasket
◆ Renew
m
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22 Exhaust manifold
on in
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Cop py
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167
Prote AG.
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments
AG. Volkswagen AG d
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satelettronica
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Cop py
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Prote AG.
23 Gasket
◆ Renew
24 Bracket
25 Washer
◆ Not present if collared nut fitted
26 25 Nm
◆ Renew
27 10 Nm
28 To throttle valve control part (J338*)
29 25 Nm
30 Pipe
◆ Exhaust gas recirculation system =>Page 182

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Silencer with mountings
thi
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1 Front exhaust pipe with catalyst

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2 Marking
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3 Double clamp C py
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4 Dimension-a- = ca. 5 mm p by
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5 Carriage bolt Prote AG.
6 40 Nm
7 Front silencer
8 Mounting
9 25 Nm
10 Connecting piece
11 15 Nm
12 Bump stop
AG. Volkswagen AG d
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13 Mounting nf
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◆ With retaining ring

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14 20 Nm + 1/4 turn (90 °) further

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15 Rear silencer
thi
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16 Separating point
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◆ For repair cases

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◆ Marked by three impressions on circumference of exhaust pipe

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◆ As standard, front and rear silencers are installed as a single component. For repair purposes the front
C py
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and rear silencers are supplied individually with a double clamp for connecting together.
ht
pyri by
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◆ Cut through connecting pipe with suitable tool, e.g. pneumatic jig-saw V.A.G 1523, at right angle to
co lksw
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separating point => Fig. 1 Prote AG.

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-> Fig. 1 Separating point on exhaust pipe
e
nl
pt
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- Separate exhaust pipe at right angles at separating point -arrow 2-.
itte
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- When installing fit repair type double clamp -4- at side markings -arrows 1 and 3-.
ab
ility
Tightening torque 40 Nm
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1.3 - Checking catalyst
es, in part or in w
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satelettronica
rrectness of i
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at
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c
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Cop py
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This test does not work for the engine codes: AEH, AKL
◆ V.A.G 1551 Fault reader

◆ V.A.G 1551/3 Cable
◆ V.A.G 1788/10 speed regulator
Note:
The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, but a print-out is not
possible.
Check conditions
• Exhaust system between catalyst and cylinder head must be free of leaks
• Coolant temperature must be at least 80 °C, =>display group 04, display zone 3.
Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select engine control unit with "Address
word" 01. Connecting fault reader and selecting engine control unit:
satelettronica
=> Repair group 01; Self-diagnosis general: Connecting fault reader V.A.G 1551 and selecting engine elec‐
tronics control unit. Self-diagnosis general: Connecting fault reader V.A.G 1551 and selecting engine electronics
control unit.
- Interrogate fault memory. Repair faults as necessary and then erase fault memory.
Volkswagen AG
Interrogating and erasing fault memory of engine control unit swagen AG. does
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- Leave fault reader V.A.G 1551 connected.auth eo
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Select function XXX
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- Press keys 0 and 4 for the function "Initiating basic settings" and confirm entry with Q key. wit
, is n
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Basic setting
rrectness of i
- Press keys 0, 4 and 6 for "Display group number 46" and confirm entry with Q key.
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Basic setting 46
orm
1 2 3 4
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- Depress brake pedal.

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The engine speed is increased by the control unit to

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approx. 1100...1300 rpm.

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- Allow engine to run at increased engine speed until
C py
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display zone 4 jumps from "Test OFF" to "Test ON". The catalyst temperature in rig ht
py by
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display zone 2 must be a minimum of 400 °C.
co lksw
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Prote AG.

AG. Volkswagen APolo
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agen es n
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4-cyl. injection engine Mechanicsby Vol
(1.6 l engine) - Edition
ot g
ua 12.1999
ed ran
ris tee
Note: ut
ho
or
a ac
ss
This process can take a few minutes.
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le
un
pt
an
d
itte
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- Allow the engine to continue to run at increased engine speed until
rm
ab
display zone 4 displays "Cat B1 OK."
pe
ility
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If "Cat. B1 not OK" appears in display zone 4:
h re
hole
spec
es, in part or in w
- Interrogate fault memory:
t to the co
rrectness of i
Not for vehicles with D4 emissions standard (emissions warning lamp not in service)
l purpos
This test is intended for vehicles with on-board diagnosis and indicates possible damage to catalyst. If "Cat B1
nform
ercia
n. OK" is displayed, the catalyst need not always be renewed, but only if the next emissions test is not passed
or if visible damage to catalyst can be determined.
m
a
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tion in
If the emissions test is not passed or if damage to catalyst can be determined:
r
te o
thi
s
iva
do
- Renew catalyst.
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t.
If the specification "Cat B1 OK" is obtained:
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Cop py
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- Press ⇒key. pyri by
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co lksw
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Prote AG.
Select function XXX
2 - Secondary air system

2.1 - Secondary air system
2.2 - Function
The secondary air system blows air in behind the exhaust valve for up to 100 seconds following a cold start
(+17 °C ... +33 °C coolant temperature). This enriches the exhaust gas with oxygen, causing afterburning and
shortening the heating phase of the catalyst. Activation is performed by the Simos control unit (J361) via the
secondary air pump relay (J299) to the secondary air inlet valve (N112, change-over valve) and combi-valve.
1.3 - Checking catalyst 173

2.3 - Removing and installing parts of the secondary air system
satelettronica
AG. Volkswagen AG d
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Notes:
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◆ Components marked with an * are checked by the self-diagnosis:

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◆ Components marked with ** are checked by the final control diagnosis:

rrectness of i
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◆ Secondary air pump relay (J299) =>Page 178 , Fig. 1

nform
mercia
1 Combi-valve
at
om
io
◆ Checking =>Page 180

n
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2 Vacuum hose
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3 Connector
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◆ 2-pin
satelettronica
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4 Secondary air inlet valve (N112)*/**

h re
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5 To connection on pipe to brake servo

spec
6 25 Nm
t to the co
7 EGR valve (N18)*/** with potentiometer for exhaust gas recirculation (G212)*
◆ Check EGR valve (N18):
rrectne
ss o
cial p
f in
◆ Check potentiometer for exhaust gas recirculation (G212) =>Page 188

form
mer
atio
8 25 Nm
om
n
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9 Pipe
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Cop py
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rig ht
py by
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Prote AG.
2.3 - Removing and installing parts of the secondary air system 175
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a
com
tion in
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te o
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s
iva
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10 To union on exhaust manifold

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ng
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11 O-ring
C py
ht. rig
rig ht
◆ Renew py by
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12 Pressure hose cted agen
Prote AG.
◆ Ensure seated tightly
◆ Press together at front to release
13 Intake hose
◆ For secondary air pump motor
14 From air cleaner
15 Secondary air pump motor (V101)
◆ Checking function =>Page 178
16 Connector
◆ 2-pin
17 10 Nm
18 25 Nm

AG. Volkswagen AG d
agen oes
olksw not Polo Estate 1996 ➤
byV gu
ara
rised
4-cyl. injection engine Mechanics nte (1.6 l engine) - Edition 12.1999
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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ab
ility
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wit
is n
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spec
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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o
pr
cum
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fo
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en
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rig ht
py by
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Prote AG.
19 15 Nm
20 Bracket
◆ For secondary air pump motor
◆ Secured to intake manifold
21 Intake manifold - lower part
22 10 Nm
23 Connecting piece
◆ With mounting for combi-valve and EGR valve (N18)
24 Gasket
◆ Renew
25 Union, 35 Nm
2.3 - Removing and installing parts of the secondary air system 177
AG. Volkswagen AG d
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-> Fig.1 Secondary air pump relay (J299) -arrow-
wit
is n
h re
ole,
◆ If tools are necessary to pull relays or control units out of the relay plate, first disconnect battery earth strap.
spec
◆ Before disconnecting battery earth strap obtain code for radios with anti-theft coding.
t to the co
2.4 - Checking secondary air pump motor
rrectne
satelettronica
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.
Note:
The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
is not possible.

Check conditions
AG. Volkswagen AG d
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pt
du
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• -> The main fuses must be OK.
erm
ab
• The intake hose for secondary air pump is not blocked or kinked.
ility
ot p
wit
, is n
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hole
spec
Test sequence
es, in part or in w
t to the co
- Detach the pressure hose from the secondary air pump motor.
satelettronica
rrectness of i
Note:
l purpos
To release, press together the buttons on the hose coupling.

- Activate the secondary air pump relay via the final control diagnosis.
nf
ercia
orm
m
atio
m

o
n in
or c
thi
- The secondary air pump motor must run for approx. 10 seconds, and air must exit the outlet connections.
te
sd
iva
o
r
rp
cu
If the motor runs, but little or no air exits:

o
m
f
en
ng
t.
yi
- Press ⇒key.
Co
op py
- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.
t. C rig
gh ht
yri
- Replace secondary air pump motor. p by
o Vo
by c lksw
cted agen
Prote AG.
If the secondary air pump motor does not run:
- Check activation of secondary air pump motor:
2.5 - Checking combi-valve
2.4 - Checking secondary air pump motor 179

◆ V.A.G 1390 Hand vacuum pump
Check conditions
• Vacuum pipes and hose connections free of leaks.

• Vacuum pipes not blocked/kinked.
Test sequence
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
ris nte
- -> Pull vacuum hose
ut
h -1- off secondary air inlet valve -2- (N112).e o
o
r
- Connect hand svacuum
s a pump V.A.G 1390 to vacuum hose -1-. ac
ce
e
nl
pt
Note:
du
an
itte
y li
erm
ab
Do not use compressed air during the following check!

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
mercia
at
om
ion
c
in t
r
- -> Detach pressure hose from secondary air pump motor and blow in lightly -arrow-.
o
his
te
Combi-valve must be closed.

a
do
riv
- Operate hand vacuum pump.

p
cum
or
Combi-valve must open.

f
en
ng
t.
yi Co
Cop py
If the combi-valve does not open, or is permanently open: ht. rig
rig ht
py by
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by lksw
- Replace the combi-valve cted agen
Prote AG.

2.6 - Checking secondary air inlet valve
AG. Volkswagen AG d
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ris nte
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
Note:
satelettronica
s
The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
o
cial p
f
is not possible.
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.
Test conditions
• Secondary air pump motor OK.

• Vacuum pipes connected and air-tight.
• Vacuum pipes not blocked/kinked.
Test sequence
2.6 - Checking secondary air inlet valve 181

- -> Pull upper vacuum hose -arrow- off secondary air inlet.
- Activate the secondary air pump relay via the final control diagnosis.
- The secondary air pump motor must run at approx. 10 second intervals, and suction (negative air pressure)
must be felt at secondary air inlet valve connections.
If no intake manifold vacuum is perceptible:
- Check activation of valve:
3 - Exhaust gas recirculation system

3.1 - Exhaust gas recirculation system
satelettronica
Notes: agen
AG. Volkswagen AG d
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◆ The function/control of the exhaust ise gas recirculation system is checked by
d b ara the self-diagnosis
nte of the Simos
r
control unit (J361). utho eo
ra
◆ Pulsed control makes every ss aconceivable valve position possible. c
◆ The cone shaped plunger in the (electric) EGR valve ensures that various cross sectional openings are
ce
le
un
possible at different plunger lifts. pt

an
d
itte
◆ Checking exhaust gas recirculation valve (N18). y li

erm
ab
ility
ot p
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐ wit
is n

h re
ole,
spec
◆ Components marked with an * are checked via the self-diagnosis.

t to the co
rrectne
◆ Components marked with ** are checked via the final control diagnosis.
ss
o
cial p
f i

nform
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.

3.2 - Servicing parts of exhaust gas recirculation system
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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satelettronica
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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spec
es, in part or in w
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rrectness of i
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nform
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ion
c
in t
or
his
ate
1 Gasket
do
priv
cum
or
◆ Renew
f
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ng
t.
2 10 Nm
yi Co
Cop py
3 Connecting pipe
t. rig
gh ht
yri by
4 25 Nm
op Vo
by c lksw
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5 From combi-valve Prote AG.

6 Exhaust manifold
7 6-pin connector
◆ Black for Lambda probe 1 before catalyst (G39) and Lambda probe heater (Z19)
◆ Contacts gold plated
3.2 - Servicing parts of exhaust gas recirculation system 183

satelettronica
AG. Volkswagen AG d
agen oes
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8 Lambda probe 1 before catalyst (G39)*, 50Nm

nl
pt
du
an
itte
◆ Constantly operating Lambda probe

y li
erm
ab
ility
ot p
body
wit
, is n
h re
◆ Checking:
hole
spec
es, in part or in w
=> Repair group 24; Checking functions; Checking Lambda probe and Lambda control in front of catalyst
t to the co
Checking functions Checking Lambda probe and Lambda control in front of catalyst
9 60 Nm
rrectness of i
10 Throttle valve control part (J338)*

l purpos
11 25 Nm
nf
ercia
orm
m
atio
om
n in
or c
thi
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sd
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o
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f
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

satelettronica
AG. Volkswagen AG d
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nl
pt
du
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spec
es, in part or in w
t to the co
rrectness of i
12 EGR valve (N18)*/** with potentiometer for exhaust gas recirculation (G212)*
l purpos
◆ Check EGR valve (N18):
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐ nf
ercia
o
rm
m
atio
om
n in
◆ Check potentiometer for exhaust gas recirculation (G212) =>Page 188

or c
thi
te
sd
a
13 6-pin connector
iv
o
r
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14 From air cleaner

o
m
f
en
ng
t.
yi
15 Air hose
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.2 - Servicing parts of exhaust gas recirculation system 185

3.3 - Checking exhaust gas recirculation system
Only engine code AUR
◆ Fault reader V.A.G 1551 (or vehicle system tester V.A.G 1552) with cable V.A.G 1551/3
satelettronica
Test conditions
• The fuses must be OK. . Volkswagen AG

• The battery voltage must belkat gen AG
swaleast 11.5 V. does
not
• All electrical consumers,
d bye.g.
V lights and rear window heating
o gu must be switched off.
a
• Coolant temperatureorismust be at least 80 °C, =>display groupra04,
e nte display zone 3.
e th or
au ac
Work sequence ss
ce
e
nl
pt
du
an
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and let it idle. Select engine control unit with
itte
y li
"Address word" 01. Connecting fault reader and selecting engine control unit:
erm
ab
ility
ot p
wit
=> Repair group 01; Self-diagnosis general: Connecting fault reader V.A.G 1551 and selecting engine elec‐
, is n
h re
tronics control unit. Self-diagnosis general: Connecting fault reader V.A.G 1551 and selecting engine electronics
hole
control unit.
spec
es, in part or in w
t to the co

Select function XXX
rrectness of i
l purpos
- Press keys 0 and 4 for the "Introduce basic setting" function and confirm entry with Q key.

nform
ercia
Basic setting
m
at

om
ion
c
in t
or
his
ate
do
priv

um
for
en
g

n
t.
yi Co
op py
System in basic setting 75 ht. C rig
1 2 3 4 rig by
ht
copy Vo
by lksw
cted agen
If the diagnosis is initiated by engine control unit the display in display zone 4 jumps from "Test OFF" to "Test
Prote AG.
ON"
Note:
During "Test on" the exhaust gas recirculation valve is open partially by the engine control unit. The idling speed
drops and the engine runs uneven. The potentiometer for the exhaust gas recirculation informs the engine

control unit of the actual opening angle. The actual status is compared with the specified status and the result
of the diagnosis is displayed.
- Let engine continue to idle until the result of the functional test is displayed in display zone 4:
Specification: "Syst. OK"
If the display does not indicate as described:
- Interrogate fault memory:
- Check exhaust gas recirculation valve activation: AG. Volkswagen AG d

agen oes
o lksw not
y V gu
b ara
=> Repair group 01; Final control diagnosis; Performing
orise
d
final control diagnosis Final control ndiagnosis
tee Per‐
forming final control diagnosis auth or
ac
ss
ce
e
- Check exhaust gas recirculation potentiometer =>Page 188
nl
pt
du
an
itte
y li
If the display indicates as described:
erm
ab
ility
ot p
- Press ⇒key.
wit
, is n
satelettronica
h re
- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.
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 lksw
by
cted agen
Prote AG.
3.3 - Checking exhaust gas recirculation system 187

Polo Estate 1996 ➤ AG. Volkswagen AG d
agen
4-cyl. injection engineVoMechanics (1.6 l engine) not - Edition 12.1999
oes
lksw
by gu
ara
ed
3.4 - Checking potentiometer
thoris for exhaust gas recirculation ntee o
au ra
c
ss
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
satelettronica
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.
◆ V.A.G 1526 Hand multimeter

◆ V.A.G 1598/31 Test box
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
Test conditions

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
oris Polo Estate nte1996 ➤
eo
th
4-cyl. injection engine
s au Mechanics (1.6 l engine) - Edition 12.1999 ra
c
s
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
Test sequence
m
atio
om
n in
c
- -> Pull off 6-pin connector -arrow- (grey) from EGR valve.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
satelettronica
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Connect multimeter to contacts 2 and 4 of 6-pin connector for voltage measurement.
- Switch on ignition.
Specification: min. 4.5 V
If the specification is not attained:

- -> Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains discon‐
nected.
3.4 - Checking potentiometer for exhaust gas recirculation 189

- -> Check wiring for open circuit between test box and 6-pin connector using current flow diagram.
Contact 2 and test box socket 96
Wire resistance: max. 1.5 ω
- Additionally check wiring for short to one another, and for short to positive or earth.
If the specification is obtained:
- Connect test box V.A.G 1598/31 to engine control unit as well and reconnect 6-pin connector to EGR valve.
satelettronica
- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
G. Volkswagen
=> Repair group 01; Self-diagnosis general: wagConnecting
en A faultAreader
G do
es n V.A.G 1551 and selecting engine elec‐
olks
tronics control unit. Self-diagnosis general:
d by V Connecting fault reader V.A.G
ot g
ua1551 and selecting engine electronics
control unit. o
ir se
ran
te
h eo
ut ra
sa
- Initiate final control diagnosis
s and select EGR valve (N18): c
ce
e
nl
pt
du
an
itte
y li

erm
ab
ility
ot p
wit
- Connect diode test lamp V.A.G 1527 B to socket 108 of test box and earth using adapters from V.A.G 1594.
, is n
h re
The LED must flash.

hole
- Proceed with final control diagnosis until completed.

spec
es, in part or in w
t to the co

- Depending on conditions, renew following components:
rrectness of i
LED flashes:
l purpos
- Renew EGR valve (N18) with potentiometer (G212).

nform
ercia
- Erase learnt values and re-adapt engine control unit

m
at
om
=> Repair group 24; Engine control unit; Erasing learnt values and adapting engine control unit to throttle valve
ion
c
control part and EGR valve Engine control unit Erasing learnt values and adapting engine control unit to throttle
in t
or
his
e
valve control part and EGR valve

at
do
priv
cum
or
If no wiring fault is detected and the LED does not flash:

f
en
ng
t.
yi Co
op py
- Renew engine control unit. t. C rig
gh ht
pyri by
Vo
co
=> Repair group 24; Engine control unit; Renewing engine control unit Engine control unit Renewing engine
by lksw
cted agen
Prote
control unit
AG.

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Service

Polo Estate 1996 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg 00056408120

1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.7 Renewing bonded rubber bushes on subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

3.2 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

3.3 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

3.4 Adjusting pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

4.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

4.3 Servicing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

2.1 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

3.1 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

3.3 Checking exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186

1.2 - Engine number

1.3 - Engine data

Code letters AEH AKL APF AUR

Manufactured 10.99 ▸ 10.99 ▸ 01.00 ▸ 05.00 ▸

Capacity ltr. 1.6 1.6 1.6 1.6

Torque Nm at rpm 145/3800 145/3800 145/3800 145/3800

Bore ø mm 81.0 81.0 81.0 81.0

Stroke mm 77.4 77.4 77.4 77.4

Compression 10.2 10.2 10.2 10.2

RON min. 95 unleaded 95 unleaded 95 unleaded 95 unleaded

Knock control Yes Yes Yes Yes

1.1 - Technical data 1

Code letters AEH AKL APF AUR

Code letters AEH AKL APF AUR

1) With 2 Lambda probes

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)

1.2 - Notes on removing

- The engine is removed forwards together with the gearbox.

- Unscrew power steering reservoir and tie-up.

4 10 - Removing and installing engine

- Observe rules for cleanliness => Page 131 .

- Pull hose -3- off activated charcoal filter solenoid valve 1.

- Remove noise insulation tray.

- Remove ribbed belt => Page 26 .

- Disconnect drive shafts at gearbox:

- Unscrew pipes for power steering from engine carrier.

- Drain coolant => Page 114 .

- Pull connectors off thermo-switch and radiator fan.

- Removing lock carrier with attachments:

- Observe additional information and removal instructions => Page 14 .

1.2 - Notes on removing 5

Vehicles with automatic gearbox