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Service
Polo Estate 1998 ➤

4-Cyl. injection engine (2 valve, roller rocker finger),
Mechanics
Engine ID AKK ANW AUD
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
Mechanics
Repair Group
00 - Technical data agen
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13 - Crankshaft group
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15 - Cylinder head, Valve gear

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17 - Lubrication
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19 - Cooling system
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20 - Fuel supply system
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26 - Exhaust system
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Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg 00056407820

4-Cyl. injection engine (2 valve, roller rocker finger), Mechanics - Edition 12.1999
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.5 Tightening torquesag. e.n.A.G.. V . o. lk. s.w.a.ge. n. A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
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1.6 Assembly mounting
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1.7 Replacing
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1.8 Additional
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
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1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
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1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
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1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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1.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
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1.5 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

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2 Removing and installing cylinder block, sealing flange and flywheel . . . . . . . . . . . . . . . . . .27
2.1 Removing and installing cylinder block, sealing flange and flywheel . . . . . . . . . . . . . . . . . .27
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2.2 Aluminium cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

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2.3 Renewing crankshaft oil seal -belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

2.4 Renewing crankshaft sealing flange -flywheel end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
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3 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

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3.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

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3.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

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15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

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1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

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1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
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1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
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1.3 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
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2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
2.3 Replacing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2.4 Removing and installing cylinder head cover and camshaft . . . . . . . . . . . . . . . . . . . . . . . .72
2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
1.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Contents i
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
1.2 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
1.3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
1.4 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
1.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
1.2 Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate . . . . . . . .110
1.3 Removing and installing fuel tank with its attachments, Caddy . . . . . . . . . . . . . . . . . . . . . .115
1.4 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .120
1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
1.6 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
1.7 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
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1.8 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
1.9 Removing and installing swage fuel tank . . . . . .d.o.es. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
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1.10 Checking fuelbpump yV
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2 Electronictho power control (EPC) . . . . . . . . . . . . . . . . . e.o. . . . . . . . . . . . . . . . . . . . . . . . . . . .131
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2.1 Electronic
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2.2 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
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2.3 Servicing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

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2.4 Checking EPC warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

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2.5 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

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2.6 Adjusting pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

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3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

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3.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

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3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

3.3 Servicing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
3.4 Checking activated charcoal filter solenoid valve 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
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3.5 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

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1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

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1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . . . . . .152
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1.3 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

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1.4 Checking catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162

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ii 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 front of the cylinder block at
the gearbox end below the thermostat housing.
Additionally there is a sticker on the toothed belt guard with "Engine code" and "Serial number".
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1.3 - Engine data
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Codes AKK ANW AUD
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Manufactured 11.99 ▸ 11.99 ▸ 06.00 ▸
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Exhaust emissions fulfil MVEG II standard D4 standard EU4 standard

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Capacity cm3 1390 1390 1390

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Output kW at rpm 44/4700 44/4700 44/4700

Torque Nm at rpm 116/3000 116/3000 116/3000
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Bore mm ø 76.5 76.5 76.5

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Codes AKK ANW AUD

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Compression ratio 10.4:1 10.4:1 10.4:1

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RON min. 95 unleaded1) 95 unleaded1) 95 unleaded1)

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Injection, ignition Motronic Motronic Motronic

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ME 7.5.10 ME 7.5.10 ME 7.5.10

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Knock control yes yes yes

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Lambda regulation 1 Lambda probes 2 Lambda probes 2 Lambda probes
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1.1 - Technical data 1

Codes AKK ANW AUD

Catalyst yes yes2) yes2)
Exhaust gas recirculation no no no
Charging no no no
1) In exceptional circumstances min. 91 RON, however with reduced performance
2) Additionally with integrated pre-catalyst in exhaust manifold
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2 00 - Technical data
10 - Removing and installing engine
1 - Removing and installing engine

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

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

◆ -> V.A.G 1332 Torque wrench (40...200 Nm)
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◆ VAS 5024 Assembly tool for spring-type
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◆ G 000 100 grease
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◆ Cable tie
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Note:
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- The engine is removed forwards together with the gearbox.

- With ignition switched off disconnect battery earth strap.
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- All cable ties which are opened or cut open when removing engine, must be replaced in the same position
when installing engine.
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- Remove air cleaner:

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=> Repair group 24; Servicing injection; Dismantling and assembling air cleaner Servicing injection Dismantling
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- Open and close the expansion tank sealing cap to release pressure in cooling system.
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- Disconnect all electric wires from gearbox, alternator and starter and move clear.
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- Loosen or separate the following components: Cop py
- The hose from intake manifold to activated charcoal filter system
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- The vacuum hose from inlet manifold at brake servo
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- The collective connectors below the thermostat housing
- The ignition transformer and Hall sender connectors
- The engine speed sender connector
- Lambda probe connector in exhaust manifold
- The 2-pin connector from knock sensor (rear of cylinder block)
- The road speed sender connector
- The reversing light connector
4 10 - Removing and installing engine

- The earth wire from the gearbox
- The cable holder connection (front of gearbox)
- Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.
Warning!
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off connection.
- Now separate fuel supply as well as fuel return pipes at connecting point on suspension strut turret.
- Disconnect clutch cable:
=> 5-speed manual gearbox 085; Repair group 30; Servicing clutch control Servicing clutch control
- Disconnect selector mechanism from gearbox.
=> 5-speed manual gearbox 085; Repair group 34; Servicing selector mechanism Servicing selector mecha‐
nism
- Drain coolant => Page 103 .
- Loosen hose clips and pull coolant hoses off coolant thermostat housing.
Vehicles with power assisted steering
satelettronica
- Remove power steering reservoir and tie up. agen
AG. Volkswagen AG d
oes
- Unscrew power steering pressure hose clamp on front yof olksw
engine console. not
V gu
- Loosen belt pulley securing bolts from power steering
rised vane
b
pump. ara
nte
- Remove ribbed belt => Page 21 . ut
ho eo
r
- Unbolt power steering vane pump and securessto sub-frame with wire; hoses remain connected: ac
a
ce
e
nl
pt
du
=> Running gear, axles, steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines;
an
itte
Removing and installing power steering vane pump. Assembly overview: vane pump, reservoir, hydraulic lines
y li
erm
ab
Removing and installing power steering vane pump.
ility
ot p
wit
Vehicles with air conditioner
, is n
h re
hole
- Removing air conditioner compressor:
spec
- Observe additional information and removal instructions =>Page 11
es, in part or in w
t to the co
Continuation for all vehicles
- Remove left and right-hand drive shaft on gearbox and tie up:
rrectness of i
l purpos
=> Running gear, axles, steering; Repair group 40; Servicing front suspension; Removing and installing drive
shafts Servicing front suspension Removing and installing drive shafts
nform
ercia
- Separate front exhaust pipe from exhaust manifold => Page 152 , exhaust manifold, front exhaust pipe
and catalyst with attachments.
m
at
- Removing lock carrier with attachments:
om
ion
c
in t
or
his
=> General body repairs; Repair group 50; Body, front; Removing and installing lock carrier with attachments.
ate
do
riv
Body, front Removing and installing lock carrier with attachments.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.2 - Notes on removing 5

- -> Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:
Pulley end:
2nd hole in hook at position 1
Flywheel end:
2nd hole in hook at position 5
AG. Volkswagen AG d
agen oes
olksw not
Warning! d by V gu
ara
The hooks and locating pins hmust
rise be secured with locking pins. nte
t o eo
au ra
ss c
Notes:
ce
e
nl
pt
du
an
itte
◆ The positions marked 1...4 on the bar must be towards the pulley end.
y li
erm
ab
◆ The holes in the hook rails are counted up from the hook.
ility
ot p
wit
, is n
- Unbolt assembly at gearbox and engine mountings.
h re
hole
- Pull assembly out forwards. When doing this, the assembly should be lifted and turned as necessary.
spec
es, in part or in w
t to the co
Note:
When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.
rrectness of i
satelettronica
l purpos
1.3 - Securing engine to assembly stand
nform
mercia
When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the
at
om
io
engine and gearbox box support VW 540.
n
c
in t
or
his
te
Work sequence
a
do
priv
cum
or
- Remove gearbox.
f
en
ng
t.
yi
- Secure engine to support clamp VW 313 using engine and gearbox support VW 540.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
1.4 - Notes on installing
Prote AG.
Installation is carried out in the reverse sequence, when doing this note the following:
- Check clutch release bearing for wear, renew if necessary.

- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000
100.
- Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if neces‐
sary.
- When swinging the assembly in, ensure that clearance exists between the drive shafts.

- -> When installing the engine mounting ensure that the rib on the rear right console also the recess on the
front console locates on the lugs of the bonded rubber mounting -arrows-.
- Align engine mountings stress-free by rocking.
Note:
AG. Volkswagen AG d
agen oes
Assembly mounting tightening torques Volksw not
gu
d by ara
ise nte
r
=> Page 8 . ut
ho eo
ra
s a c
s
- Install drive shafts:
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
- Installing P.A.S. vane pump:
h re
hole
spec
=> Running gear, axles, steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines;
es, in part or in w
t to the co
Removing and installing power steering vane pump. Assembly overview: vane pump, reservoir, hydraulic lines
Removing and installing power steering vane pump.
rrectness of i
- Installing front exhaust pipe => Page 152 , Exhaust manifold, front exhaust pipe and catalyst with attach‐
ments.
l purpos
satelettronica
nf
ercia
or
- Install air conditioner compressor.
m
m
atio
om
n in
c
Continuation for all vehicles

or
thi
te
sd
iva
- Electrical connections and routing:
o
r
rp
cu
o
m
f
en
ng
t.
=> Electrical system; Repair group 97
yi Co
Cop py
t. rig
gh ht
- Install ribbed belt => Page 21 . yri
p by
o Vo
by c
- Installing clutch cable:
lksw
cted agen
Prote AG.
=> 5-speed manual gearbox 085; Repair group 30; Servicing clutch control Servicing clutch control
- Connecting selector mechanism to gearbox.
=> 5-speed manual gearbox 085; Repair group 34; Servicing selector mechanism Servicing selector mecha‐
nism
- Renew pointed bolt for securing shift finger (clean threads in shift finger).
- Filling with coolant => Page 103
- Install air cleaner:
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner. Servicing injection
system Dismantling and assembling air cleaner.
- Perform the work sequence "Procedure after interrupting voltage supply".
=> Repair group 24; Engine control unit; Procedure after interrupting voltage supply. Engine control unit Pro‐
cedure after interrupting voltage supply.
- Carry out a test drive and interrogate fault memory:
=> Repair group 01; Fault memory; Interrogating and erasing fault memory of engine control unit Fault memory
Interrogating and erasing fault memory of engine control unit
1.4 - Notes on installing 7

1.5 - Tightening torques

G. Volkswagen AG d
Bolted connection wage
nA Tightening torque
oes
Volks not
Bolts, nuts ed
by M6 10 Nm gu
ara
ris nte
tho M8 20 Nm eo
au ra
ss M10 45 Nm c
ce
e
nl
M 12 60 Nm
pt
du
an
itte
y li
in variation of this
erm
ab
ility
Exhaust pipe to manifold 40 Nm
ot p
wit
, is n
h re
hole
spec
1.6 - Assembly mounting
es, in part or in w
t to the co
Tightening torques
rrectness of i
l purpos
nf
ercia
satelettronica
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note:
The bolts must not be used again.
(Bolts oiled)
-> Front assembly mounting
A = 50 Nm
B = 50 Nm
C = 50 Nm

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
ut
ho Polo Estate 1998 eo ➤
ra
a
4-Cyl. injection engine (2 valve, rollers rocker finger), Mechanics - Edition 12.1999
s c
ce
le
un
pt
-> Rear right assembly mounting
an
d
itte
y li
rm
ab
A = 40 Nm
pe
ility
ot
B = 50 Nm
wit
, is n
C = 25 Nm
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
-> Gearbox mounting
ng
t.
yi Co
Cop py
satelettronica
t. rig
A = 50 Nm gh ht
yri by
B = 45 Nm
op Vo
by c lksw
C = 25 Nm
cted agen
Prote AG.
1.6 - Assembly mounting 9

1.7 - Replacing engine carrier rubber mounting
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
◆ 10-222A Engine support bracket with legs 10-222A/1

n
c
i
or
◆ 3302 Peening tool

thi
te
sd
a
◆ VW 432 Press piece

iv
o
pr
cum
r
fo
Work sequence
en
ng
t.
yi Co
Cop py
t. rig
- Fit engine support bracket 10-222A with legs 10-222A/1. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
- Locate support bracket in lifting eye on left of cylinder head and take-up weight of engine.
spec
- Remove engine carrier.
es, in part or in w
- -> Lever off washers from the spacer sleeves with pliers (replace any washers which are damaged e.g. bent
t to the co
washers).
- Pull out spacer sleeves and detach rubber mounting.
- Fit new rubber mounting and insert spacer sleeves as far as possible.
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
- -> Fit washers -1- over peening tool 3302 onto the rubber mounting -2-.
AG.
- Fit press sleeve of peening tool 3302 and using a press, press the washers onto the spacer sleeves and
peen. Use VW 432 as packing.
- Remove any resulting protrusion/burr on the peening.
1.8 - Additional information and removal instructions for vehicles with air conditioner
Warning!
The air conditioning system refrigerant circuit must not be opened.
Note:
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
not stretched, kinked or bent.
To facilitate removing and installing the engine without opening the refrigerant circuit:
- Detach air conditioning fluid container.

- Unbolt retaining clamp(s) for refrigerant lines.
- Remove ribbed belt => Page 21 .
- Remove lock carrier with attachments:
=> General body repairs; Repair group 50; Body, front; Removing and installing lock carrier with attachments.
Body, front Removing and installing lock carrier with attachments.
1.7 - Replacing engine carrier rubber mounting 11

- Remove air conditioner compressor with attached refrigerant hoses from support:
=> Heating, air conditioner system; Repair group 87
- Set the lock carrier with radiator, condenser and air conditioner compressor to the side so that the refrigerant
hoses and pipes -arrows- are not strained.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
c
satelettronica
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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.

4-Cyl. injection engineen(2
AGvalve,
. Volkswagroller
en rocker
AG do finger), Mechanics - Edition 12.1999
wag e ks s no
Vol
13 - Crankshaft group
t gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
1 - Dismantling and assembling engine
erm
ab
ility
ot p
wit
, is n
1.1 - Dismantling and assembling engine
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
satelettronica
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
I =>Page 14
II =>Page 18
1.1 - Dismantling and assembling engine 13

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Part I
h re
hole
spec
1 Toothed belt guard - upper part
es, in part or in w
t to the co
2 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear rrectness of i
◆ Do not kink
l purpos
◆ Removing, installing and tensioning

=> Page 24
3 20 Nm + 1/4 turn (90 °) further
nf
ercia
◆ To loosen and tighten, hold with retainer 3036

rm
m
atio
◆ Renew
om
n in
4 Camshaft sprocket
or c
thi
e
◆ Note position when installing toothed belt

t
sd
iva
=> Page 24
o
r
rp
cu
o
5 10 Nm
f
en
ng
t.
yi
◆ Install with D6
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
14 13 - Crankshaft group
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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
satelettronica
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6 Rear toothed belt guard

7 12 Nm
◆ Renew
8 Coolant pump
◆ With integrated seal
◆ Seal must not be separated from coolant pump
◆ Replace damaged or leaking coolant pump together with seal
◆ Check for ease of movement
◆ Removing and installing
=> Page 107
9 20 Nm
10 Tensioner
◆ Checking => Page 26
◆ Tensioning toothed belts
=> Page 24

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
11 Crankshaft toothed belt sprocket
rm
ab
pe
ility
ot
wit
=> Page 24
, is n
h re
12 Belt pulley
hole
◆ When installing note fixing arrangement spec

es, in part or in w
t to the co
13 20 Nm
14 Ribbed belt
◆ Mark direction of rotation before removing
rrectness of i
◆ Check for wear

l purpos
◆ Do not kink
=> Page 21
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
satelettronica
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
15 90 Nm + 1/4 turn (90 °) further C py
t. rig
gh ht
◆ Renew yri
p by
o Vo
◆ Oil threads
c by lksw
cted agen
◆ Hold toothed belt sprocket with toothed belt sprocket holder 3099
Prote AG.
◆ The turning further can be done in several stages

◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690
16 Toothed belt guard - lower part

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
Part II
an
d
itte
y li
rm
ab
pe
ility
Note:
ot
wit
, is n
h re
hole
Servicing the clutch:

spec
es, in part or in w
t to the co
=> 5-Speed manual gearbox 085; Repair group 30; Servicing clutch Servicing clutch
1 Cylinder block
rrectness of i
◆ Dismantling and assembling aluminium cylinder block => Page 28

◆ Dismantling and assembling pistons and conrods
l purpos
=> Page 43
2 50 Nm
nform
ercia
◆ Tightening sequence:
m
Upper right bolt first, then lower right bolt, and bolts on left last (as seen from direction of travel)
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
3 Oil filter
erm
◆ Loosen at hexagon bolt head ab

ility
ot p
◆ Note instructions on filter when installing wit

is n
◆ Screw on threaded connector piece by hand until limit stop h re

ole,
◆ Tighten by hand
spec
4 Compact bracket
t to the co
◆ For vane pump, alternator and air conditioner compressor

5 15 Nm
rrectne
◆ Loosen and tighten the flywheel end bolts only with socket insert 3249
6 Sump
s

s o
cial p
=> Page 85
f inform
7 Oil drain plug, 30 Nm

mer
◆ With attached seal

atio
om
◆ Renew
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.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
8 20 Nm + 1/4 turn (90 °) further s aut ra
c
s
◆ Renew
ce
le
un

pt
an
d
itte
y li
erm
ab
9 45 Nm
ility
ot p
10 Washer
wit
is n
h re
11 Tensioning roller
ole,
spec
12 Tensioning element
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.2 - Removing and installing ribbed belt
Vehicles without power assisted steering
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
AG. Volkswagen AG d
◆ -> 3297 Tensioning lever agen oes
olksw not
y V gu
b
satelettronica
d ara
ise nte
Work sequence thor eo
au ra
ss c
- Mark direction of rotation of ribbed belt.
ce
le
un
- Loosen alternator securing bolts.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
- -> Install tensioning lever 3297, secure with spring clip and swivel alternator down (to turn 3297 use e.g.
atio
m
torque wrench).
o
n
c
- Remove/fit ribbed belt

or
n thi
te
sd
iva
Note:
o
pr
cum
r
fo
en
ng
t.
yi
When installing the ribbed belt ensure that it sits correctly in the pulleys.
Co
Cop py
t. rig
gh ht
yri
- After fitting ribbed belt with alternator loose, rotate engine several times (approx. 10 revolutions of engine
p by
co Vo
by operating starter briefly.
by lksw
cted agen
Prote
- First tighten lower and then upper alternator bolts to
AG.
25 Nm.
Vehicles with power assisted steering
Removing
- Remove ribbed belt cover.

- Mark ribbed belt direction of rotation.
1.2 - Removing and installing ribbed belt 21

AG. Volkswagen AG d
Polo Estate 1998 ➤ agen oes
olksw not
V
4-Cyl. injection engine (2 valve, roller rocker
ed b finger), Mechanics - Editiongu12.1999
y ara
ris nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
- -> Using a spanner on the securing bolt swivel tensioning roller in direction of arrow.
l purpos
- Remove ribbed V-belt.
nform
ercia
Installing
m
at
om
- Place ribbed V-belt onto crankshaft pulley first. Slide belt onto tensioning roller last.
ion
c
in t
or
his
Ribbed belt routing
ate
do
priv
cum
satelettronica
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
-> Basic belt drive
1- Crankshaft/pulley
2- Ribbed belt
3- Pulley - Alternator
-> Belt drive without air conditioner compressor
2- Ribbed belt
3- Pulley - P.A.S. vane pump
5- Tensioner
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
-> Belt drive with air conditioner compressor ss
a ac
ce
le
un
pt
an
d
itte
y li
2- Tensioner
rm
ab
pe
ility
4- Air conditioner compressor
ot
wit
, is n
satelettronica
5- Pulley - P.A.S. vane pump
h re
hole
spec
Note:
es, in part or in w
t to the co
When installing the ribbed V-belt, ensure the belt runs in the right direction and seats correctly on the belt
pulleys.
rrectness of i
The rest of the assembly is basically a reverse of the dismantling sequence.
l purpos
nform
ercia
1.3 - Checking valve timing

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- Remove the toothed belt guard upper part.

- -> Set crankshaft to top dead centre No. 1 cylinder.
The notch on the pulley must align with the edge of the -O- marking on the lower toothed belt guard and the
dot on the camshaft sprocket -arrow- with the marking on the rear toothed belt guard.
1.2 - Removing and installing ribbed belt 23

1.4 - Removing and installing toothed belt
(Adjusting valve timing)
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- Mark D.O.R. of toothed belt.
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- Release tensioner and take off toothed belt.
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Installing
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Prerequisites
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• The engine must be no more than warm to touch.

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• The pistons must not be positioned at TDC.
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If a piston is at TDC the valves could strike the piston when turning the camshaft.
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Work sequence
- -> Set camshaft sprocket to mark -arrow A-.
- Set crankshaft to TDC No. 1 cylinder. The chamfered tooth on the crankshaft toothed belt sprocket must
align with the marking on the sealing flange -arrow B-.
- Fit toothed belt. For used belts note direction of rotation.
- -> Tighten tensioning roller securing bolt hand-tight. The slot in the base plate -1- must locate around se‐
curing bolt -2- .
- Tension toothed belt by turning the tensioning roller in direction of arrow until the indicator -3- aligns with
the groove in the base plate -arrow-.
- Tighten clamping nut on tensioning roller.
Tightening torque: 20 Nm
satelettronica
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- Now turn the crankshaft
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The TDC marking for crankshaft and camshaft sprockets must align; adjust if necessary.
-> The tensioning roller indicator must align again with the notch in the base plate -arrow-.
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If the indicator and notch do not align:

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- Retension toothed belt and repeat test.

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- Install toothed belt guard upper and lower parts.

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- Install belt pulley (note fixing arrangement).

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- Refit the ribbed belt and the cover.

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1.4 - Removing and installing toothed belt 25

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Mechanics - Edition 12.1999
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1.5 - Checking semi-automatic toothed belt db
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Test sequence
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- Now turn the crankshaft two turns in direction of rotation until it is at top dead centre No. 1 cylinder.
- -> Note the position of the tensioning roller indicator -arrow-. Press the toothed belt with firm thumb pressure.
The indicator must move.
- Release tension on toothed belt.
- Turn crankshaft two turns in engine direction of rotation.
- -> Then check the position of the tensioning roller indicator -arrow-. It must have returned to its initial position.
If tensioning roller does not return to initial position:
- Replace tensioning roller.
If the tensioning roller is OK:
- Reinstall belt pulley and toothed belt guard upper and lower parts.
- Refit the ribbed belt and the cover.
Note:
2 - Removing and installing cylinder block, sealing flange and flywheel

2.1 - Removing and installing cylinder block, sealing flange and flywheel
satelettronica
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1.5 - Checking semi-automatic toothed belt tensioning roller 27

2.2 - Aluminium cylinder block

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cylinder blocks abearing pedestals. This deformation will cause a r reduction ac of the bearing clearance. Even if the
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bearing shells are not renewed bearing damage could occur due to a different bearing clearance.
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If the bearing cap bolts are loosened, the cylinder block must be replaced complete with the crankshaft.
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Measuring the main bearing clearance is not possible with normal workshop equipment.
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Note:
For repairs to the clutch:
=> 5-Speed manual gearbox 085; Repair group 30; Servicing clutch Servicing clutch
1 10 Nm
2 Suction pipe
◆ Clean strainer if soiled
3 Aluminium cylinder block
◆ Dismantling and assembling pistons and conrods
=> Page 43
4 Knock sensor
5 20 Nm
◆ Tightening torque influences the function of the knock sensor
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6 60 Nm + 1/4 turn (90 °) further

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◆ Renew
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7 Flywheel
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◆ To remove and install flywheel counter-hold with 3067

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8 12 Nm
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◆ Renew
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9 Sealing flange with sender wheel and oil seal

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◆ Only renew complete with oil seal and sender wheel

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◆ Removing and installing sealing flange =>Page 33 , Renewing crankshaft sealing flange -flywheel end-
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2.2 - Aluminium cylinder block 29

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10 Gasket
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11 Oil pump
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◆ Only renew complete

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◆ When installing note follower -item 13 - on crankshaft

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◆ Must be located on dowel sleeves

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◆ Removing and installing => Page 79 , Removing and installing parts of lubrication system
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12 Oil seal
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◆ Renewing => Page 31

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2.3 - Renewing crankshaft oil seal -belt pulley end
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◆ 3240 Oil seal extractor

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- First remove toothed belt
=> Page 24 .
- Then remove crankshaft toothed belt sprocket. To do this, screw on counter-hold tool 3099 to toothed belt
sprocket (first press off cable guide on oil sump).
- To guide oil seal extractor screw crankshaft sprocket securing bolt into crankshaft onto stop.
- Unscrew inner part of oil seal extractor 3240 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.
2.3 - Renewing crankshaft oil seal -belt pulley end 31

- -> Lubricate threaded head of oil seal extractor, 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
satelettronica
- Lightly oil sealing lip of oil seal.
- -> Fit sleeve T10022 onto crankshaft journal and turn spindle T10022/2 in onto stop.
- Slide oil seal over guide sleeve.
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- -> Press in oil seal onto stop with press piece T10022/1.
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- Install toothed belt => Page 24

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- Install crankshaft toothed belt sprocket and hold with counter-hold 3099.
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2.4 - Renewing crankshaft sealing flange -flywheel end-
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◆ T10017 Assembly device

◆ V.A.G 1332/11 Open ring spanner insert
◆ Hexagon bolts (Qty. 3)
M6 x 35 mm
◆ Feeler gauge
◆ Vernier gauge
Pressing sealing flange with sender wheel off crankshaft
Notes:
◆ To show the work sequence more clearly, the sequence is described for a removed engine.
◆ The work sequence is the same when the engine is in the vehicle and the gearbox removed.
Work sequence
- Remove the flywheel.
2.4 - Renewing crankshaft sealing flange -flywheel end- 33

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- -> Set camshaft sprocket to mark -arrow A-.
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- Set crankshaft to TDC No. 1 cylinder. The chamfered tooth on the crankshaft toothed belt sprocket must
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- Remove oil sump =>Page 85 .
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- -> Remove engine speed sender -arrow-.
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- Undo sealing flange securing bolts.
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Sealing flange and sender wheel are pressed off the crankshaft together with Qty. 3 M6 x 35 mm bolts.
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- -> Screw Qty. 3 M6 x 35 mm bolts into the threaded holes -arrows- of the sealing flange.
- Screw the bolts alternately (a 1/2 turn(180°) for each bolt) into the sealing flange and press the sealing flange
along with the sender wheel off the crankshaft.
Pressing sealing flange with sender wheel onto crankshaft

Notes:
◆ Gradual introduction of a new generation of sealing flanges with PTFE seal (Teflon). The sealing flange with
spring ring will continue to be offered as spare part.
When fitting a new sealing flange, be careful to use the same type of sealing flange that was previously
fitted.
◆ The sealing flange with a PTFE sealing ring is equipped with a sealing lip support ring. This support ring
serves the function of a fitting sleeve and may not be removed prior to installation.
◆ Sealing flange and sender wheel must not be separated or twisted after removal from packaging.
◆ The sender wheel of a sealing flange with spring ring has an Elastomer coating on the sealing surface to
crankshaft. This coating must never come into contact with dirt or grease.
◆ The sender wheel is held in its installation position by a fixture on the assembly device T10017 locating pin.
◆ Sealing flange and seal are one unit and must be replaced together with the sender wheel only.
◆ The assembly appliance T10017 maintains its installation position to the crankshaft via a guide pin which is
satelettronica
inserted into a threaded hole in the pressure plate/drive plate.
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B - Clamping tsurface
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D - Socket head bolt

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F - Locating pin
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A-Assembling sealing flange with sender wheel on assembly appliance T10017

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- -> Screw hexagon nut -A- to shortly before the clamping surface (ground section) -B- on the threaded spindle.
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- -> Clamp assembly appliance T10017 in a vice on clamping surface (ground section) on threaded spindle.
- Press assembly bell housing -C- downwards so that it lies on the hexagon nut -A- -arrow-.
Note:
Inner part of assembly appliance and assembly bell housing must be at same height (level).
AG. Volkswagen AG d
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The sender wheel must not be taken out of the sealing flange or twisted.
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-> The locating hole -B- on the sender wheel -C- must align with the marking -A- on the sealing flange.
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- -> Place the sealing flange (with the forward side downwards) on a clean flat surface.
- Push the sender wheel (sealing lip support ring for PTFE sealing ring) -A- downwards in direction of arrow
until it lies on the flat surface.
-> The upper edge of the sender wheel and the forward edge of the sealing flange must align -arrows-.
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- -> Place the sealing flange, with the forward side on the assembly appliance T10017, so that the locating
spec
pin -A- can be inserted in the sender wheel hole -B-.

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Note:
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Ensure the sealing flange lies flat on the assembly appliance.

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- -> Push the sender wheel -B- (Sealing lip support ring for PTFE sealing ring) onto the surface of the assembly
appliance whilst tightening the three knurled screws -A-, so that the locating pin cannot slide out of sender
wheel hole.
Note:
Ensure the sender wheel remains fixed on the assembly appliance when installing the sealing flange.
B-Assembling appliance T10017 with sealing flange on crankshaft flange
Prerequisites
• Crankshaft flange must be free of oil and grease.

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• Engine positioned at TDC No. 1 cylinder.
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- -> Unscrew hexagon nut -A- to end of threaded spindle.
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- Press assembly appliance threaded spindle in direction of arrow, until the hexagon nut -A- lies against the
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assembly bell housing -C-.
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- Align flat side of assembly bell housing towards oil sump side of crankcase sealing surface.
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- -> Secure assembly appliance to crankshaft flange with hexagon socket head bolts -A-
Note:
Screw hexagon socket head bolts -A- into crankshaft flange (approx. 5 threads).
- -> Screw two M6 x 35 mm bolts -A- into cylinder block to guide sealing flange.
C-Fitting assembly appliance T10017 onto crankshaft flange
- -> Slide assembly bell housing -A- in direction of arrow by hand until the sender wheel - B- (Sealing lip
support ring for PTFE sealing ring) lies against the crankshaft flange -C-.
Note:
The assembly appliance guide pin -D- is guided into threaded hole in crankshaft during the fitting sequence.
This ensures the sender wheel reaches its final installation position.
- Hold assembly bell housing in this position and screw both assembly appliance hexagon socket head bolts
satelettronica
hand tight.
- Screw hexagon nut -E- onto threaded spindle by hand until it lies against the assembly bell housing -A-.
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D-Pressing sender wheel onto crankshaft flange with assembly appliance T10017
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- -> Tighten assembly device hexagon nut with torque wrench V.A.G 1331 and open ring spanner insert V.A.G
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1332/11.
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Note:
A small air gap must be present between cylinder block and sealing flange after tightening hexagon nut to 35
rrectness of i
Nm.
E-Checking sender wheel installation position on crankshaft
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- -> Screw hexagon nut -A- to end of threaded spindle.
- Remove the two M6 x 35 mm hexagon bolts -B- from cylinder block.
- Screw the three thumb wheels -C- out of sealing flange.
- Pull assembly appliance assembly bell housing -D- back to hexagon nut -A- (Only for sealing flange with
spring ring).
-> The sender wheel has the correct installation position on crankshaft when a gap of
-a- = 0.5 mm
exists between crankshaft flange -A- and sender wheel -B-.
satelettronica
Note:
If the sealing flange has a PTFE sealing ring, completely unbolt the assembly appliance T10017 and remove
the sealing lip support ring.
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- -> Place a vernier caliper against the crankshaft flange -A- (hatched area).
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- -> Measure the distance -a- between vernier caliper and sender wheel with a feeler gauge -A-.
Is measurement -a- too small:
- Re-press sender wheel =>Page 41 .
When dimension -a- is achieved:

- Remove assembly appliance.
- Tighten the new securing bolts for the sealing flange using alternate and diagonal sequence.
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- -> Install engine speed sender -arrow-.
- Install sump => Page 85 .
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- Install flywheel with new bolts.
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F-Re-pressing sender wheel

- -> Slide assembly bell housing -A- to sealing flange -B- by hand.
- Screw two M6 x 35 mm bolts -C- into cylinder block to guide sealing flange -B-.
- Screw hexagon nut -D- along threaded spindle, by hand, until it contacts the assembly bell housing -A-.
- -> Tighten assembly device hexagon nut with torque wrench V.A.G 1331 and open ring spanner insert V.A.G
1332/11.

- Check installation position of sender wheel on crankshaft again => Page 39 .
If dimension -a- is too small again:
- Tighten hexagon nut to

45 Nm.
- Check installation position of sender wheel on crankshaft again => Page 39 .
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-0.037
3rd undersize -0.022
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-0.037
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3 - Dismantling and assembling pistons and conrods

3.1 - Dismantling and assembling pistons and conrods
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1 Circlip
2 Piston pin
◆ If difficult to remove, heat piston to 60 °C
◆ Remove and install with 10-14
3 Piston
◆ Checking => Fig. 3
◆ Mark installation position and cylinder number
◆ Arrow on piston crown points to pulley end
◆ Install using piston ring clamp
3.1 - Dismantling and assembling pistons and conrods 43

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4 Compression rings
◆ Offset gaps by 120 °
◆ Remove and install compression rings with piston ring pliers
◆ "TOP" faces towards piston crown
◆ Checking ring gap=> Fig. 1
◆ Checking ring to groove clearance
=> Fig. 2
5 Oil scraper ring
◆ Remove and install spiral-type expander carefully by hand
◆ "TOP" faces towards piston crown
◆ Checking ring gap=> Fig. 1
◆ Checking ring to groove clearance
=> Fig. 2
6 Conrod
◆ Only renew as a set
◆ Mark cylinder number -A-
◆ Installation position:
Marking -B- faces towards pulley end
◆ Guided axially via piston
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7 Conrod bearing cap

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(cracking) separating the cap from the con-rod
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8 Conrod bolt, 20 Nm + 1/4 turn (90 °) further

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◆ Renew
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◆ Oil threads and contact surface

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◆ Do not interchange used bearing shells
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◆ Insert bearing shells centrally

◆ Check radial clearance with Plastigage: t to the co
New: 0.020...0.061 mm
Wear limit: 0.091 mm
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Do not rotate crankshaft when checking radial clearance

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-> Fig. 1 Checking piston ring gap
- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.
Piston ring Wear limit

Compression rings 1.0 mm
Oil scraper ring 1.0 mm
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4-Cyl. injection engine (2
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-> Fig. 3 Checking piston
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- Approx. 10 mm from lower edge and offset 90 ° to piston pin axis. Deviations from nominal dimensions
max. 0.04 mm
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Nominal dimension => Page 48 ; Piston and cylinder dimensions
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-> Fig. 4 Checking cylinder bores
◆ Internal dial gauge 50...100 mm
- Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions, as illustrated. Deviation
from nominal dimension
max. 0.08 mm
Nominal dimension => Page 48 ; Piston and cylinder dimensions
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.
3.2 - Piston and cylinder dimensions
Honing Piston-ø Cylinder bore-ø

dimension
Basic dimen. mm 76.475 76.51
1st undersize mm 76.725 76.76
2nd undersize mm 76.975 77.01
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3.2 - Piston and cylinder dimensions 49

15 - Cylinder head, Valve gear
1 - Removing and installing cylinder head

1.1 - Removing and installing cylinder head
Checking compressions=> Page 59

Notes:
◆ When installing an exchange cylinder head, all the contact surfaces between the support elements, roller
rocker fingers and the cams must be oiled before installing the camshaft.
◆ The plastic packing pieces for protecting the open valves must not be removed until immediately before
fitting cylinder head.
◆ If the cylinder head is replaced, all the coolant in the system must also be renewed.
◆ Removing and installing intake manifold:
=> Repair group 24; Servicing injection system; Removing and installing parts of injection system Servicing
injection system Removing and installing parts of injection system
satelettronica
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50 15 - Cylinder head, Valve gear

1 6 Nm + 1/4turn (90 °) further
◆ Renew
◆ Note installation instructions and sequence when loosening and tightening
=> Page 72
2 Screening cover
◆ Observe installation position
◆ Is clipped in or out
3 Boot
◆ Renew if damaged
4 Cap
◆ Renew seal if damaged
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5 Cylinder head cover

◆ Sealing surface must not be treated
◆ With integrated camshaft bearings
=> Page 72
◆ Remove remnants of old sealant
◆ Coat with AMV 154 103 before fitting
◆ Install vertically from above with dowel pins in holes in cylinder head
6 10 Nm
7 Bracket
◆ For wiring harness
1.1 - Removing and installing cylinder head 51

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4-Cyl. injection engine (2 valve,
Volksw roller rocker finger), not Mechanics - Edition 12.1999
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9 Camshaft
◆ => Page 61 , Servicing valve gear
=> Page 72
10 20 Nm
11 Cylinder head bolt
◆ Renew
◆ Note installation instructions and sequence when loosening and tightening
=> Page 55
12 Lifting eye
13 Cylinder head
◆ Check for distortion => Fig. 1
◆ Reworking of sealing surface on camshaft side not permissible
=> Page 55
◆ After replacing renew the complete coolant

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◆ Do not interchange
◆ With hydraulic valve clearance compensation
◆ Oil contact surface
◆ Before installing, check camshaft
axial clearance
=>Page 66 , Fig. 2
15 Retaining clip
16 Roller rocker finger
◆ Check bearing for ease of movement
◆ Use securing clip to clip onto support element when installing
17 Cylinder head gasket
◆ Metal gasket
◆ Renew
◆ If replaced renew the complete
coolant

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18 Oil seal
AG.
◆ Lightly oil sealing lip of oil seal

◆ Renew=> Page 70
-> Fig. 1 Checking cylinder head for distortion
Max. permissible distortion: 0.05 mm

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Mechanics - Edition 12.1999
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1.2 - Removing and installing
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◆ 3036 Counter hold tool

◆ 3450 Guide pin
◆ VAS 5024 Assembly tool for spring-type clip
Prerequisites
• The engine must be no more than warm to touch.
Notes:
◆ When repairing an engine where it is not necessary to dismantle the cylinder head, the cylinder head can
be removed without removing cylinder head cover or camshaft.
◆ Then start with work sequence 1.
If the cylinder head is to be dismantled

=> Work sequence 2 on Page 56 .

Work sequence
- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With the ignition switched off disconnect the battery earth strap.
- Loosen toothed belt tensioning roller and remove toothed belt from camshaft sprocket. Description of work
=> Page 24 , Removing, installing and tensioning toothed belt.
- Remove camshaft sprocket. When loosening camshaft sprocket bolt counter-hold with 3036.
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- Unscrew top 3 bolts from rear toothed belt guard.
spec
- Open cylinder head cover sealing cap, unclip the screening cover and take it out.
t to the co
- -> Pull 3-pin connector off Hall sender -arrow-.
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- -> Pull 4 pin connector off ignition transformer -arrow-.
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- Remove cylinder head cover and camshaft

=> Page 72 .
Work sequence 1 and 2
Warning!

- Separate fuel supply -1- and fuel return pipe -2- at connecting points on suspension strut turret (press release
button).
- Seal the pipes so that the fuel system is not contaminated by dirt etc.
- Loosen or separate the following components:
- The connector from coolant temperature sender and oil pressure switch
- The collective connectors below thermostat housing
- The engine speed sender connector
- Lambda probe connector in exhaust manifold
- Connector on knock sensor
- Oil pressure switch connector
satelettronica
- Remove fuel rail with all injectors from cylinder head.
=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail with injectors Servicing
injection system Dismantling and assembling fuel rail with injectors
- Pull the clamps which secure the coolant pipe to coolant pump off the thermostat housing.
- Remove thermostat housing from cylinder head. en AG. Volkswagen AG
- Disconnect all other inter-connecting, coolant, ag
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- Remove front exhaust pipe from exhaust ed b manifold.
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- Unscrew dipstick guide tube from intake horis manifold (max. screw rotation speed n350 tee rpm; 6 Nm).
- Remove lifting eye in area of oil sfiller
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nf
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- Carefully lift cylinder head off.

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◆ Only remove the new cylinder head gasket from its packing immediately before installing.
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- Carefully clean cylinder head and cylinder block sealing surfaces. Thereby ensuring that no scoring or
agen
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scratches are formed (when using abrasive paper the grade must not be less than 100).

- Carefully remove metal particles, emery remains and cloths.
- Set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly.
- -> To centralize cylinder head, screw guide pins from 3450/1 into holes for rear outer cylinder head bolts -
arrows-.
- Place new cylinder head gasket on centralizing pins -A-. Lettering (Part No.) must be readable.
- Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
- Unscrew guide pins through bolt holes using pin driver from 3450. To do this turn pin driver anti-clockwise
until the pins are free.
- Fit remaining cylinder head bolts and tighten hand-tight.
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- -> Tighten cylinder head in tightening sequence as follows:
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- Tighten all bolts to 30 Nm.
- Then tighten all bolts a 1/4 turn (90 °) further using a rigid wrench.
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- Then tighten all bolts again a 1/4 turn (90 °) further.
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When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
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- Install camshaft and cylinder head cover (if necessary) => Page 73 .
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- Install toothed belt and set valve timing => Page 24 .

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=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner. Servicing injection
Prote AG.
system Dismantling and assembling air cleaner.

1.3 - Checking compression pressures
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◆ 3122 B Spark plug spanner

◆ V.A.G 1763 Compression tester
Test conditions
• Engine oil temperature must be at least 30 °C.
Work sequence
- Remove spark plugs with spark plug spanner 3122B.
1.3 - Checking compression pressures 59

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- -> Pull 4 pin connector
s au off ignition transformer -arrow-. ra
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- Remove fuse 40 for fuel pump. s
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- Use a second mechanic to depress the accelerator so that the throttle valve is fully open.
un
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- Check compressions with compression tester V.A.G 1381 or V.A.G 1763.

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- Operate starter until tester shows no further pressure increase.
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Compression pressure:
rrectne
New: 10...15 bar
Wear limit: 7 bar
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- Insert spark plugs with spark plug spanner 3122B and tighten to 30 Nm.
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- Interrogate fault memory:

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=> Repair group 01; Fault memory; Interrogating and erasing fault memory Fault memory Interrogating and
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2 - Servicing valve gear

2.1 - Servicing valve gear
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Note:
nf
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orm
m
Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug
atio
om
thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.5
n in
or c
mm in width, or when no more than the first turns of the spark plug thread are cracked.
thi
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1 Camshaft
o
m
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◆ Checking axial clearance => Fig. 2

t.
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=> Fig. 3 gh ht
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=> Page 72
cted agen
Prote AG.
◆ Checking radial clearance with plastigage
Wear limit: 0.1 mm
◆ Run-out: max. 0.05 mm
2.1 - Servicing valve gear 61

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te o
thi
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fo
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Cop py
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co lksw
by
cted agen
Prote AG.
2 6 Nm + 1/4turn (90 °) further

◆ Renew
◆ Note installation instructions and sequence when loosening and tightening => Page 72
3 Cylinder head cover
◆ Reworking the sealing surface is not permitted
◆ With integrated camshaft bearings
◆ Remove remnants of old sealant
◆ Coat with AMV 154 103 before fitting
=> Page 72
4 Oil seal
◆ Lightly oil sealing lip of oil seal
◆ Renew=> Page 70

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nform
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com
tion in
r
te o
thi
s
iva
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cum
fo
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Cop py
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pyri by
Vo
co lksw
by
cted
5 Roller rocker finger
agen
Prote AG.
◆ Check bearing for ease of movement
◆ Use securing clip to clip onto support element when installing
6 Retaining clip
7 Support element
◆ Do not interchange
◆ With hydraulic valve clearance compensation
◆ Before installing, check camshaft axial clearance
=>Fig. 2
8 20 Nm
9 Bracket/lifting eye

AG. Volkswagen AG d
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satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
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t.
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Cop py
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gh ht
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Vo
co lksw
by
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Prote AG.
10 Cylinder head
◆ Reworking of camshaft side sealing surface is not permitted
◆ Reworking valve seats
=> Page 67
◆ Reworking sealing surface, cylinder block side => Fig. 1
11 Valves
◆ Do not rework only grinding-in is permitted
◆ Valve dimensions => Fig. 4
12 Valve guide
13 Valve stem seal
◆ Renewing=> Page 76

satelettronica
AG. Volkswagen AG d
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14 Valve spring t to the co

◆ Removing and installing:
rrectness of i
Cylinder head
removed: with 2037
l purpos
installed: => Page 76 , renewing valve stem seals

15 Upper valve spring plate
nform
ercia
16 Cotters
m
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
gh ht
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Vo
co lksw
by
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Prote AG.

-> Fig. 1 Reworking cylinder head sealing surface, cylinder block side
Cylinder head reworking dimension:

a = At least 135.6 mm
AG. Volkswagen AG d
agen oes
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spec
-> Fig. 2 Checking camshaft axial clearance
t to the co
satelettronica
rrectne
◆ VW 387 Universal dial gauge bracket
◆ Dial gauge
ss o
cial p
f
Check with support elements and cylinder head cover removed.
inform
mer
- Pull camshaft seal off with 3364. Pre-load camshaft at centre bearing -arrow- using thumb pressure and
atio
m
check axial clearance by moving camshaft to and fro.

o
n
c
i
or
n thi
te
Wear limit: max. 0.15 mm
sd
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
-> Fig.3 Camshaft identification, valve timing
Marking between number 1 cylinder inlet and exhaust

cam tabs
Engine codes "030 BQ"
AKK, ANW
Valve timing at 1 mm valve lift
Engine codes AKK, ANW

Inlet opens ATDC 15.0°
Inlet closes ABDC 22.4°


Exhaust opens BBDC 16.7°
Exhaust closes ATDC 9.3°
AG. Volkswagen AG d
agen oes
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-> Fig. 4 Valve dimensions ss c
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un
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an
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satelettronica
Note:
erm
ab
ility
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Valves must not be reworked. Only lapping-in is permitted.
is n
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ole,
spec
t to the co
Dimension Inlet valve Exhaust valve
øa mm 33.5 28.0
rrectne
øb mm 5.973 5.953
c mm 99.20 99.20
ss o
α <° 45 45
cial p
f inform
mer
atio
om
2.2 - Reworking valve seats
n
c
i
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sd
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t.
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op
◆ Depth gauge
C py
ht. rig
◆ Valve seat refacing tool
rig ht
py by
co Vo
by lksw
cted agen
Notes:
Prote AG.
◆ When repairing engines with leaking valves, it is not sufficient to replace or renew valve seats and valves.
It is also necessary to check the valve guides for wear. This particularly important on high mileage engines
=> Page 75 .
◆ 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.

lkswage es n
o ot g
byV ua
d ran
Polo Estate 1998 ➤ ho
ir se tee
t or
au roller rocker finger), Mechanics - Edition
ac 12.1999
ss
ce
le
un
pt
an
d
itte
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ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- -> Measure distance -a- between end of valve stem and upper edge of cylinder head.
nform
ercia
- Calculate max. permissible reworking dimension from measured distance and minimum dimension.
m
a
com
Minimum dimension:
tion in
Inlet valve and outlet valve 32.1 mm
r
te o
thi
s
iva
do
Measured distance minus minimum dimension
r
rp
cum
= max. permissible reworking dimension.
fo
en
ng
t.
yi Co
op
satelettronica
Example: C py
t. rig
gh ht
pyri by
Vo
co
- Measured gap 32.5 mm
by lksw
cted agen
Prote
Minimum dimension 32.1 mm
AG.
= Max. permissible reworking dimension* 0.4 mm
*) The max. permissible reworking dimension is shown on illustrations for reworking valve seats as
dimension "b".
-> Reworking inlet valve seat
a = ø 31.9 mm
b = max. permissible reworking dimension*
c = 1.8 ... 2.0 mm
Z = Lower edge of cylinder head
α = 45°valve seat angle
β = 30°upper correction angle
γ = 60°lower correction angle
Note:
Valve seat rings having restrictor may only be reworked so far that the restrictor is not damaged.

AG. Volkswagen AG d
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-> Reworking exhaust valve seat
ab
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a = ø 26.6 mm
h re
b = max. permissible reworking dimension*
hole
spec
c = max. 1.8 ... 2.0 mm
es, in part or in w
Z = Lower edge of cylinder head
t to the co
α = 45°valve seat angle
β = 30°upper correction angle
satelettronica
γ = 60°lower correction angle
rrectness of i
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nf
ercia
orm
m
atio
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n in
or c
thi
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t.
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Cop py
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gh ht
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Vo
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by c lksw
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Prote AG.
2.2 - Reworking valve seats 69

2.3 - Replacing camshaft oil seal
satelettronica
AG. Volkswagen AG d
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nform
ercia

◆ 3240 Oil seal extractor
m
at
◆ 3241 Fitting sleeves

om
io
◆ T10015/3 Fitting sleeve bolt

n
c
in t
or
◆ T10022/1 Press piece

his
ate

do
priv
cum
for
Removing
en
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t.
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Cop py
. rig
ht ht
rig by
py
- Remove toothed belt => Page 24 . co Vo
by lksw
- Turn crankshaft back slightly. cted agen
Prote AG.
- Remove toothed rear belt guard together with coolant pump =>Page 107 .
- Screw camshaft sprocket securing bolt into camshaft onto stop by hand, to guide seal extractor.

- Unscrew inner part of oil seal extractor 3240 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into
oil seal as far as possible.
- Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.
- Remove camshaft sprocket securing screw.
satelettronica
AG. Volkswagen AG d
agen oes
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Installing
es, in part or in w
t to the co
- Lightly oil sealing lip of oil seal.

- -> Fit guide sleeve 3241/2 onto camshaft journal.
- Slide oil seal over guide sleeve.
rrectness of i
- Remove guide sleeve.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
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cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
- -> Press oil seal with press piece T10022/1 and bolt from T10015/3 in onto stop. Place washer between
press sleeve and hexagon head bolt.
- Install camshaft sprocket and tighten new bolt (use counter-hold tool 3036).
Tightening torque:
20 Nm and 1/4turn (90 °) further.
2.3 - Replacing camshaft oil seal 71

Installing toothed belt and adjusting timing => Page 24 .
2.4 - Removing and installing cylinder head cover and camshaft
satelettronica
◆ 3036 Counter-hold
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es, in part or in w
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◆ AMV 154 103 Sealant
Removing
rrectness of i
Notes:
l purpos
◆ The sealing surfaces on cylinder head cover and cylinder head must not be reworked.
nform
ercia
◆ In this cylinder head the camshaft bearings are integrated into the cylinder head and cylinder head cover.
m
at
om
Before removing cylinder head cover, the toothed belt tension must be relieved.
ion
c
◆ If the cylinder head cover has been loosened, replace camshaft oil seal.
in t
or
his
ate
do
riv
Work sequence
p
cum
for
en
ng
t.
yi Co
op
- With the ignition switched off disconnect the battery earth strap.
C py
t. rig
gh
- Loosen toothed belt tensioning roller and remove toothed belt from camshaft sprocket. Description of work
ht
pyri by
Vo
o
=> Page 24 , Removing, installing and tensioning toothed belt.
c by lksw
cted agen
- Remove camshaft sprocket. When loosening camshaft sprocket bolt counter-hold with 3036. Prote AG.
- Unscrew top 3 bolts from rear toothed belt guard.
- Unscrew ignition transformer screws out of cylinder head cover.

- -> Pull 3-pin connector off Hall sender -arrow-.

- Open cylinder head cover sealing cap and unclip screening cover and remove.
satelettronica
- -> Remove cylinder head cover bolts in the sequence prescribed and loosen items 8 and 9 using diagonally
and alternating sequence.
- Carefully remove cylinder head cover.
- Lift camshaft carefully, remove and place on a clean surface.
- Remove roller rocker finger together with support elements and place oon a clean surface.
- Ensure the roller rocker fingers and the support elements are not G. V lkswagen AG d
interchanged.
gen A
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k not
Vol gu
by ara
Installing ris
ed
nte
utho eo
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a c
ss
Prerequisites
ce
le
un
pt
an
d
itte
• Prevent dirt and sealant remnants from entering cylinder head. y li

erm
• Sealing surfaces must be free of oil and grease. ab

ility
ot p
• When installing cylinder head cover or camshaft, the cams for Cyl. 1 must face upwards. wit
is n
• The pistons must not be positioned at TDC.

h re
ole,
spec
- Remove sealant remnants on cylinder head and camshaft housing with a commercially available sealant
t to the co
remover.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.4 - Removing and installing cylinder head cover and camshaft 73

- Insert support element in cylinder head and fit roller rocker finger onto respective valve stem end and support
element.
- -> Ensure all roller rocker fingers contact the valve ends -1- correctly and they are clipped into their respective
support elements -2-.
- Oil the camshaft contact surfaces.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
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un
pt
an
d
- Carefully place camshaft in camshaft bearing of cylinder head.

itte
y li
erm
- -> Apply a thin even coat of sealant onto the clean cylinder head cover sealing surface. See shadowed area
ab
ility
in diagram.
satelettronica
ot p
wit
is n
h re
Note:
ole,
spec
The sealant must not be applied too thick, otherwise excess sealant can enter the oil channels or camshaft
bearing and cause damage to the engine.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
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t.
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- -> Install the cylinder head cover carefully from above ensuring that the dowel pins fit in holes -arrows- in
Co
Cop py
the cylinder head.
t. rig
gh ht
pyri by
Vo
o
by c lksw
Notes: Prote
cted AG.
agen
◆ Positioning and securing the cylinder head cover must be completed without interruption, as the sealing
surfaces start to cure immediately they have contact.
◆ The cylinder head cover bolts must be replaced.

4-Cyl. injection engine (2 valve, roller rocker. Vfinger), Mechanics
olkswagen AG - Edition 12.1999
en AG g does
swa
- -> First tighten bolts items 1 and 2 alternately
by
Vol
k
using diagonal sequencenoand
t gu tighten to 6 Nm.
ara
- Then tighten the other bolts to 6 Nmrisin
e sequence prescribed.
d
nte
- Then tighten all bolts a 1/4 turn (90
ut °) further.
ho eo
r a ac
ss
Note:
ce
e
nl
pt
du
an
itte
y li
Sealant must be left dry for approx. 30 minutes after installing cylinder head cover.
erm
ab
ility
ot p
- Install new oil seal in camshaft,
wit
=> Page 70 . , is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
2.5 - Checking valve guides
or c
satelettronica
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
◆ -> 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.
2.4 - Removing and installing cylinder head cover and camshaft 75

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Polo Estateut
ho 1998 ➤ eo
ra
a
4-Cyl. s injection engine (2 valve, roller rocker finger),
s c Mechanics - Edition 12.1999
ce
le
un
pt
Wear limit: 0.8 mm
an
d
itte
y li
erm
ab
If rock is greater than 0.8 mm:
ility
ot p
wit
is n
- Renew cylinder head.
h re
ole,
spec
t to the co
2.6 - Renewing valve stem seals
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
satelettronica
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

◆ VW 541/1A Valve lever
◆ VW 541/5 Thrust piece
◆ VW 653/3 Pressure hose
◆ 2036 Assembly appliance
◆ 3364 Puller

◆ -> 3365 Press tool
Removing
(with cylinder head fitted)
- Remove cylinder head cover and camshaft
=> Page 72 .
- Remove roller rocker finger together with support elements and place on a clean surface.
- Ensure the roller rocker fingers and the support elements are not interchanged.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
- Remove spark plugs. hor eo
ut
- Set piston of appropriate cylinder
ss a to "bottom dead centre". ra
c
- -> Fit assembly tool 2063 to cylinder head using old bolts from cylinder head cover.
ce
le
un
pt
an
d
itte
- Screw pressure hose VW 653/3 into the spark plug thread.

y li
rm
ab
- Connect pressure hose to a compressed air system of at least

pe
ility
6 bar.
ot
wit
, is n
- Remove valve springs with lever VW 541/1A and press piece VW 541/5.
h re
hole
spec
Note:
es, in part or in w
Tight cotters can be loosened by tapping lightly on the lever.

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

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.6 - Renewing valve stem seals 77

wage es n
Polo Estate 1998 ➤ yV
olks ot g
b ua
4-Cyl. injection engine ris(2
ed valve, roller rocker finger), Mechanics ran
tee - Edition 12.1999
tho
u or
Installing ss
a ac
ce
le
un
pt
- -> Place the plastic sleeve supplied -A- on the appropriate valve stem. This will prevent the new valve stem
an
d
itte
seal -B- being damaged.
y li
erm
ab
- Insert new valve stem seal in fitting tool 3365.
ility
ot p
- Oil valve stem seal sealing lip and press carefully onto the valve guide.
wit
is n
h re
ole,
spec
t to the co
- Install cylinder head cover and camshaft => Page 72 .
- Install new camshaft oil seal =>Page 70 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

17 - Lubrication
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1 - Removing and installing parts of the lubrication system
a ac
ss
ce
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un
pt
an
d
1.1 - Removing and installing parts of the lubrication system
itte
y li
erm
ab
ility
ot p
Note:
wit
is n
h re
The oil level must not be above the max. mark - danger of damaging catalyst!
ole,
spec
Marks => Page 85 , Fig. 1 . urposes, in part or in wh
Checking oil pressure => Page 90
t to the co
Oil system capacity1):
with oil filter 3.2 ltr.
rrectne
1) Up-to-date figures:
=> Exhaust emissions test binder
ss
Engine oil specifications:
o
cial p
f
Use engine oil to VW standard 500 00, 501 01 or 502 00. Only in exceptional cases: Multi-grade oils corre‐
inform
sponding to API-SF or SG.
satelettronica
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.
1.1 - Removing and installing parts of the lubrication system 79

. Volkswagen AG
gen AG does
1 0.3...0.6 bar oil pressure switch (F1), 25 Nm olks
wa not
yV gu
◆ Checking => Page 90 ed b ara
nte
ris
◆ If sealing ring is leaking nip open and replace.
tho eo
au ra
2 Guide tube ss c
ce
le
3 To air cleaner
un
pt
an
d
4 Self-tapping bolt
itte
y li
erm
ab
◆ max. rotational speed if using power tools: 350 rpm
ility
ot p
◆ Fixture of guide tube on intake manifold
wit
is n
5 Guide
h re
◆ Pull off to extract oil ole,
spec
6 Dipstick
t to the co
◆ The oil level must not be above the max. mark!
◆ Markings => Fig. 1
rrectne
7 Sealing cap
ss o
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8 Coolant pump
9 Oil filter
◆ Loosen at hexagon bolt head
80 17 - Lubrication
◆ Note instructions on filter when installing
◆ Screw on threaded connector piece by hand until limit stop
◆ Tighten by hand
10 Tensioner
=> Page 24
11 20 Nm
AG. Volkswagen AG d
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13 Camshaft sprocket
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Prote AG.
=> Page 24
14 20 Nm + 1/4 turn (90 °) further
◆ Renew
15 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
=> Page 24
16 Crankshaft toothed belt sprocket

=> Page 24
AG. Volkswagen AG d
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17 90 Nm + 1/4 turn (90 °) further
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◆ Renew
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◆ Oil threads
AG.
◆ Hold toothed belt sprocket with toothed belt sprocket holder 3099
◆ The turning further angle can be measured with a commercial protractor e.g. Hazet 6690
18 12 Nm
◆ Renew
19 Oil seal
◆ Renewing => Page 31
20 Oil pump
◆ Only renew complete
◆ When installing note drive cam on crankshaft
=> item 29
=> Page 87
82 17 - Lubrication
AG. Volkswagen AG d
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21 Gasket
◆ Renew
22 Gasket
◆ Renew
23 10 Nm
24 Suction pipe
◆ Clean strainer if soiled
25 Cable guide
26 Sump
=> Page 85
◆ Clean sealing surface before installing
◆ Install with silicone sealant
D 176 404 A2
=> Page 85

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27 Oil drain plug, 30 Nm

◆ With attached seal
◆ Renew
28 15 Nm
◆ Loosen and tighten the flywheel end bolts only with socket insert 3249
29 Drive cam
◆ Coat with oil before installing oil pump
30 O-ring
◆ Renew
31 Oil separator
84 17 - Lubrication
AG. Volkswagen AG d
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-> Fig. 1 Markings on oil dipstick
spec
t to the co
1- max. mark
2- min. mark
a- Area above hatched field up to max. mark: Do not replenish with engine oil!
rrectne
b- Oil level within hatched field: can be replenished with engine oil
c- Area from min. mark up to hatched field: replenish with max. 0.5 ltr. of engine oil!
ss
satelettronica
o
cial p
f inform
1.2 - Removing and installing oil sump
mer
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◆ -> 3249 Socket
◆ -> V.A.G 1331 Torque wrench (5...50 Nm)

◆ Hand drill with plastic brush
◆ Flat scraper
◆ Silicone sealant D176404 A2

Work sequence
- Drain engine oil.

- Remove cable guide from the sump.
- Unbolt right-hand drive shaft at gearbox.
- Remove cover plate for flywheel.

- Unbolt sump sealed with liquid gasket.
- Remove sump, it may be necessary to release sump by tapping lightly with a rubber head hammer.
- Remove sealant residue on cylinder block with a flat scraper.
AG. Volkswagen AG d
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- -> Remove sealant residue on the sump with a rotating brush, e.g. a hand drill with a plastic brush (wear
spec
eye protection).
es, in part or in w
t to the co
- Clean sealing surface, must be free of oil and grease.
Installing
rrectness of i
Notes:
l purpos
◆ Note the use by date of the sealant.

nform
ercia
◆ Sump must be installed within 5 minutes of applying silicone sealing compound.

◆ The oil sump can be positioned easier and more securely if threaded studs are screwed in for guidance at
m
at
two points on the cylinder block flange.

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- -> 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-.
86 17 - Lubrication
Note:
The sealing compound bead must not be thicker, otherwise excessive sealing compound will enter the sump
and may block the oil suction pipe strainer.
- Install sump immediately and tighten all sump bolts lightly.
- Tighten sump bolts to
15 Nm.
Note:
After installing sump the sealant must be allowed to dry for approx. 30 minutes before engine oil is replenished.
1.3 - Removing and installing oil pump
satelettronica
AG. Volkswagen AG d
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◆ T10022 Sleeve
◆ 3083 Oil seal fitting tool
1.2 - Removing and installing oil sump 87

◆ 3099 Counter-hold tool
AG. Volkswagen AG d
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Removing
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- Remove toothed belt => Page 24 , Removing, installing and tensioning toothed belt.
l purpos
- -> Position crankshaft at TDC No. 1 cylinder -arrow-:
nform
ercia
The chamfered tooth on the toothed belt sprocket must align with the marking on the oil pump.
satelettronica
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- -> Turn crankshaft/toothed belt sprocket three teeth anti-clockwise away from TDC:
The third tooth -arrow-, to the right of the chamfered tooth -A- on the toothed belt sprocket, must align with
the TDC marking on the oil pump housing.
Note:
This procedure moves the crankshaft to the correct installation position for the oil pump. One of the polygon
cams on the crankshaft is uppermost.
- Remove toothed rear belt guard together with coolant pump =>Page 107 .
- Remove the toothed belt sprocket camshaft and toothed belt tensioning roller.
- Remove sump => Page 85 .
- Remove suction pipe => Page 83 , item 24 .
- Remove oil pump.
- Remove gasket.
- Remove sealant remnants on cylinder block with a flat scraper.
88 17 - Lubrication
- Clean sealing surfaces, they must be oil and grease free.

AG. Volkswagen AG d
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Installing Volksw not
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Conditions orise nte
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• -> One of the polygonss cams -arrow- on the crankshaft is uppermost. r ac
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Work sequence f inform

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- -> Fit sleeve T10022 and hexagon socket head bolt from 3083 onto crankshaft and tighten hand tight.
atio
m
- Fit new gasket onto guide pins -A-.

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- -> Position one of the oil pump inner rotor markings arrow -A- on installation position mark arrow -B- on oil
pump housing cover.
- Coat the four crankshaft polygon cams with oil.
- Guide oil pump carefully onto crankshaft polygon cams.
- Align inner rotor to crankshaft polygon cams by turning slightly if necessary.

- Then slide oil pump carefully onto guide pins.
- Secure oil pump with new bolts.
- Remove sleeve T10022.
- Install suction pipe => Page 83 , item 24 .
1.3 - Removing and installing oil pump 89

- Install oil sump => Page 85 .
1.4 - Checking oil pressure and

swa
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G. Volkswagenswitch
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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
90 17 - Lubrication
after switching the ignition on.
Switch-in delay of oil pressure warning

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

approx. 5 seconds.
Checking warning lamp
After switching on the ignition and engine not started the oil pressure warning lamp in dash panel insert must
light for
approx. 3 seconds
and then go out. The test will be terminated if the engine is running.
Criteria for warning
The optical oil pressure warning

wage
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three times for the
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• "Ignition
uth on", engine stationary, oil pressure switch closed
o eo
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• Engine
ss speed above 1500 rpm, oil pressure switch openc
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Notes:
an
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If the oil pressure switch is closed, the warning lamp will remain switched on if the engine speed is above 5000
pe
rpm. The warning lamp will be switched off again if the engine speed is below 5000 rpm. ility
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If the oil pressure switch is open for 0.3 ... 3.0 seconds when the engine speed is above 1500 rpm, it will be
spec
stored in the combi-processor in the dash panel insert. If this condition occurs three times when the engine is
es, in part or in w
t to the co
running, the oil pressure warning will be activated and will not be cancelled even below 1500 rpm.
The oil pressure warning will be cancelled when the oil pressure switch is closed for longer than 5 seconds at
rrectness of i
an engine speed above 1500 rpm or when the ignition is switched off.
l purpos
Test conditions
nform
ercia
• Engine oil level OK, checking => Page 85

• Oil pressure warning lamp (K3) must light up for approx. 3 seconds when ignition is switched on
m
• Engine oil temperature at least 80 °C (radiator fan must have run once)
com
tion in
r
te o
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Test sequence
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- -> Remove oil pressure switch (F1) and screw into tester.
- Screw tester into the cylinder head in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 B using aux. cables from V.A.G 1594 A to battery positive (+) and oil
pressure switch.
- If the LED lights up, renew oil pressure switch (F1) .
1.4 - Checking oil pressure and oil pressure switch 91

If the LED does not light up:
- Start engine and increase speed slowly.

At
0.3...0.6 bar
the LED must light up; otherwise renew oil pressure switch.
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed 7.0 bar.
satelettronica
AG. Volkswagen AG d
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92 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.
◆ For fitting the spring-type clips, assembly tool VAS 5024 is recommended.
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.
Parts of cooling system body side =>Page 94 .
satelettronica
Parts of cooling system engine side => 97 .
n AG. gen AG Volkswa
wage =>Page 102 . does n
Coolant hose connection diagram
olks ot
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Draining and fillingthwith
ori coolant=> Page 103 . nte
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Coolant mixture ratios => Page 103 , draining and filling with coolant
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1.1 - Removing and installing parts of cooling system 93

1.2 - Parts of cooling system body side
satelettronica
AG. Volkswagen AG d
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1 Clamp
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2 Radiator
nf
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=>Page 105
rm
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◆ After replacing renew entire coolant

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3 8 Nm
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4 Lock carrier
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5 Radiator fan
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6 Additional fan yi
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7 Series resistance yri
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◆ Only with optional extras Prote
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8 Double fan ring

◆ Only with optional extras
94 19 - Cooling system
AG. Volkswagen AG d
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9 Connector
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◆ For radiator fan

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10 Cover
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11 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
Co
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12 To thermostat housing pyri
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◆ Coolant hose connection diagram =>Page 102

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13 Cap
Prote AG.
◆ Check with V.A.G 1274 and 1274/4

◆ Test pressure 1.4...1.6 bar
14 To thermostat housing
1.2 - Parts of cooling system body side 95

AG. Volkswagen AG d
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15 Connector
do
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◆ For radiator fan thermo-switch (F18)
for
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t.
16 Thermo-switch (F18), 35 Nm
yi Co
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◆ For electric fan
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◆ Switching temperatures: p by
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Stage 1
lksw
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on: 92...97 °C
AG.
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C
17 Lower coolant hose
18 Rubber washer
19 Upper coolant hose
20 Air ducting
1.3 - Parts of cooling system engine side
AG. Volkswagen AG d
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1 Retainer
AG.
◆ For connectors
2 From bottom of radiator
3 Self-tapping bolt, 10 Nm
4 Connection
5 O-ring
◆ Renew
6 Coolant thermostat
◆ Checking operation: heat-up thermostat in water the thermo element pin must move out
◆ Temperature check: Opening starts (approx. 84 °C) and ends (approx. 98 °C) cannot be checked.
1.3 - Parts of cooling system engine side 97

satelettronica
AG. Volkswagen AG d
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7 To expansion tank
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8 To heat exchanger
9 From expansion tank
ss

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10 Retaining clip
inform
mer
11 From heat exchanger

atio
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12 Coolant pump housing on cylinder block

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13 Seal
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◆ Renew
sd
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14 Coolant pipe
um
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15 Thermostat housing
t.
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16 10 Nm
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satelettronica
AG. Volkswagen AG d
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17 Coolant temperature sender (G62)

◆ With coolant temperature gauge sender (G2)
nform
ercia
18 Sealing plug
19 To top of radiator
m
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n in
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20 Self-tapping bolt
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Coolant pump side
1 Coolant pump
=> Page 107
3 10 Nm
◆ Install with D6
4 Camshaft sprocket
=> Page 24

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5 20 Nm + 1/4 turn (90 °) further

◆ Renew
6 Toothed belt
◆ Check for wear
◆ Do not kink
=> Page 24
7 Toothed belt guard - upper part
8 12 Nm
◆ Renew
9 Toothed belt guard - lower part
10 20 Nm
11 Tensioner
=> Page 24

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1.4 - Coolant hose connectionauthodiagram or
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1 Coolant pump
2 Intake manifold
3 Heating system heat exchanger
4 Expansion tank
5 Upper coolant hose
6 Radiator
7 Lower coolant hose
8 Thermostat housing
9 Cylinder block

1.5 - Draining and filling cooling system
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- Remove cap from coolant expansion tank.
- Drain coolant from bottom radiator hose.
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countries with tropical climates.
AG.
◆ 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
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
effectiveness is also reduced.
1.5 - Draining and filling cooling system 103

◆ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Recommended mixture ratios: n AG. Volkswagen AG do

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1) The quantity of coolant can vary depending upon the vehicle equipment.
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Not using cooling system charging unit VAS 6096
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- -> Fill with coolant up to max. mark on expansion tank.
With and without cooling system charging unit VAS 6096
- Fit expansion tank cap.

- Start engine and maintain an engine speed of about 2000 rpm for approx. 3 minutes.
- Run engine until radiator fan cuts-in.
- Check coolant level and replenish as necessary. When the engine is at normal operating temperature, the
coolant level must be on the max. mark, when the engine is cold, between the min. and max. marks.

1.6 - Removing and installing radiator
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Removing
- Pull coolant hoses off radiator.
- Pull connectors off thermo-switch.
- Remove radiator fan together with fan ring.
- Remove radiator securing bolts and take out radiator.

- Pull coolant hoses off radiator.
- Pull connectors off thermo-switch.
1.6 - Removing and installing radiator 105

- Remove radiator securing bolts.
Warning!
The air conditioning system refrigerant circuit must not be opened.
Note:
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
not stretched, kinked or bent.
- Remove retaining clamp(s) from refrigerant pipes.

- Removing lock carrier with attachments:
=> General body repairs; Repair Group 50; Body, front; Removing and installing lock carrier with attachments
Body, front Removing and installing
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- Pull radiator out carefully.
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- Unbolt double fan ring from radiator.
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Installing
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Installation is carried out in the reverse order, when doing this note the following:
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- Filling with coolant => Page 103 t to the co

- Electrical connections and routing:
=> Current flow diagrams, Electrical fault finding and Fitting locations
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4-Cyl. injection
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ss c
1.7 - Removing and installing coolant pump
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Notes:
◆ The integrated coolant pump seal must not be separated from the coolant pump.
◆ Damaged or leaking coolant pumps must be replaced complete with seal.
Removing
- Drain coolant => Page 103

- Remove toothed belt => Page 24 , Removing, installing and tensioning toothed belt.
1.7 - Removing and installing coolant pump 107

4-Cyl. injection engine (2
AGvalve,
. Volkswagroller
en A rocker finger), Mechanics - Edition 12.1999
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- Remove toothed belt tensioning roller.
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- -> Remove bolts -arrows- from rear toothed belt guard.
- Remove securing bolts from coolant pump and remove coolant pump together with toothed belt guard, rear.
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Installing
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- Position coolant pump with rear toothed belt guard and tighten securing bolts.
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Torque setting: 20 Nm
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- Install ribbed belt => Page 21 .

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

1.1 - Removing and installing parts of fuel supply system
Notes:
◆ Always replace clamp-type clips with spring or screw-type clips.

◆ Fuel hoses in engine compartment must agen
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Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate => Page 110 .
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Removing and installing fuel tank with its attachments, Caddy => Page 115 .
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Observe crash fuel shut-off => Page 121 .
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Servicing parts of electronic accelerator control (EPC) => Page 132 .
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Servicing parts of the activated charcoal filter system => Page 145 .
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1.1 - Removing and installing parts of fuel supply system 109

AG. Volkswagen
1.2 - Removing and
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1 Cap
2 Rubber cup
◆ For filler pipes
3 Gravity/overflow valve
◆ With shrink-fit vent pipe
◆ To remove, release locking lug and unclip valve upwards out of filler neck
◆ Check valve for through-flow
valve vertical: open,
valve tilted 90 °: closed
4 O-ring
110 20 - Fuel supply system

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5 Earth connection
6 4 Nm
7 Return pipe
◆ Blue
◆ From fuel manifold
8 Union nut
◆ Remove and install with ring nut spanner 3217
9 Fuel delivery unit
=> Page 121
◆ Checking fuel pump
=> Page 125
◆ Note fitting position on fuel tank => Fig. 1
1.2 - Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate
111
satelettronica
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10 Fuel gauge sender
◆ Removing and installing => Page 122
◆ Adjusting:
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=> Electrical system self-diagnosis; Repair group 01; Self-diagnosis for dash panel insert; Checking fuel gauge
(adapting) Self-diagnosis for dash panel insert Checking fuel gauge (adapting)
nf
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12 Fuel filter
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=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail with injectors Servicing Prote
cted AG.
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14 2 Nm
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15 Fuel tank
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=> Page 123 t. Cop py
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16 Clamping washer
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17 Heat shield
AG.
18 Securing strap
19 25 Nm
20 Connecting strut/bracket
21 Vent pipe
◆ To activated charcoal filter
=>Page 145 , item 5
1.2 - Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate
113
AG. Volkswagen AG d
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22 Sealing boot
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24 Vent valve Prote AG.
◆ Checking =>Fig. 2
◆ To remove pull locking latch lightly to inside -arrow- and pull valve out
=>Fig. 2 -arrow-
25 Retaining ring
26 Tank flap unit
27 3 Nm

1.3 - Removing and installing fuel tank with its attachments, Caddy
satelettronica
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3 Tank flap unit
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=> General body repairs; Repair group 55; fuel flap unit fuel flap unit
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4 Gravity/overflow valve
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◆ With shrink-fit vent pipe

◆ To remove, release locking lug and unclip valve upwards out of filler neck
nform
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◆ Check valve for through-flow

valve vertical: open,
m
valve tilted 90 °: closed

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1.3 - Removing and installing fuel tank with its attachments, Caddy 115
AG. Volkswagen AG d
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Polo Estate 1998 ➤ ut
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4-Cyl. injection engines (2 valve, roller rocker finger), Mechanics -c
s Edition 12.1999
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5 O-ring
6 Earth connection
7 4 Nm
8 Return pipe
◆ Blue
◆ From fuel manifold
9 Union nut
◆ Remove and install with ring nut spanner 3217
10 Fuel delivery unit
=> Page 121
◆ Checking fuel pump
=> Page 125

AG. Volkswagen AG d
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11 Fuel gauge sender

nform
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=> Electrical system self-diagnosis; Repair group 01; Self-diagnosis for dash panel insert; Checking fuel gauge
om
(adapting) Self-diagnosis for dash panel insert Checking fuel gauge (adapting) ion
c
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12 Sealing ring
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◆ Coat with fuel when installing

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13 Fuel filter
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14 Supply pipe cted agen
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◆ Black
◆ To fuel manifold
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16 Fuel tank Prote AG.

=> Page 123
17 Heat shield
18 Securing strap
19 25 Nm
21 Vent pipe
◆ To activated charcoal filter
=>Page 145 , item 5
22 Sealing boot
◆ After installing filler pipes fit over fuel tank connections, having turned boot inside out
23 Filler neck
◆ With non-return valve

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25 Cup
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4-Cyl. injection engine V(2 wage
olksvalve, roller rocker finger), Mechanics - Edition 12.1999
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-> Fig. 1 Installation position se fuel
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Marking on the flange must align with marking on the fuel tank -arrow-.
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-> Fig. 2 Checking vent valve
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Lever in rest position: Closed

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1.4 - Safety precautions when working on the fuel supply system
AG.
◆ For safety reasons fuse No. 40 must be removed from fuse holder before opening the fuel system, otherwise
the fuel pump can be activated by the door contact switch in driver's door.
Warning!
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:
◆ 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!
1.5 - Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.

Do not move vehicle unless absolutely necessary.
1.6 - Crash fuel shut-off
Function
Vehicles with an airbag are fitted with a crash fuel shut-off system. It reduces the danger of a fire in a crash as
the fuel pump is switched off via the fuel pump relay.
Simultaneously this system provides improved starting characteristics for the engine.
When the door is opened the fuel pump is activated for 2 seconds to build-up the pressure in fuel system.
When opening the fuel system:
Observe safety precautions=> Page 120 .
- Check fuel pump relay:
satelettronica
1.7 - Removing and installing fuel delivery unit
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◆ -> 3217 Union nut spanner

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Removing
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- Note safety precautions before starting work => Page 120

- With ignition switched off disconnect battery earth strap.
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Caddy Van:
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- Lift front, right load area floor covering.

- Now remove the right-hand load area floor piece.
nform
- Remove cover from fuel delivery unit.

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- Fold rear seat bench forwards.

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1.5 - Rules for cleanliness 121

Warning!
- -> Pull connector -2- supply pipe -3-, and return pipe -1- off flange.
- Disconnect supply pipe -4- and breather pipe -5-.
- Place all pipes outside of well.
- Place the spanner 3217 on the three rounded-off ribs on the union nut and unscrew union nut from flange.
- Pull delivery unit and seal out of the opening in fuel tank.
satelettronica
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:
◆ When inserting the fuel delivery unit ensure that the fuel gauge sender is not bent.
◆ Coat flange seal with fuel when fitting.
◆ Fitting position of fuel delivery unit flange => Page 120 , Fig. 1 .

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=> Repair group 24; Engineolks
wacontrol
ge unit; Procedure
doesafter interrupting voltage supply. Engine control unit Pro‐
not
cedure after interrupting
d by voltage supply.
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1.8 - Removing and installing fuel gauge sender
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- Remove fuel delivery unit=> Page 121 .

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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-.
Installing
- Insert fuel gauge sender in the guides on the fuel delivery unit and push up until it engages.
- Remove fuel delivery unit=> Page 121 .
1.9 - Removing and installing fuel tank
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Special tools, workshopaut equipment, testers, measuring instruments and
ho e o auxiliary
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◆ -> V.A.G 1331 Torque wrench (5...50 Nm) ce
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◆ -> V.A.G 1383 A Engine/gearbox jack

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=> Page 120

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- With ignition switched off disconnect battery earth strap. Cop py
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1.8 - Removing and installing fuel gauge sender 123


- -> Pull fuel return pipe -1- and connector -2- off flange.
- Disconnect fuel supply pipe -4- and breather pipe -5- at hose connections.
- Drain fuel tank and clean area around fuel filler pipe.
satelettronica
- -> Remove connecting strut/bracket -1- from body (bracket -2- is welded to connecting strut).
- Remove all rear exhaust system mountings from body. Then lower the exhaust system slightly and secure
to body with wire.
- Remove rear right wheel.
- Remove rear right wheel housing liner.
- Unbolt filler neck from body. AG. Volkswagen AG d
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- Take filler cap off filler neck and
by
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- Pull off breather hoses at filler neck.

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- Remove clamping disc for fuel tank heat shield.

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- Unbolt fuel tank from body and lower slightly using engine/gearbox jack.
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- Remove filler neck.

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- Take out fuel tank together with heat shield.

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Caddy:
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- Remove shock absorber upper securing nut and push securing bolt out inwards approx. 2 cm (Do not remove
shock absorber).
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- Remove heat shield on fuel tank.

- Take out fuel tank, when doing this guide fuel filler neck out between shock absorber and spring (turn fuel
l purpos
tank through 90°).

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Installing
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Installing is basically in the reverse order but note following:

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◆ Install breather and fuel pipes kink-free.

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◆ Secure fuel hoses with screw-type clamps.
◆ Do not interchange supply

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- Perform the work
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=> au
Repair group
ra
24; Engine control unit; Procedure after interrupting
c voltage supply. Engine control unit Pro‐
ss
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1.10 - Checking fuel pump
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◆ 3217 Spanner for union nut

◆ V.A.G 1318 Pressure gauge
◆ V.A.G 1318/1 Adapter
◆ V.A.G1318/7 Adapter
1.9 - Removing and installing fuel tank 125

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◆ V.A.G1318/17 Adapter
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◆ V.A.G 1348/3 A Remote control
◆ V.A.G 1348/3-2 Adapter cable
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◆ V.A.G 1527 B Diode test lamp

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◆ -> V.A.G 1715 Multimeter

◆ Measuring container
◆ Current flow diagram

Test conditions
• Battery voltage at least 11.5 V
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• -> Fuse No. 40 O.K.
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Note:
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Observe functional description of crash fuel shut-off=> Page 121 .
satelettronica
Test sequence
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Checking function and voltage supply
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Note:
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Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
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must be disconnected. Obtain radio code first if necessary.

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

- Remove cover in front of fuse holder.
- Pull fuse No. 40 out of fuse holder.
1.10 - Checking fuel pump 127

- -> Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to contact 40b -arrow- to fuel
pump and battery positive (+).
- Operate remote control.
Fuel pump runs:

- Check activation of fuel pump relay:
Fuel pump does not run:
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- -> Pull 4-pin connector -1- off fuel tank flange -2-.
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- Connect diode test lamp V.A.G 1527 using aux. cables from V.A.G 1594 to the outer contacts of the con‐
hole
spec
nector.
es, in part or in w
- Operate remote control.
t to the co
LED must light up
LED does not light up:
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- Locate and eliminate open circuit using current flow diagram
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LED lights up (voltage supply OK.):
nform
ercia
- Fit spanner 3217 on the three rounded ribs of union nut and unscrew union nut from flange.
- Check that the electrical wires between flange and fuel pump are connected.
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If not open circuit can be found:
in t
or
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- Fuel pump defective, renew fuel delivery unit =>Page 121 , Removing and installing fuel delivery unit.
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Checking delivery rate

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Test conditions C py
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Test sequence
- Remove filler cap from fuel tank filler neck.

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4-Cyl. injection engine (2 valve,s auroller rocker finger), Mechanics - Editionr ac12.1999
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Warning!
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- -> Pull fuel supply hose (white marking) off fuel supply pipe -1-.
hole
spec
- Connect pressure gauge V.A.G 1318 with adapter /1 to fuel supply pipe.
es, in part or in w
- Screw adapter hose /13 with adapter /7 to pressure gauge and hold hose in measuring container.
t to the co
- Open the pressure gauge shut-off tap. The lever then points in the direction of flow -A-.
- Operate remote control V.A.G 1348/3A and slowly close cut-off tap, until pressure gauge shows
rrectness of i
3 bar.
From this point on do not move position of cut-off tap.
l purpos
- Empty the measuring container.

- The fuel pump delivery range is dependent upon battery voltage. Therefore connect the multimeter with
nform
ercia
adapter cables from V.A.G 1594 to the vehicle battery.

- Operate remote control for
m
a
30 seconds
com
tion in
and measure battery voltage
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satelettronica
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- -> Compare the quantity of fuel delivered with specification.
*) Minimum delivery cm3/30 seconds
**) Voltage at fuel pump with engine stopped and pump running (approx. 2 volts less than battery voltage).
Example:
During the test, a voltage of 12.5 volts is measured at the battery. As the voltage at the pump is approx. 2 volts
less than the battery voltage, this will equate to a minimum delivery of 540 cm3/30 s.
If the minimum delivery rate is not attained:
- Check the fuel pipes for possible restrictions (kinks) or blockages.

- -> Pull supply hose -1- off inlet to fuel filter.
- Connect pressure gauge V.A.G 1318 with adapter 1318/17 to fuel supply pipe.

- Repeat delivery rate check.
If the minimum delivery rate is now attained:

- Replace the fuel filter.
If the minimum delivery rate is again not attained:

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

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:
satelettronica
lkswage es n
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- Reconnect all disconnected fuel pipes. o
ir se tee
- -> Connect the multimeter V.A.G 1715 using the current clamp
auth to the red/yellow wire from wiring harness.or a
- Start the engine and run at idling speed. ss c
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- Measure the current draw of the fuel pump.

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Specification: max. 8 amps.
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Note:
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If the fuel system malfunction is intermittent, you can perform the check during a test drive with the help of a
h re
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2nd person.
spec
es, in part or in w
t to the co
If the current draw is exceeded:
Checking fuel pump non-return valve rrectness of i

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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.

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Test sequence
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Note:
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With this check the fuel supply pipe connections from the fuel delivery unit to the point at which the pressure C py
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gauge V.A.G 1318 is connected will be checked for leaks at the same time.
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- Close pressure gauge cut-off tap (lever at right angle to direction of flow).
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Prote AG.
- Operate remote control at short intervals until a pressure of
3 bar

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

2.1 - Electronic power control (EPC)
satelettronica
AG. Volkswagen AG d
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2.2 - Function of EPC system Vo gu
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With the EPC system the throttle valve is not operated by a cable. There is no mechanical connection between
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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.
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The throttle valve is operated over the complete revolution and load range by an electric motor (throttle valve
t to the co
positioner) in the throttle valve control part.
rrectness of i
The throttle valve is operated by the throttle valve positioner which is controlled by the engine control unit.
l purpos
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
nf
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approximately half open.

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When the engine is running (under load) the engine control unit can open or close the throttle valve independ‐
n in
or c
ently of the accelerator pedal position sender.

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This means that the throttle valve can already be completely open even though the accelerator pedal is de‐
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pressed half way.

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This also gives vastly improved consumption and exhaust emission levels at certain load conditions.
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The torque required by the engine can be produced by the engine control unit by optimising the combination
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of throttle valve cross-section and charge pressure.
It is incorrect to believe that the "EPC" is comprised of one or two components only. The EPC is a system,
which is comprised of all components which have an influence, control or monitor the position of the throttle
valve, e.g. the accelerator pedal position sender, the throttle valve control unit, the EPC warning lamp, the
engine control unit.

Checking electronic accelerator warning lamp => Page 135 .
2.3 - Servicing parts of electronic power control (EPC)
satelettronica
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1 Bracket
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=> 5-speed manual gearbox 02K from 10.99; Repair Group 30; Servicing clutch control; Removing and installing
nform
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bracket Servicing clutch control Removing and installing bracket

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2 Accelerator pedal position sender (G79 and G185)

on
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◆ Checking =>Page 138

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◆ Adjusting =>Page 142

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◆ To remove, remove driver's side footwell cover

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=> General body repairs; Repair Group 68; Compartments, covers and trim; Removing driver's side footwell
Co
Cop py
cover Compartments, covers and trim Removing driver's side footwell cover ht. rig
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3 10 Nm
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satelettronica
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4 Cable cam
◆ Installing
=>Page 134 , Fig. 1
5 Spring washer
6 Adjustment bolt
7 20 Nm
8 Accelerator pedal
9 Hexagon bolt
2.3 - Servicing parts of electronic power control (EPC) 133

-> Fig.1 Installing cable cam
- Secure cable cam to sender so that the dimensions shown are adhered to when facing forwards.
a = 22 ±0.05 mm
b = 41±0.05 mm
c = Forwards
Note:
satelettronica
The cable cam eye must be parallel to the forward direction.
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2.4 - Checking EPC warning lamp
satelettronica
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◆ V.A.G 1526 Hand multimeter

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◆ V.A.G 1598/22 Test box

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t to the co
Note:
The electronic accelerator warning lamp -K132 is known also as the EPC warning lamp.
rrectness of i
l purpos
Check conditions
• The fuses must be OK.

nform
ercia
• The battery voltage must be at least 11.5 V.

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135
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2.4 - Checking EPC warning lamp
Checking function of warning lamp
- Switch on ignition.
-> The EPC warning lamp must light up.
- Start engine and run at idling speed.
The EPC warning lamp must
satelettronica
go out
when no EPC fault has been stored.
- Switch off ignition. wage

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Electronic accelerator warning ir selamp does not light up
d ran
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es, in part or in w
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- Remove left plenum chamber cover.

- -> Connect test box V.A.G 1598/22 to control unit wiring harness.
- Bridge test box sockets 2 + 30 with aux. cables from V.A.G 1594.
nform
ercia
- Switch ignition on.

m
The fault lamp must light up

at
om
ion
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in t
or
If the fault lamp does not light up:

his
ate
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priv

um
for
- Remove dash panel insert and check the bulb and its voltage supply.:
en
ng
t.
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Cop py
. rig
=> Electrical system; Repair group 90; Dash panel insert; Removing and installing dash panel insert Dash panel
t
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insert Removing and installing dash panel insert cop Vo
by lksw
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Prote AG.
If no fault is found:
- Check wiring for open circuit between test box socket 30 and dash panel insert using current flow diagram:

If no wiring fault is detected:
- Renew engine control unit:
=> Repair group 24; Engine control unit; Renewing engine control unit Engine control unit Renewing engine
control unit
Electronic accelerator fault lamp lights up continuously
satelettronica
- Check wiring for short to earth between test box socket 30 and dash panel insert using current flow diagram:
Volkswa AG. gen AG
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=> Current flow diagrams, Electrical fault finding d by Vand Fitting locations
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If no wiring fault is detected: auth
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- Renew engine control unit:

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=> Repair group 24; Engine control unit; Renewing engine control unit Engine control unit Renewing engine
ab
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control unit
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2.4 - Checking EPC warning lamp 137

2.5 - Checking accelerator pedal position sender
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◆ V.A.G 1526 Hand multimeter

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

• The battery voltage must be at least 11.5 V.
• Setting from accelerator pedal position sender is O.K.:
=> Page 142 .

Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics control
unit with the "Address word" 01:
=> Repair group 01; General to self-diagnosis; Connecting fault reader V.A.G 1551 and selecting engine control
unit General to self-diagnosis Connecting fault reader V.A.G 1551 and selecting engine control unit
-> Indicated on display:

Rapid data transfer HELP
Select function XX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

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

(1...4 = Display zones)
satelettronica
Read measured value block 62
1 2 3 4
- Check specifications of sender 1 (G79) at idling stop in display zone 3.

Specification: 3...100 %
- Check specifications of sender 2 (G185) at idling stop in display zone 4.
Specification: 3...100 %
Note:
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
wage
voltage
n AG. Volkequates
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doe
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- Operate the accelerator pedalris
e slowly
d until fully depressed and observe
ara
nte the angle sender figures in display
zones 3 and 4: utho eo
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The percent figures in display zone 3 and 4 must rise evenly. The tolerance range of 3...100 % is not covered
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completely.
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End specification value not achieved:

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- Press the ⇒key.

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Select function XX
rrectne
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
s
- Check accelerator pedal position sender voltage supply and wiring connections =>Page 139 .
s o
cial p
f inform
Checking voltage supply and wiring to control unit

mer
atio
m
- Remove driver's side footwell cover.

o
n
c
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or
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=> General body repairs; Repair Group 68; Compartments, covers and trim; Removing driver's side footwell
t
sd
iva
cover Compartments, covers and trim Removing driver's side footwell cover
pr
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fo
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- Disconnect 6-pin connector for accelerator pedal position sender.
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2.5 - Checking accelerator pedal position sender 139

Left-hand drive vehicles
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- -> Connect multimeter to measure voltage at the following contacts of the connector:
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Contact 1 + earth
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Contact 1 + 5
spec
Contact 2 + earth
es, in part or in w
t to the co
Contact 2 + 3
Specification: minimum 4.5 V
rrectness of i
Right-hand drive vehicles
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- -> Connect multimeter to measure voltage at the following contacts of the connector:
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Contact 2 + earth
Contact 2 + 3
Contact 5 + earth
Contact 5 + 4
Specification: minimum 4.5 V
Continued for all vehicles

If the specifications are not attained:


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4-Cyl. injection engine
tho (2 valve, roller rocker finger), Mechanics tee
o - Edition 12.1999
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Left-hand drive vehicles
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io
- -> Check wiring for open circuit between test box and 6-pin connector (connector to control unit) using current
n
c
in t
flow diagram.
or
his
e
Contact 1+socket 6
at
do
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Contact 2+socket 8
p
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Contact 3+socket 7
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Contact 4+socket 33
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Contact 5+socket 19
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Contact 6+socket 45
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Wire resistance: Max. 1.5 ω
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Observe connector allocation in latest current flow diagram.
Right-hand drive vehicles
- -> Check wiring for open circuit between test box and 6-pin connector (connector to control unit) using current
flow diagram.
Contact 1+socket 33
Contact 2+socket 8
Contact 3+socket 7
Contact 4+socket 19
Contact 5+socket 6
Contact 6+socket 45
Wire resistance: Max. 1.5 ω
Observe connector allocation in latest current flow diagram.
Continued for all vehicles
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
Specification: ∞ω
If voltage supply is OK and no wiring fault is detected:
2.5 - Checking accelerator pedal position sender 141

- Renew accelerator pedal position sender
=> Page 132 , item 2
If voltage supply is not OK and no wiring fault is detected:

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- Renew engine control unit: y Volk not
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=> Repair group 24; Engineut control unit; Renewing engine control unit Engine
ho eo
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control unit ss a c
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2.6 - Adjusting pedal position sender
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◆ V.A.G 1551 Fault reader

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Note:
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The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
Prote
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is not possible.
AG.
All functions of V.A.G 1551/1552 can also be carried out with the new tester VAS 5051.
◆ V.A.G 1551/3A Cable
Work sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics control
unit with the "Address word" 01:
=> Repair group 01; 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 XX
swage es n
- Press keys 0 and 8 for the function "Read measured byV
o value block" and confirm
lk
entry
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-> Indicated on display: tho or
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Read measured value block ss
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- Press keys 0, 5 and 4 for "Display group number 54" and confirm entry with Q key.
ab
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- measured value block
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rpm 0 0 0 0.0 % 18.4 5C
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-> Check accelerator pedal position display in display zone 3. The accelerator pedal should not be depressed
spec
when doing this.
es, in part or in w
t to the co
Specification: 0.0 %
- measured value block
Read 54
rpm 0 0 0 100 % 18.4 5C
rrectness of i
-> Slowly depress accelerator pedal and at the same time observe display zone 3. The accelerator pedal
position value must continually rise and reach
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100 %
just before the maximum acceleration limit.
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- -> If necessary adjust accelerator pedal -2- by turning the adjustment screw -1- so that when accelerator
pedal is not depressed (idling position)
0.0 %
and with accelerator pedal depressed to just before full throttle position
100 %
is displayed.
3 - Activated charcoal filter system

3.1 - Activated charcoal filter system
3.2 - Function
Depending upon the air pressure and ambient temperature, fuel vapour will form above the level of fuel in the
tank.
The activated charcoal filter system prevents these HC emissions escaping to the atmosphere.
In limited quantities, fuel vapours pass through a gravity valve (which closes at an angle of 32 °) located at the
highest point in the tank and through a breather valve into the activated charcoal filter.
2.6 - Adjusting pedal position sender 143

The activated charcoal stores these vapours like a sponge.
When the Lambda control is active when driving (engine warm), the tank venting valve (N80), also known as
the regeneration valve), is activated (pulsed) from engine control unit depending upon load and engine speed.
The opening period is dependent on the input signals.
Intake manifold vacuum draws fresh air through the vent opening on the underside of the activated charcoal
filter during the purging procedure (regenerating the activated charcoal). The fuel vapours stored in the activated
charcoal and fresh air are pulse-fed for combustion.
The pressure retention valve prevents fuel vapours from being drawn from the tank when the solenoid valve is
open and intake manifold vacuum is present. It therefore ensures that the evacuation of the activated charcoal
filter has priority.
No voltage (e.g. wiring open circuit) the
gen AG
. Votank venting
lkswagen AG
doevalve is closed. The activated charcoal filter will not be
swa s no
purged. yV
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Notes: ara b
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ris
◆ Hose connections ut
ho are secured with either spring-type or clamp-type
eo
ra clips.
◆ Always replacess a
clamp-type clips with spring-type clips. c
◆ For fitting the spring-type clips, assembly tool VAS 5024 is recommended.
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3.3 - Servicing parts of the activated charcoal filter system
es, in part or in w
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1 Activated charcoal filter
◆ Location: in engine compartment, right
◆ Secured to body
◆ With solenoid valve 1 for activated charcoal filter (N80)
◆ When the engine is warm the valve will be activated from the engine control unit (pulsed)
◆ Checking:
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐
forming final control diagnosis
2 Pressure retention valve with connecting hose
◆ Shuts-off the tank venting when the solenoid valve (N80) is open and intake manifold pressure is present
3 Throttle valve control part
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4 Connector
◆ 2-pin
◆ For solenoid valve 1
5 Breather pipe
◆ Check securely seated
◆ From gravity valve on fuel tank
=> Page 118 , item 21
6 Breather pipe
3.3 - Servicing parts of the activated charcoal filter system 145

3.4 - Checking activated charcoal filter solenoid valve 1

AG. Volkswagen AG d
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In a no-current situation the solenoid valve d by Vis closed.
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Checking activation:
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Test conditions

• -> Fuse No. 1 must be OK.
• Coolant temperature must be at least 80 °C, =>display group 04, display zone 3.
Functional check
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select the engine control unit with the
"Address word" 01. Connecting fault reader and selecting engine control unit:

Select function XX
- Press keys 0 and 4 for the function "Initiating basic settings" and confirm entry with Q key.
-> Indicated on display: AG. Volkswagen AG d

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Input display group number XXX d by ara
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- Press keys 0, 7 and 0 for "Display
ss a
group number 70" and confirm entry with Q key. c
satelettronica
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Note:
an
d
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ab
The engine must not be loaded during this diagnosis because the diagnosis will be interrupted and will not be
pe
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ot
started again until the engine is revved-up.
wit
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System in basic setting 70
1 2 3 4
rrectness of i
When the diagnosis is initiated by the engine control unit, the display in display zone 4 jumps from "Test OFF"
to "Test ON"
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- Leave the engine running at idle until the result of short diagnosis is displayed
nform
ercia
Specification: "TVV OK"

m
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Note:
on in
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thi
TVV stands for tank vent valve (activated charcoal filter system solenoid valve 1).
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If the display jumps from "Test ON" to "Test OFF" during the test, rev up briefly and the test will be repeated.
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If "TVV not OK" appears in display zone 4:
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- Initiate the final control diagnosis and activate the activated charcoal filter solenoid valve -N80:
Prote
cted AG.
agen
If the specification "TVV OK" is obtained:
- Press ⇒key.

Select function XX
- Press keys 0 and 6 for the "End data transfer" function and confirm input with the Q key.
3.4 - Checking activated charcoal filter solenoid valve 1 147

3.5 - Checking fuel tank breather
◆ -> V.A.G 1368 Vacuum tester
satelettronica
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◆ -> V.A.G 1390 Hand
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Test conditions
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• Ignition must be switched off

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Test sequence
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- -> Pull breather pipe/hose -2- from activated charcoal filter -1- off at throttle valve control part -3-.
um
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- Connect hand vacuum pump V.A.G 1390 to pipe/hose -2-.

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- Pull breather pipe/hose -5- from fuel tank off activated charcoal filter and connect to -connection A- of vacuum
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- Connect vacuum tester V.A.G 1368 -connection B- to breather pipe/hose -4-. py by
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- Set vacuum tester to position -B-.
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- Introduce final control diagnosis and select activated charcoal filter solenoid valve (N80):
AG.

4-Cyl. injection engine (2 valve, roller rocker n AG. Volksw
agefinger),
agen AG
Mechanicsdoes - Edition 12.1999
lksw n o ot g
yV ua
db
=> Repair group 01; Final control diagnosis;orisPerforming
e final control diagnosis Finalracontrol
nte diagnosis Per‐
forming final control diagnosis au
th eo
ra
ss c
ce
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- Operate hand vacuum pump V.A.G 1390 several times.
un
pt
Vacuum must not
an
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build up.
erm
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If vacuum builds up:
te
sd
a
satelettronica
iv
o
pr
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- -> Check breather connection -6- on activated charcoal filter -1- for soiling and clean if necessary.
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If vacuum does not build up: C py
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- 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.
- Operate V.A.G 1390 several times. Vacuum must
not build-up.
If vacuum builds-up:
- Check gravity/overflow valve => Page 110 , item 3

- Check pipe/hose -1- from fuel tank for blockage.
If vacuum does not build up:
- Refit fuel filler cap.

- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not
build up.
Note:
If the fuel level in the tank is low the hand vacuum must be operated at least 20...30 times.
3.5 - Checking fuel tank breather 149

If vacuum builds up:
- Replace fuel tank cap.
satelettronica
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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 to the bodywork. If necessary, loosen double clamp(s) 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:
Interrogating and erasing fault
agen
memory
AG. Volksof
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satelettronica
- Check catalystis=>ed Page 162
b
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1.1 - Removing and installing parts of exhaust system 151

1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments
satelettronica
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1 Warm air collector plate

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2 10 Nm
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◆ Note tightening sequence

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spec
Page => 156 , Fig. 1

es, in part or in w
3 Exhaust manifold
t to the co
◆ With integrated pre-catalyst only engine codes ANW, AUD

4 Gasket
rrectness of i
◆ Renew
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5 Lock nut, 25 Nm
nform
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152 26 - Exhaust system

AG. Volkswagen AG d
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6 Lambda probe 2 after catalyst (G130)*, 50 Nm

◆ Only engine code ANW, AUD
◆ Checking:
=> Repair group 24; Check functions; Check Lambda probe and Lambda regulation after catalyst Check func‐
tions Check Lambda probe and Lambda regulation after catalyst
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
body
◆ Remove and install with 3337
7 To silencer
8 Stop
◆ For double clamp
9 Connector
◆ Only engine code ANW, AUD
◆ For Lambda probe 2 after catalyst (G130) and Lambda probe heating (Z29)
◆ Black, 4-pin
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments 153
AG. Volkswagen AG d
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Polo Estate 1998 thor ➤ eo
u ra
4-Cyl. injection
ss a engine (2 valve, roller rocker finger), Mechanics c - Edition 12.1999
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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10 Front exhaust pipe with catalyst

◆ Check catalyst (engine codes ANW, AUD) => Page 162
◆ To remove, remove subframe
=> Running gear, axles, steering; Repair Group 40; Servicing front suspension; Removing and installing sub‐
frame Servicing front suspension Removing and installing subframe
11 25 Nm
12 Mounting
13 Locating nut, 40 Nm
14 Connector
◆ For Lambda probe 1 before catalyst (G39) and Lambda probe heating (Z19)
Engine code AKK:
◆ Black,4-pin
Engine codes ANW, AUD
◆ Black, 6-pin

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15 Lambda probe 1 before catalyst (G39)*, 50Nm

◆ Checking:
=> Repair group 24; Check functions; Check Lambda probe and Lambda regulation before catalyst Check
functions Check Lambda probe and Lambda regulation before catalyst
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
body
◆ Remove and install with 3337
◆ Check Lambda probe ageing (cycle duration monitor) (only engine codes ANW, AUD) => Page 162 ,
Checking catalyst
16 Bracket
◆ For electric wiring of Lambda probe 1 before catalyst
Note:
Tighten warm air collector plate in sequence as illustrated to ensure it is installed free of stress.
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments 155
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-> Fig. 1 Tightening sequence, warm air collector plate on exhaust manifold.
rrectness of i
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1.3 - Silencer with mountings
nform
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Polo Classic, Polo Estate
Version for Caddy => Page 159
2 Stop
◆ Slide double clamp up to limit stop
3 Double clamp
4 Mushroom head screw
5 25 Nm
6 Front silencer1)
7 15 Nm
9 25 Nm
satelettronica
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11 Mounting
12 20 Nm + 1/4 turn (90 °) further
13 Rear silencer1)
1.3 - Silencer with mountings 157

14 Marking
◆ Visible from below
◆ For repair double clamp -item 16 -
15 Separating point
◆ For repair cases1)
◆ Marked by impressions on connecting pipe
satelettronica
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16 Repair double clamp

m
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io
◆ Must be slid onto the markings - 14 -

n
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1) Front and rear silencers are installed as a single component as standard. In repair cases the front and
a
do
riv
rear silencers are supplied individually and a repair double clamp item 16 is supplied as a joint. Cut through
p
cum
or
connecting pipe at separating point - 15 - with a body saw e.g. V.A.G 1523.
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Silencer with mountings Caddy

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3 Double clamp rig ht
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5 25 Nm
AG.
6 Front silencer1)
7 15 Nm
9 25 Nm

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10 Mounting
11 Mounting
12 20 Nm + 1/4 turn (90 °) further
13 Rear silencer1)
14 Marking
◆ Visible from below
◆ For repair double clamp -item 16 -
15 Separating point
◆ For repair cases1)
◆ Marked by impressions on connecting pipe

AG. Volkswagen AG d
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16 Repair double clamp

form
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◆ Must be slid onto the markings - 14 -

atio
om
n
c
1) Front and rear silencers are installed as a single component as standard. In repair cases the front and
i
or
n thi
e
rear silencers are supplied individually and a repair double clamp item 16 is supplied as a joint. Cut through
t
sd
va
connecting pipe at separating point - 15 - with a body saw e.g. V.A.G 1523.
i
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1.4 - Checking catalyst
lkswage es n
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Only engine codes ANW, AUD
hole
spec
es, in part or in w
t to the co
rrectness of i
Note:
satelettronica
l purpos
is not possible.
nform
ercia
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at
om
ion
c
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ate
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Test conditions
• -> Fuse No. 1 must be OK.

• Vehicle stationary
• All electrical consumers, e.g. lights and rear window heating must be switched off.
• If the vehicle is equipped with an air conditioning system, this must be switched off.

• 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.
• Intake air temperature less than 60°C
=>display group 04, display zone 4
Functional check
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select the engine control unit with the
"Address word" 01. Connecting fault reader and selecting engine control unit:
Lambda probe ageing diagnosis (cycle duration monitor)

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Select function o l
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- Press
s aut keys 0 and 4 for the "Introduce basic setting" function ra
c
and confirm entry with Q key.
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1 2 3 4
rrectness of i
- Depress brake pedal.

l purpos
The engine speed is increased to

nform
ercia
approx. 1100...1300 rpm

by the engine control unit
m
at
om
ion
- Allow engine to run at increased engine speed until

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

do
priv
cum
for
en
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Note:
n
t.
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This process can take a few minutes.
gh ht
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- Check the amplitude quality in display zone 3:
Prote AG.
Specification: 0.7... 2.00
- Allow engine to continue to run at increased engine speed until
display zone 4 displays the specification "B1-P1 OK.".
If the display does not indicate as described:
If the display indicates as described:
- Press C key.
The engine speed drops to idling speed.
1.4 - Checking catalyst 163

Catalyst diagnosis
Note:
The diagnosis will only be terminated if the Lambda probe ageing diagnosis (cycle duration monitor) is first
successfully completed.

Basic setting

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

approx. 1100...1300 rpm
by the engine control unit
satelettronica
- Allow engine to run at increased engine speed until
display zone 4 jumps from "Test OFF" to "Test ON". The catalyst temperature in
display zone 2 must be a minimum of 400 °C.
- Check the amplitude ratio in display zone 3:
AG. Volkswagen AG d
Specification: max. 0.50 lksw
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db ran
- Allow the engine to continue to run at increased engine
rise speed until tee
display zone 4 displays "Cat B1 OK." ho
aut or
ac
ss
ce
le
If the display does not indicate as described:

un
pt
an
d
itte
y li
erm
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ility
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spec
If the display indicates as described:
- Press ⇒key. t to the co

rrectne
The engine speed drops to idling speed.

ss
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
o
cial p

inform
mer
atio
om
n
c
i
or
n thi
te
sd
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t. rig
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Service

Polo Estate 1998 ➤

Service Department. Technical Information

15 - Cylinder head, Valve gear

20 - Fuel supply system

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg 00056407820

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

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

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

1.5 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

2.2 Aluminium cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

2.3 Renewing crankshaft oil seal -belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

3 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

3.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

3.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

2.3 Servicing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

2.4 Checking EPC warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

2.5 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

2.6 Adjusting pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

3.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

3.5 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

1.3 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

1.4 Checking catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162

1.2 - Engine number

Exhaust emissions fulfil MVEG II standard D4 standard EU4 standard

Capacity cm3 1390 1390 1390

Output kW at rpm 44/4700 44/4700 44/4700

Bore mm ø 76.5 76.5 76.5

Stroke mm 75.6 75.6 75.6

Codes AKK ANW AUD

Compression ratio 10.4:1 10.4:1 10.4:1

RON min. 95 unleaded1) 95 unleaded1) 95 unleaded1)

Injection, ignition Motronic Motronic Motronic

ME 7.5.10 ME 7.5.10 ME 7.5.10

Knock control yes yes yes

1.1 - Technical data 1

Codes AKK ANW AUD

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

2) Additionally with integrated pre-catalyst in exhaust manifold

10 - Removing and installing engine

1 - Removing and installing engine

◆ 2024 A Lifting tackle

1.1 - Removing and installing engine 3

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

- The engine is removed forwards together with the gearbox.

- Remove air cleaner:

and assembling air cleaner

4 10 - Removing and installing engine

Vehicles with power assisted steering

- Removing air conditioner compressor:

Body, front Removing and installing lock carrier with attachments.

1.2 - Notes on removing 5

- Unbolt assembly at gearbox and engine mountings.