Service

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Polo Estate 1998 ➤

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4-Cyl. injection engine (4 valve), Mechanics

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Engine ID APE AUA
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Edition 11.1999

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Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
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19 - Cooling system by Volkswa
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20 - Fuel supply system ise nte
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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 00056407620

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . s.w.ag.e.n A. G.. .Vo.lk.sw. a.ge. n.A.G.do.es. . . . . . . . . . . . . .1

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1 Technical data . . . . . . . . . . . . . . . . . . e.d.b.y V. . . . . . . . . . . . . . . . . . . . . . . . . g. u.ar.a. . . . . . . . . . .1
s n
1.1 Technical data . . . . . . . . . . . . . . . .tho. ri. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee.o. . . . . . . .1
u
1.2 Engine number . . . . . . . . . . . . .ss.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . .1
1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

spec
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
es, in part or in w

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1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

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1.7 Replacing engine carrier rubber mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
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1.8 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . . .10

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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

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1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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1.4 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
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1.5 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

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2 Removing and installing cylinder block, sealing flange and flywheel . . . . . . . . . . . . . . . . . .33
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2.1 Removing and installing cylinder block, sealing flange and flywheel . . . . . . . . . . . . . . . . . .33 p by
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2.2 Aluminium cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
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cted AG.
agen

2.3 Renewing crankshaft oil seal -belt pulley end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

2.4 Renewing crankshaft sealing flange -flywheel end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
3 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
3.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
3.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
1.2 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
1.4 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
2.3 Replacing camshaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
2.5 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Contents i
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

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19 - Cooling system . . . . . . . . . . . y.V. . . . . . . . . . . . . . . . . .es.n.ot .gu. . . . . . . . .
olks . . . . . . . . . .97
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1 Removing and installingoriparts
se of cooling system . . . . . . . . . . . . . a.nt.ee. . . . . . . . . . . . . . . . . . .97
th
1.1 Removing and installing
au parts of cooling system . . . . . . . . . . . . . . . . .r a.c . . . .
o
. . . . . . . . . . . .97
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1.2 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

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1.3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

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1.4 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
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1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
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1.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

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1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

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1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

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1.2 Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate . . . . . . . .114
1.3 Removing and installing fuel tank with its attachments, Caddy . . . . . . . . . . . . . . . . . . . . . .119
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1.4 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .124
1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

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1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

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1.7 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
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1.8 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
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1.9 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

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1.10 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
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2 Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

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2.1 Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
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2.2 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
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2.3 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
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3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
3.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
3.3 Servicing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
3.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . . . . . .148
1.3 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
2.1 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
2.2 Servicing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
2.3 Checking potentiometer for exhaust gas recirculation (G212) . . . . . . . . . . . . . . . . . . . . . . . .156

ii Contents
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

00 - Technical data

1 - Technical data
1.1 - Technical data

1.2 - Engine number

-> Engine code and engine number can be found on the sticker -arrow-
Volkswa
on the toothed belt guard.
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The engine code is also on the vehicle data plate and by V on the crankcase above the ogearbox.
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The engine number consists of up to nine characters
auth
(alphanumeric). The first part (maximal r a3 characters)
makes up the "engine code", and the second
ss part (6 characters), the "serial number". If more cthan 999,999

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engines with the same engine code are produced, the first of the six characters is replaced with a letter.
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1.3 - Engine data wit

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Codes APE AUA

Manufactured 11.99 ▸ 06.00 ▸
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Exhaust emissions fulfil D4 standard EU4 standard

Capacity cm3 1390 1390
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Output kW at rpm 55/5000 55/5000

Torque Nm at rpm 126/3900 126/3900
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Bore mm ø 76.5 76.5

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Stroke mm 75.6 75.6

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Compression ratio 10.5:1 10.5:1

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RON min. 95 unleaded1) 95 unleaded1)

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Injection, ignition 4LV 4LV

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Self-diagnosis yes yes
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Catalyst Prote yes AG.
yes

1.1 - Technical data 1

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

Codes APE AUA

Exhaust gas recirculation yes yes
Charging no no

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

2) With 2 Lambda probes

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2 00 - Technical data
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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
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◆ 2024 A Lifting tackle

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◆ VW 313 Support clamp

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◆ VW 540 Engine and gearbox support

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◆ V.A.G 1202 A Workshop crane

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◆ V.A.G 1306 Drip tray

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◆ V.A.G 1331 Torque wrench (5...50 Nm) ht. Cop py
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1.1 - Removing and installing engine 3

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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

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◆ VAS 5024 Assembly tool for spring-type clips

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◆ G 000 100 grease (vehicles with manual gearbox)

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◆ Cable tie

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1.2 - Notes on removing

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Note:
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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- The engine is removed forwards together with the gearbox.

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

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- Remove engine cover.

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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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- Pull off/disconnect all other electrical connections as necessary from engine and lay to one side. . C rig
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- Remove air cleaner together with air intake connecting piece:
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=> Repair group 24; Servicing injection; Dismantling and assembling air cleaner Servicing injection Dismantling
AG.

and assembling air cleaner

- Disconnect fuel supply and fuel return pipes at fuel rail.

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.

- Pull vacuum and breather hoses off engine.

- Pull connectors off thermo-switch and radiator fan.
- Remove noise insulation tray.

4 10 - Removing and installing engine

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- Separate front exhaust pipe from exhaust manifold => Page 148 , exhaust manifold, front exhaust pipe
and catalyst with attachments.
- Disconnect clutch cable:
olksw
=> Repair group 30; Servicing hydraulic clutchswcontrol
agen Servicing hydraulic
AG. V agen AG
does clutch control
k not
Vol gu
by ara
- Disconnect selector mechanism from ris gearbox.
ed
nte
utho eo
ra
a
=> Repair group 34; Servicing gear
ss change mechanism Servicing gear change mechanism c

ce
le
un

pt
an
- Drain coolant => Page 107 .
d
itte

y li
- Loosen hose clips and pull coolant hoses off coolant thermostat housing.
erm

ab
- Loosen belt pulley securing bolts from power steering vane pump.

ility
ot p

- Remove ribbed belt => Page 21 .

wit
is n

- Unbolt power steering vane pump and secure to sub-frame with wire; hoses remain connected:

h re
ole,

spec
urposes, in part or in wh

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and

t to the co
installing power steering vane pump. Assembly overview: vane pump, reservoir, hydraulic lines Removing and
installing power steering vane pump.

rrectne
- Remove power steering reservoir and tie up.

s
Vehicles with air conditioner

s o
cial p

f in
- Removing air conditioner compressor:

form
mer

- Observe additional information and removal instructions =>Page 10

atio
om

n
c

Continuation for all vehicles

i
or

n thi
te

sd
va

- Remove left and right-hand drive shaft on gearbox and tie up:
i

o
pr

cum
r
fo

en
ng

t.
=> Running gear; Repair group 40; Servicing front suspension; Removing and installing wheel bearing, sus‐
yi Co
op
pension strut and drive shaft Servicing front suspension Removing and installing wheel bearing, suspension
C py
t. rig
gh
strut and drive shaft
ht
pyri by
Vo
co lksw
by
cted agen
- Removing lock carrier with attachments:
Prote AG.

=> General body repairs; Repair group 50; Body, front; Removing and installing lock carrier with attachments.
Body, front Removing and installing lock carrier with attachments.

- -> Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:

Pulley end:
3rd hole in hook at position 1

Flywheel end:
3rd hole in hook at position 5

1.2 - Notes on removing 5

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

Warning!
The hooks and locating pins must be secured with locking pins.

Notes:

◆ The positions marked 1...4 on the bar must be towards the pulley end.
◆ The holes in the hook rails are counted up from the hook.

- Unbolt assembly at gearbox and engine mountings.

- Lower assembly until it is released from the gearbox mounting.
- Pull assembly out forwards. When doing this, if necessary turn assembly and lower slightly.

Note:

When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.

1.3 - Securing engine to assembly stand

When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the
engine and gearbox box support VW 540. gen AG
. Volkswagen AG
d a oes
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Work sequence d by ara
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ris
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- Remove gearbox. au ra
c
ss
- Secure engine to support clamp VW 313 using engine and gearbox support VW 540.

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un

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1.4 - Notes on installing
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urposes, in part or in wh

Installation is carried out in the reverse sequence, when doing this note the following:

t to the co
- 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

rrectne
100.
- Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if neces‐
sary. ss
- When swinging the assembly in, ensure that clearance exists between the drive shafts.
o
cial p

f inform
mer

atio
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c

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te

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pyri by
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cted agen
Prote AG.

- -> When installing the engine mounting ensure that the recess on the rear console and the recess on the
front console locates on the lugs of the bonded rubber mounting -arrows-.
- Align engine mountings stress-free by rocking.

6 10 - Removing and installing engine

 olkswagen AG
Polo Estate 1998 ➤
4-Cyl.w en AG. V
aginjection engine d(4
oes valve), Mechanics - Edition 11.1999
lk
os n
ot g
yV ua
db
Note: ris
e ran
tee
tho or
au ac
Assembly mounting
ss tightening torques

ce
e
nl

pt
du
=> Page 8 .

an
itte

y li
erm

ab
- Install drive shafts:

ility
ot p

wit
, is n

h re
=> Running gear; Repair group 40; Servicing front suspension; Removing and installing wheel bearing, sus‐
hole

pension strut and drive shaft Servicing front suspension Removing and installing wheel bearing, suspension

spec
strut and drive shaft
es, in part or in w

t to the co
- Installing P.A.S. vane pump:

rrectness of i
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes Assembly over‐
view: vane pump, reservoir, hydraulic pipes
l purpos

Vehicles with air conditioner

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

=> Electrical system; Repair group 97

t.
yi Co
Cop py
t. rig
- Install ribbed belt => Page 21 .
gh ht
pyri by
- Installing clutch cable:
o Vo
by c lksw
cted agen
Prote AG.
=> Repair group 30; Servicing hydraulic clutch control Servicing hydraulic clutch control

- Connecting selector mechanism to gearbox.

=> Repair group 34; Servicing gear change mechanism Servicing gear change mechanism

- Filling with coolant => Page 107

- Install air cleaner:

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

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

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

- 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

1.5 - Tightening torques

Bolted connection Tightening torque

Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M 12 60 Nm
in variation of this

1.4 - Notes on installing 7

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

Bolted connection Tightening torque

Exhaust pipe to manifold 40 Nm

1.6 - Assembly mountings

Tightening torques

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Note:

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The bolts must not be used again.
rm

ab
pe

(Bolts oiled)

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-> Front assembly mounting
, is n

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A = 50 Nm
hole

spec
B = 50 Nm
es, in part or in w

C = 50 Nm

t to the co
rrectness of i
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nform
mercia

a
com

tion in
r
te o

thi
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cum
fo

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t.
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Cop py
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-> Rear right assembly mounting
ht
pyri by
Vo
co
A = 40 Nm
by lksw
cted agen
Prote
B = 50 Nm
AG.

C = 25 Nm

8 10 - Removing and installing engine

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Vehicles with manual gearbox

-> Gearbox mounting

A = 50 Nm
C = 45 Nm
D = 25 Nm

1.7 - Replacing engine carrier rubber mounting

AG. Volkswagen AG d
agen oes
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es, in part or in w

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nform
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tion in
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thi
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cum

Special tools, workshop equipment, test and measuring appliances and auxiliary items required
fo

en
ng

t.
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op
◆ 10-222A Engine support bracket with legs 10-222A/1
C py
t. rig
gh
◆ 3302 Peening tool
ht
pyri by
Vo
◆ VW 432 Press piece
o
by c lksw
cted agen
Prote AG.

Work sequence

- Fit engine support bracket 10-222A with legs 10-222A/1.

1.6 - Assembly mountings 9

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

- Locate support bracket in lifting eye on left of cylinder head and take-up weight of engine.
- Remove engine carrier.
- -> Lever off washers from the spacer sleeves with pliers (replace any washersGwhich
. Volksware
agendamaged e.g. bent
washers). wagen A AG do
es no
olks
- Pull out spacer sleeves and detach rubber mounting. db
yV t gu
ara
- Fit new rubber mounting and insert spacer sleeves as far asoripossible.
se nte
th eo
au ra
c
ss

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ab
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

- -> Fit washers -1- over peening tool 3302 onto the rubber mounting -2-.
- Fit press sleeve of peening tool 3302 and using a press, press the washers onto the spacer sleeves and
peen. Use VW 432 as packing.

nform
ercia

- Remove any resulting protrusion/burr on the peening.

m

a
com

tion in
r
te o

thi
1.8 - Additional information and removal instructions for vehicles with air conditioner

s
iva

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cum
fo

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t.
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Warning!
. C rig
ht ht
rig
The air conditioning system refrigerant circuit must not be opened. py by
co Vo
by lksw
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Prote AG.

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.

- Remove retaining clamp(s) from refrigerant pipes.
- Remove ribbed belt => Page 21 .
- 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 lock carrier with attachments.

10 10 - Removing and installing engine

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- Set lock carrier with radiator and condenser to the side so that the refrigerant pipes and hoses are not
stressed.
- Removing air conditioner compressor:

=> Repair group 87; Air conditioner with manual control; Removing and installing compressor bracket Air con‐
ditioner with manual control Removing and installing compressor bracket

AG. Volkswagen AG d
agen oes
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V gu
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ab
pe

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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cum
fo

en
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

1.8 - Additional information and removal instructions for vehicles with air conditioner

11
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

13 - Crankshaft group

1 - Dismantling and assembling engine

1.1 - Dismantling and assembling engine

AG. Volkswagen AG d
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au ra
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nl

pt
du

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ab
ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
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m

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Cop py
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I =>Page 13

II =>Page 18

12 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
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Part I s aut ra
c
s
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le

1 Toothed belt guard - upper part

un

pt
an
d
itte

2 20 Nm + 1/4 turn (90 °) further

y li
erm

ab

◆ Renew
ility
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◆ Use tool T 10016 to loosen and tighten=>Page 75 , Fig. 1

wit
is n

3 Camshaft sprocket
h re
ole,

spec

◆ Note position when installing the toothed belt

urposes, in part or in wh

=> Page 24
t to the co

4 Coupling drive tensioning roller

◆ Checking => Page 30
◆ Tensioning toothed belts
rrectne

=> Page 24
5 Coupling drive toothed belt
ss o

◆ Mark D.O.R. before removing

cial p

f in

◆ Check for wear

form
mer

◆ Do not kink
atio

◆ Removing and installing

om

=> Page 24
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by

13
co Vo
by lksw
cted 1.1 - Dismantling and assembling engine
agen
Prote AG.
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl

pt
du

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ab
ility
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, is n

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hole

spec
es, in part or in w

t to the co

6 Bracket
rrectness of i

7 10 Nm
l purpos

8 Coolant pump
◆ If damaged or leaking renew complete
nf
ercia

◆ Removing and installing

or

=> Page 111

m
m

atio
m

9 Rear toothed belt guard

o

n in
or c

10 20 Nm
thi
te

sd
a

11 50 Nm
iv

o
r
rp

cu

12 Main drive toothed belt idler roller

o

m
f

en
ng

13 Main drive tensioning roller

t.
yi Co
op py
◆ Checking => Page 30 t. C rig
gh ht
◆ Tensioning toothed belts pyri by
Vo
co
=> Page 24
by lksw
cted agen
Prote AG.

14 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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14 Crankshaft toothed belt sprocket utho eo
ra
a
◆ Note position when installing toothed
ss belt c
=> Page 24
ce
e
nl

pt
du

an

15 Main drive toothed belt

itte

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erm

◆ Mark D.O.R. before removing

ab
ility

◆ Check for wear

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wit

◆ Do not kink
, is n

h re

◆ Toothed belt routing => Fig. 21

hole

spec

◆ Removing, installing and tensioning

es, in part or in w

=> Page 24
t to the co

16 12 Nm
◆ Renew
rrectness of i

17 Belt pulley
◆ When installing note fixing arrangement
l purpos

◆ Removing and installing

=> Page 24 ; Removing, installing and tensioning toothed belt
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by
15
cted agen
Prote
1.1 - Dismantling and assembling engine
AG.
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
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ce
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un

pt
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d
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ab
ility
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wit
is n

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spec
urposes, in part or in wh

t to the co

18 90 Nm + 1/4 turn (90 °) further

rrectne

◆ Renew
◆ Oil threads
ss

◆ The turning further can be done in several stages

o
cial p

◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690
inform

19 Ribbed belt
mer

atio

◆ Mark direction of rotation before removing

om

◆ Removing and installing

c

i
or

=> Page 21
thi
te

sd
a

◆ Ribbed belt routing

iv

o
pr

=> Page 22
um
r
fo

◆ Vehicles with air conditioning system have an additional idler roller

en
ng

t.
yi Co
op
20 Toothed belt guard - lower part C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

16 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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ce
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nl

pt
du

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erm

ab
ility
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, is n

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spec
es, in part or in w

t to the co
rrectness of i
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21 Console
o

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t.
22 50 Nm
yi Co
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◆ Renew
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23 25 Nm cop Vo
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24 Idler roller Prote AG.

1.1 - Dismantling and assembling engine 17

 n AG. Volkswagen AG do
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Polo Estate 1998 ➤ tho tee
or
u
4-Cyl. injection engine (4ss valve), Mechanics - Edition 11.1999
a ac

ce
le
un

pt
an
d
itte

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pe

ility
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, is n

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hole

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es, in part or in w

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rrectness of i
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nform
mercia

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com

tion in
r
te o

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s
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do
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cum
fo

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Part II

Note:

Servicing the clutch:

=> Repair group 30; Servicing clutch; Removing and installing clutch Servicing clutch Removing and installing
clutch

1 Cylinder block
◆ Dismantling and assembling aluminium cylinder block => Page 34
◆ Dismantling and assembling pistons and conrods
=> Page 49
2 45 Nm
◆ Renew
◆ Before turning in, clean thread and coat with locking fluid D 000 600 A2
◆ Tightening order:

=> Repair group 87; Air conditioner with manual controls; Removing and installing compressor bracket Air
conditioner with manual controls Removing and installing compressor bracket

18 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

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nl

pt
du

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ab
ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
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3 Oil filter
n

t.
yi Co
op py
◆ Loosen at hexagon bolt head
. C rig
ht ht
◆ Tighten by hand
rig by
opy Vo
◆ Note instructions on filter when installing by c lksw
cted agen
Prote AG.
4 M8: 20 Nm + 1/4 turn (90 °) further
5 15 Nm
◆ Loosen and tighten only bolts on flywheel end with socket insert T10058
6 Sump
◆ Removing and installing
=> Page 90
7 Oil drain plug, 30 Nm
◆ With attached seal
◆ Renew

1.1 - Dismantling and assembling engine 19

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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an
d
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ab
ility
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wit
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

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c

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or

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t.
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Cop py
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Vo
co lksw
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cted agen
Prote AG.

8 Compact bracket
◆ For vane pump and alternator
◆ Removing and installing compact bracket on vehicles with air conditioner:

=> Repair group 87; Air conditioner with manual controls; Removing and installing compressor bracket Air
conditioner with manual controls Removing and installing compressor bracket

9 45 Nm
10 Washer
11 Tensioning roller
12 Tensioning element

20 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

n AG. Volkswagen AG do
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urposes, in part or in wh

-> Fig. 1 Toothed belt routing

t to the co
A - Coupling drive toothed belt

rrectne
B - Main drive toothed belt

ss o
cial p

f inform
mer

1.2 - Removing and installing ribbed belt

atio
om

n
c

i
or

n thi
te

sd
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Removing
iv

o
pr

cum
r
fo

en
- Remove right insulation tray.
ng

t.
yi Co
- Mark ribbed belt direction of rotation. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- -> Using a spanner on the securing bolt swivel tensioning roller in direction of arrow.
- Remove ribbed V-belt.

Installing

- Place ribbed V-belt onto crankshaft pulley first. Slide belt onto tensioning roller last.

1.1 - Dismantling and assembling engine 21

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

n AG. Volkswagen AG do
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Ribbed belt routing

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, is n

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hole

-> Belt drive with air conditioner compressor

spec
es, in part or in w

t to the co
1- Crankshaft/pulley
2- Tensioner
3- Pulley - Alternator

rrectness of i
4- Air conditioner compressor
5- Pulley - P.A.S. vane pump
l purpos

6- Ribbed belt

nform
mercia

at
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or

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-> Belt drive without air conditioner compressor

1- Crankshaft/pulley
2- Tensioner
3- Pulley - Alternator
4- Ribbed belt
5- Pulley - P.A.S. vane pump

Note:

When installing the ribbed V-belt, ensure the belt runs in the right direction and seats correctly on the belt
pulleys.

The rest of the assembly is basically a reverse of the dismantling sequence.

1.3 - Checking valve timing

- Remove the toothed belt guard upper part.

22 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

- -> Position the crankshaft to top dead centre No. 1 cylinder. The notch on the pulley must align with the
edge of the -O- mark.
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spec
es, in part or in w

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- -> The locking pin holes in the camshaft pulleys must align with the fitting holes in the camshaft housing -
arrows-.

rrectness of i
l purpos

Note:

If the locking pin holes are positioned to the outside on the toothed belt pulleys, the crankshaft must be turned

nf
ercia

o
one revolution further.

rm
m

atio
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n in
or c

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sd
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1.3 - Checking valve timing 23

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.4 - Removing, installing and tensioning toothed

swa
gen AGbelts
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es, in part or in w

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nform
mercia

at
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c

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or

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do
priv

cum
for

en
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t.
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Cop py
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Vo
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cted agen
Prote AG.

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

◆ 3415 Counter support

◆ 3415/1 Pins
◆ T 10016 Camshaft locking device
◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1332 Torque wrench (40...200 Nm)

24 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Removing

AG. Volkswagen AG d
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- -> Remove cover above camshaft housing -arrows-.
hole

spec
- Remove air cleaner together with air intake connecting piece:
es, in part or in w

t to the co
=> Repair group 24; Servicing injection; Dismantling and assembling air cleaner Servicing injection Dismantling
and assembling air cleaner

rrectness of i
- Remove the toothed belt guard upper part.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- -> Position the crankshaft to top dead centre No. 1 cylinder. The notch on the pulley must align with the
edge of the -O- mark.

- -> The locking pin holes in the camshaft sprockets must align with the fitting holes in the camshaft housing
-arrows-.

Note:

If the locking pin holes are positioned to the outside on the toothed belt sprockets, the crankshaft must be turned
one revolution further.

Fix both camshaft sprockets with camshaft locking device T 10016 as follows:

1.4 - Removing, installing and tensioning toothed belts 25

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
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ab
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ility
ot

wit
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h re
- -> Guide both locking pins through camshaft sprocket locking pin holes onto stop in camshaft housing fitting
hole

holes.

spec
es, in part or in w

t to the co
Note:

Both locking pins are inserted correctly when the ends -D- align with line -A-.

rrectness of i
- Slide retainer -B- onto stop on inlet camshaft sprocket -C-.
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

en
ng

t.
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Cop py
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pyri by
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by
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- Remove right insulation tray.

- Mark the direction of rotation of the ribbed belt and remove belt as follows.
- -> Using a spanner on the securing bolt swivel tensioning roller in direction of arrow.
- Remove ribbed belt.

- -> Remove pulley and toothed belt sprocket securing bolt. To do this hold the pulley with counter-hold tool
3415 and 3415/1.
- Remove pulley. Refit securing bolt with two washers and tighten to secure toothed belt sprocket.
- Remove idler roller on vehicles with air conditioning system and ribbed belt tensioning roller.
- Remove lower toothed belt guard.
- Mark direction of rotation of both toothed belts.

26 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
AG. Volkswagen AG d
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spec
es, in part or in w

t to the co
Removing main drive toothed belt:
- -> Release main drive tensioner -1- and slacken toothed belt by turning tensioning roller anti-clockwise -

rrectness of i
arrow-.
l purpos

- Loosen clamping bolt on tensioning roller.

- Take off toothed belt.

nform
ercia

Removing coupling drive toothed belt:

m

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- -> Loosen coupling drive tensioner -1- and slacken toothed belt by turning tensioning roller clockwise.
- Remove coupling drive tensioning roller.
- Take off toothed belt.

Installing

Prerequisites
• The pistons must not be positioned at TDC.
• The crankshaft toothed belt sprocket is secured to the crankshaft with the securing bolt and two washers.
• Camshaft sprockets arrested in camshaft housing fitting holes with T 10 016 and secured against turning.

Note:
If a piston is at TDC the valves could strike the piston when turning the camshafts.

1.4 - Removing, installing and tensioning toothed belts 27

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Work sequence

- -> Set the crankshaft to TDC No. 1 cylinder. The tooth with end ground down must align with the mark on
the oil pump -arrow-.
- Fit toothed belt for coupling the camshafts in a clockwise direction starting at top on inlet camshaft sprocket
and then onto exhaust camshaft sprocket. The slack section of the toothed belt must be downwards. Note
direction of rotation with used belts.

Install coupling drive tensioning roller as follows:

AG. Volkswagen AG d
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es, in part or in w

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- -> Turn coupling drive tensioning roller clockwise towards marking window -arrow- using a hexagon key -1-

rrectness of i
(tensioning roller in untensioned position).
- Press lower section of toothed belt for coupling the camshafts upwards with tensioning roller and fit ten‐
l purpos

sioning roller securing bolt.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

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t.
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- Tighten securing bolt hand tight. The lug in the base plate must engage in the hole in the cylinder head -2-.
- -> Then tension toothed belt by turning tensioning roller anti-clockwise, with a hexagon key item -1-, until
the indicator -2- aligns over the lug in the base plate in the marking window -arrow-.
- Tighten clamping nut on tensioning roller.
Tightening torque: 20 Nm

Note:

The tool must secure camshaft against turning until the main drive toothed belt is fitted.

- Fit main drive toothed belt on in anti-clockwise direction starting at water pump then via tensioning roller,
crankshaft, idler roller and inlet camshaft sprocket. Note direction of rotation with used belts.

28 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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es, in part or in w

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If tensioning roller was removed beforehand, install tensioning roller as follows:

rrectness of i
- -> Using Allen key turn main drive tensioning roller anti-clockwise to position shown -arrow-.
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
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t.
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- -> Tighten securing bolt hand tight. The base plate -1- cut-out must engage over securing bolt -2-.
- Loosen securing bolt on used tensioning roller.
- Then 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-.
- Remove tool from camshaft sprockets.
- Tighten clamping nut on tensioning roller.
Tightening torque: 20 Nm

- Now turn the crankshaft two turns in engine direction of rotation until it is again at top dead centre No. 1
cylinder.
- Now the position of the toothed belts and tensioning roller must be checked again.
- Tension toothed belt again if necessary.
- Refit toothed belt guard.
- Refit crankshaft belt pulley. When doing this note the following:
- The securing bolt for the pulley and toothed belt sprocket must be renewed.
- When installing the pulley observe the fixing arrangement to toothed belt sprocket.
- Tightening procedure for the new oiled bolt: 90 Nm + 1/4 turn (90°) further.

- Install ribbed belt again.

Note:

When installing the ribbed belt ensure that it sits correctly in the pulleys.

- Install air cleaner:

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

- Interrogate fault memory:

1.4 - Removing, installing and tensioning toothed belts 29

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
=> Repair group 01; Fault memory; Interrogating and erasing fault memory of engine control unit Fault memory
Interrogating and erasing fault memory of engine control unit

1.5 - Checking semi-automatic toothed belt tensioning roller

AG. Volkswagen AG d
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wit
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spec
es, in part or in w

t to the co
rrectness of i
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nf
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orm
m

atio
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f

en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

◆ 3415 Counter support

◆ 3415/1 Bolts
◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1332 Torque wrench (40...200 Nm)

30 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
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byV gu
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Checking main drive
s aut tensioning roller: ra
c
s

ce
le

Checking coupling drive tensioning roller =>Page 32 .

un

pt
an
d
itte

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Test sequence
erm

ab
ility
ot p

wit
- -> Remove cover above camshaft housing -arrows-.
is n

h re
- Remove air cleaner together with air intake connecting piece:
ole,

spec
urposes, in part or in wh

=> Repair group 24; Servicing injection; Dismantling and assembling air cleaner Servicing injection Dismantling

t to the co
and assembling air cleaner

- Remove the toothed belt guard upper part.

rrectne
- Remove right insulation tray.
- Mark ribbed belt direction of rotation.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- -> Using a spanner on the securing bolt swivel tensioning roller in direction of arrow.
- Remove ribbed belt.

- -> Remove pulley and toothed belt sprocket securing bolt. To do this hold the pulley with counter-hold tool
3415 and 3415/1.
- Remove pulley. Refit securing bolt with two washers and tighten to secure toothed belt sprocket.

1.5 - Checking semi-automatic toothed belt tensioning roller 31

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- Now turn the crankshaft two turns in engine direction of rotation until it is again at top dead centre No. 1
cylinder.

AG. Volkswagen AG d
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- -> Note the position of the tensioning roller indicator -arrow-. Press the toothed belt with firm thumb pressure.
ole,

spec
The indicator must move.
urposes, in part or in wh

- Release tension on toothed belt.

t to the co
- Turn crankshaft two turns in engine direction of rotation.
- Then check the position of the indicator. It must have returned to its original position.

rrectne
If tensioning roller does not return to initial position:

s
- Replace tensioning roller.

s o
cial p

f inform
Checking coupling drive tensioning roller:
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- -> Note the position of the tensioning roller indicator -1-. Press the toothed belt with firm thumb pressure -
arrow-. The indicator must move.
- Release tension on toothed belt.
- Turn crankshaft two turns in engine direction of rotation.
- Then check the position of the indicator. It must have returned to its original position.

If tensioning roller does not return to initial position:

- Replace tensioning roller.

If both tensioning rollers are OK:

- Refit toothed belt guard.

- Refit crankshaft belt pulley. When doing this note the following:
- The pulley and toothed belt sprocket securing bolt must be renewed.
- When installing the pulley observe the fixing arrangement to toothed belt sprocket.
- Tightening procedure for the new oiled bolt: 90 Nm + 1/4 turn (90°) further.
- Refit the ribbed belt.

32 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Note:

When installing the ribbed belt ensure that it sits correctly in the pulleys.

- Install air cleaner:

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

2 - Removing and installing kcylinder

swa
gen AG block,
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2.1 - Removing and installing
ho
rise cylinder block, sealing flange randnte flywheel
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erm

ab
ility
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
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pr

cum
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fo

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Cop py
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pyri by
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1.5 - Checking semi-automatic toothed belt tensioning roller 33

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
AG. Volkswagen AG d
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2.2 - Aluminium cylinder
horis
block nte
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pt
Warning!

an
d
itte

y li
The crankshaft must not be removed. Just loosening the main bearing caps will cause deformation of the
rm

ab
cylinder block bearing pedestals. This deformation will cause a reduction of the bearing clearance. Even if the
pe

ility
bearing shells are not renewed bearing damage could occur due to a different bearing clearance.
ot

wit
, is n

If the bearing cap bolts are loosened, the cylinder block must be replaced complete with the crankshaft.

h re
Measuring the main bearing clearance is not possible with normal workshop equipment.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

Note:
For repairs to the clutch:
=> Repair group 30; Servicing clutch; Removing and installing clutch Servicing clutch Removing and installing
clutch
1 10 Nm
2 Suction pipe
3 Aluminium cylinder block

34 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
4 Knock sensor
5 20 Nm
◆ Tightening torque influences the function of the knock sensor
6 60 Nm + 1/4 turn (90 °) further
◆ Renew

AG. Volkswagen AG d
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7 Flywheel
h re
hole

◆ To remove and install flywheel counter-hold with 3067

spec
es, in part or in w

8 12 Nm
t to the co

◆ Renew
9 Sealing flange with sender wheel and oil seal
rrectness of i

◆ Only renew complete with oil seal and sender wheel

◆ Removing and installing sealing flange =>Page 39 , Renewing crankshaft sealing flange -flywheel end-
l purpos

10 Gasket
◆ Renew
nform
mercia

a
com

tion in
r
te o

thi
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cum
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t.
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35
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Prote
2.2 - Aluminium cylinder block
AG.
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

11 Oil pump
◆ Only renew complete
◆ When installing note follower -item 13 - on crankshaft
◆ Must be located on dowel sleeves
◆ Removing and installing oil pump => Page 92
12 Oil seal
◆ Renewing => Page 37
13 Follower
◆ Coat with oil before installing oil pump

36 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

2.3 - Renewing crankshaft oil seal -belt pulley end-

AG. Volkswagen AG d
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V gu
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ise nte
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aut ra
ss c

ce
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nl

pt
du

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi
Special tools, workshop equipment, test and measuring appliances and auxiliary items required
Co
Cop py
t. rig
gh ht
yri
◆ 3240 Oil seal extractor
p by
o Vo
by c lksw
◆ T10022 Sleeve Prote
cted AG.
agen
◆ T10022/1 Press piece
◆ T10022/2 Spindle

Removing

- First remove main drive toothed belt

=> Page 24 .
- Then remove the crankshaft toothed belt sprocket.
- To guide oil seal extractor screw crankshaft sprocket securing bolt into crankshaft onto stop.

2.3 - Renewing crankshaft oil seal -belt pulley end- 37

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

- 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 3240, 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

- Lightly oil sealing lip of new oil seal.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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ss c

ce
le
un

pt
- -> Fit sleeve T10022 onto crankshaft journal and turn spindle T10022/2 in onto stop.

an
d
itte

y li
- Slide oil seal over guide sleeve.
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

- -> Press in oil seal onto stop with press piece T10022/1.
inform

- Install main drive toothed belt => Page 24 .

mer

atio
om

n
c

i
or

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te

sd
iva

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pr

cum
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fo

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t.
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Cop py
t. rig
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pyri by
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Prote AG.

38 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

2.4 - Renewing crankshaft sealing flange -flywheel end-

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
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e
nl

pt
du

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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

Special tools, workshop equipment, test and measuring appliances and auxiliary items required
l purpos

◆ T10017 Assembly device

◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1332/11 Open ring spanner
nform
ercia

◆ Hexagon bolts (Qty. 3)

m

M6 x 35 mm
at
om

io

◆ Feeler gauge
n
c

in t
r

◆ Vernier gauge
o

his
ate

do
riv

Pressing sealing flange with sender wheel off crankshaft

p

cum
for

en
ng

t.
yi
Notes:
Co
Cop py
ht. rig
rig ht
py by
◆ To show the work sequence more clearly, the sequence is described for a removed engine. co Vo
by lksw
◆ The work sequence is the same when the engine is in the vehicle and the gearbox removed. cted agen
Prote AG.

Work sequence

- Remove the flywheel/drive plate.

2.4 - Renewing crankshaft sealing flange -flywheel end- 39

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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

- Set engine to TDC No. 1 cylinder =>Page 22 , Checking valve timing.

wit
is n

- Remove oil sump =>Page 90 .

h re
ole,

- -> Remove engine speed sender -arrow-.

spec
- Undo sealing flange securing bolts.
urposes, in part or in wh

t to the co
Note:

Sealing flange and sender wheel are pressed off the crankshaft together with Qty. 3 M6 x 35 mm bolts.

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
- -> Screw Qty. 3 M6 x 35 mm bolts into the threaded holes -arrows- of the sealing flange.
AG.

- 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.

40 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

◆ The assembly appliance T10017 maintains its installation position to the crankshaft via a guide pin which is
inserted into a threaded hole in the pressure plate/drive plate.

-> A - Hexagon nut

B - Clamping surface (ground section of spindle)

C - Tool bell housing

D - Socket head bolt

E - Guide pin

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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pt
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itte

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ility
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wit
, is n

h re
hole

spec

F - Locating pin
es, in part or in w

t to the co

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

rrectness of i

- -> Screw hexagon nut -A- to shortly before the clamping surface (ground section) -B- on the threaded spindle.
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- -> Clamp assembly appliance T10017 in a vice on clamping surface (ground section) on threaded spindle.

2.4 - Renewing crankshaft sealing flange -flywheel end- 41

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- 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).

- -> Remove securing clip -A- on new sealing flange.

AG. Volkswagen AG d
Note: lksw
agen oes
not
o
byV gu
ara
d
The sender wheel must not be taken out of the sealing flangehoris or twisted.
e nte
eo
aut ra
ss c

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
-> The locating hole -B- on the sender wheel -C- must align with the marking -A- on the sealing flange.
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- -> Place 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.

42 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
-> The upper edge of the sender wheel and the forward edge of the sealing flange must align -arrows-.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
. rig
- -> Place the sealing flange, with the forward side on the assembly appliance T10017, so that the locating
ht ht
rig by
py
pin -A- can be inserted in the sender wheel hole -B-. co Vo
by lksw
cted agen
Prote AG.
Note:

Ensure the sealing flange lies flat on the assembly appliance.

- -> 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.

2.4 - Renewing crankshaft sealing flange -flywheel end- 43

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
B-Assembling appliance T10017 with sealing flange on crankshaft flange

Prerequisites

• Crankshaft flange must be free of oil and grease.

• Engine positioned at TDC No. 1 cylinder.

Work sequence

- -> Unscrew hexagon nut -A- to end of threaded spindle.

- Press assembly appliance threaded spindle in direction of arrow, until the hexagon nut -A- lies against the
assembly bell housing -C-.

AG. Volkswagen AG d
agen oes
olksw not
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pt
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ility
ot p

wit
, is n

h re
hole

spec
- Align flat side of assembly bell housing towards oil sump side of crankcase sealing surface.
es, in part or in w

t to the co
- -> Secure assembly appliance to crankshaft flange with hexagon socket head bolts -A-

Note: rrectness of i

Screw hexagon socket head bolts -A- into crankshaft flange (approx. 5 threads).
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- -> Screw two M6 x 35 mm bolts -A- into cylinder block to guide sealing flange.

44 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
C-Fitting assembly appliance T10017 onto crankshaft flange

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
- -> Slide assembly bell housing -A- in direction of arrow by hand until the sender wheel - B- (Sealing lip
s

ce
le

support ring for PTFE sealing ring) lies against the crankshaft flange -C-.
un

pt
an
d
itte

y li
Note:
erm

ab
ility
ot p

The assembly appliance guide pin -D- is guided into threaded hole in crankshaft during the fitting sequence.

wit
is n

This ensures the sender wheel reaches its final installation position.

h re
ole,

spec
- Hold assembly bell housing in this position and screw both assembly appliance hexagon socket head bolts
urposes, in part or in wh

hand tight.

t to the co
- Screw hexagon nut -E- onto threaded spindle by hand until it lies against the assembly bell housing -A-.

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
yri by
D-Pressing sender wheel onto crankshaft flange with assembly appliance T10017
op Vo
by c lksw
cted agen
Prote
- -> Tighten assembly appliance hexagon nut with torque wrench V.A.G 1331 and open ring spanner insert
AG.

V.A.G 1332/11.
Tightening torque: 35 Nm

Note:
A small air gap must be present between cylinder block and sealing flange after tightening hexagon nut to 35
Nm.

2.4 - Renewing crankshaft sealing flange -flywheel end- 45

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
E-Checking sender wheel installation position on crankshaft

- -> Screw hexagon nut -A- to end of threaded spindle.

- Remove the two M6 x 35 mm hexagon bolts -B- from cylinder block. AG. Volkswagen AG d
agen
- Screw the three thumb wheels -C- out of sealing flange. Volksw
oes
not
gu
- Pull assembly appliance assembly bell housing -D- back to hexagon
ed by nut -A- (Only for sealing flange awith
ran
spring ring). thoris tee
o
au ra
c
ss

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

-> The sender wheel has the correct installation position on crankshaft when a gap of

nform
ercia

-a- = 0.5 mm
exists between crankshaft flange -A- and sender wheel -B-.
m

a
com

tion in
Note:
r
te o

thi
s
iva

do
If the sealing flange has a PTFE sealing ring, completely unbolt the assembly appliance T10017 and remove
r
rp

cum
the sealing lip support ring.
fo

en
ng

t.
yi Co
op
To enable the measurements to be shown more clearly the crankshaft flange is illustrated without the fitted
C py
t. rig
gh
assembly appliance T10017.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

- -> Place a vernier caliper against the crankshaft flange -A- (hatched area).

46 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- -> 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 47 .

When dimension -a- is achieved:

- Remove assembly appliance.
- Tighten the new securing bolts for the sealing flange using alternate and diagonal sequence.
Tightening torque: 12 Nm

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
- -> Install engine speed sender -arrow-.
aut
h eo
ra
Tightening torque: 5 Nm s s c
- Install sump => Page 90 .

ce
e
nl

pt
du

- Install intermediate plate.

an
itte

y li
- Install flywheel/drive plate with new bolts.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

F-Re-pressing sender wheel

in t
or

his
te

- -> Slide assembly bell housing -A- to sealing flange -B- by hand.
a

do
riv

- Screw two M6 x 35 mm bolts -C- into cylinder block to guide sealing flange -B-.
p

cum
or

- Screw hexagon nut -D- along threaded spindle, by hand, until it contacts the assembly bell housing -A-.
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.4 - Renewing crankshaft sealing flange -flywheel end- 47

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- -> Tighten assembly appliance hexagon nut with torque wrench V.A.G 1331 and open ring spanner insert
V.A.G 1332/11.
Tightening torque: 40 Nm
- Check installation position of sender wheel on crankshaft again => Page 46 .
AG. Volkswagen
agen AG do
ksw es n
If dimension -a- is too small again: y Vol ot g
ua
b
ed ran
oris tee
h
- ut
Tighten hexagon nuts ato or
ac
45 Nm. s

ce
le

- Check installation position of sender wheel on crankshaft again => Page 46 .

un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

2.5 - Crankshaft dimensions

wit
, is n

h re
hole

spec
Honing dimensions Conrod
es, in part or in w

in mm journal ø

t to the co
Basic dimension -0.022
47.80

rrectness of i
-0.037
1st undersize -0.022
l purpos

47.55
-0.037

nform
ercia

2nd undersize -0.022

47.30
m

a
com

t
-0.037

ion in
r

3rd undersize -0.022

te o

thi
47.05
s
iva

-0.037 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.

48 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

3 - Dismantling and assembling pistons and conrods

3.1 - Dismantling and assembling pistons and conrods

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
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

1 Circlip
2 Piston pin
l purpos

◆ If difficult to remove, heat piston to 60 °C

◆ Remove and install with drift 10-14
nform
ercia

3 Piston
m

at

◆ Checking => Fig. 3

om

ion

◆ Mark installation position and cylinder number

c

in t
or

◆ Arrow on piston crown points to pulley end

his
ate

◆ Install using piston ring clamp

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3.1 - Dismantling and assembling pistons and conrods 49

 Polo Estate 1998 ➤ AG. Volkswagen AG d
agen oes
4-Cyl. injection engine (4 valve), Mechanics V- oEdition
lksw 11.1999 not
g y ua
db ran
rise tee
tho or
s au ac
s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

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 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 rings
◆ Carefully remove and install 3-part oil scraper rings by hand
◆ 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

50 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
a

7 Conrod bearing cap

iv

o
r
rp

cu

◆ The caps only fit in one position and only on the appropriate con-rod, this is due to the breaking procedure
o

m
f

en
ng

(cracking) separating the cap from the con-rod

t.
yi Co
op
8 Conrod bolt, 20 Nm + 1/4 turn (90 °) further
C py
ht. rig
rig ht
◆ Renew py by
co Vo
◆ Oil threads and contact surface
by lksw
cted agen
Prote
◆ To measure radial clearance tighten to 20 Nm but not further
AG.

9 Cylinder block
◆ Checking cylinder bores
=>Fig. 4
◆ Piston and cylinder dimensions
=>Page 55

3.1 - Dismantling and assembling pistons and conrods 51

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

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.

10 Bearing shell
◆ Do not interchange used bearing shells
◆ Measure pretension
=> Fig. 5
◆ Insert bearing shells centrally
◆ Check radial clearance with Plastigage:
New: 0.020...0.061 mm
Wear limit: 0.091 mm
Do not rotate crankshaft when checking radial clearance

52 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

-> Fig. 1 Checking piston ring gap

- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.

Piston ring New Wear limit

Dimensions in mm
1. Compression ring 0.20...0.50 a1.0
gen AG
. Volkswagen AG
does
lksw not
2. Compression ring 0.40...0.70by Vo 1.0 gu
ara
ed
Oil scraper ring 0.25...0.50
thoris
---1) nte
e or
au ac
ss
1) No wear limit details

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

-> Fig. 2 Checking ring to groove clearance

Clean groove before check.

Piston ring New Wear limit

Dimensions in mm
1. Compression ring 0.04...0.08 0.15

3.1 - Dismantling and assembling pistons and conrods 53

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

Piston ring New Wear limit

Dimensions in mm
2. Compression ring 0.02...0.06 0.15 AG. Volkswagen AG d
agen oes
Oil scraper ring Cannot be measured Volksw not
gu
by ara
d
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

-> Fig. 3 Checking piston

nform
ercia

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
m

a
com

ti
◆ Micrometer 75...100 mm

on in
r
te o

thi
- Approx. 10 mm from lower edge and offset 90 ° to piston pin axis. Deviations from nominal dimensions

s
iva

do
max. 0.04 mm
r
rp

cum
fo

en
ng

t.
yi
Nominal dimension => Page 55 ; Piston and cylinder dimensions
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

-> Fig. 4 Checking cylinder bores

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ 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

54 13 - Crankshaft group
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
max. 0.08 mm

Nominal dimension => Page 55 ; 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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

-> Fig. 5 Measuring bearing shell pretension

h re
hole

spec
es, in part or in w

t to the co
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Vernier caliper

rrectness of i
The bearing shell pretension is calculated as follows:
l purpos

Bearing shell dimension -a-

nform
ercia

- Conrod diameter -b-

= Pretension
m

at
om

ion
c

Minimum dimension: 1.5 mm

in t
or

his
ate

do
riv

If the pretension is not achieved:

p

cum
for

en
ng

- Renew bearing shells.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
3.2 - Piston and cylinder dimensions
agen
Prote AG.

Honing Piston-ø Cylinder bore-ø

dimension
Basic dimen. mm 76.475 76.51
1st oversize mm 76.725 76.76
2nd oversize mm 76.975 77.01

3.1 - Dismantling and assembling pistons and conrods 55

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

15 - Cylinder head, Valve gear

1 - Removing and installing cylinder head

1.1 - Removing and installing cylinder head

Checking compressions=> Page 67

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 housing.
◆ 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.

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1 Toothed belt guard - upper part

2 Main drive toothed belt
◆ Check for wear
◆ Do not kink

56 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
◆ Removing, installingand tensioning
=> Page 24
3 Coupling drive toothed belt
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 24
4 10 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Tighten from centre outwards
5 H.T. cable guide

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◆ Removing and installing C py
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=> Page 60
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◆ Remove remnants of old sealant
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◆ Carefully clean sealing surfaces. They must be free of oil and grease.
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◆ Coat with AMV 188 003 before fitting
◆ When installing fit vertically from above onto studs and dowel pins
7 10 Nm
8 Fitted pins
9 Roller rocker finger
◆ Check bearing for ease of movement
◆ Oil contact surface

1.1 - Removing and installing cylinder head 57

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
◆ Use securing clip to clip onto support element when installing

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10 Support element
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◆ Do not interchange
◆ With hydraulic valve clearance compensation
◆ Oil contact surface
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11 Cylinder head bolt

◆ Renew
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◆ Note installation instructions and sequence when loosening and tightening

cial p

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=> Page 63
form
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12 Cylinder head gasket

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◆ Renew
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◆ Metal gasket
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◆ After replacing renew the complete coolant

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58 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
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13 Cylinder head
◆ Removing and installing
=> Page 63
◆ Check for distortion => Fig. 1
◆ Sealing surfaces in contact with camshaft housing must be free of oil and grease
◆ After replacing renew the complete coolant
14 Coupling drive tensioning roller
◆ Checking => Page 30
◆ Tensioning toothed belts
=> Page 24
15 20 Nm
16 Rear toothed belt guard
17 Lifting eye

1.1 - Removing and installing cylinder head 59

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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-> Fig. 1 Checking cylinder head for distortion

h re
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Max. permissible distortion: 0.05 mm

rrectness of i
1.2 - Removing and installing camshaft housing
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Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

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◆ V.A.G 1331 Torque wrench (5...50 Nm)

◆ Two studs (M 6 x 70)
◆ D 188 003 A1 Sealant

Removing

Notes:

◆ The camshafts are mounted in the camshaft housing on this engine. Therefore, the main drive toothed belt
must be removed before the camshaft housing can be removed.
◆ The camshaft housing sealing surface must not be reworked.

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.
- First remove main drive toothed belt
=> Page 24 .
- Remove spark plug connectors with H.T. cables.
- Pull 4 pin connector off ignition transformer.
- Pull connector off Hall sender.

60 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

- -> Remove securing bolt -arrow- from cable retainer.

- Remove toothed belt guard rear securing bolt (in area of right-hand lifting eye).
- Loosen camshaft housing bolts (from outside to inside and in cross-over sequence) and remove.
- Carefully lift camshaft housing off.

Installing
Prerequisites
• The pistons must not be positioned at TDC.
• Camshaft sprockets locked into camshaft housing fitting holes with T 10016 and secured against turning.

- Remove sealant remnants on cylinder head and camshaft housing with a commercially available sealant
remover.
- Prevent dirt and sealant remnants from entering cylinder head.

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- Clean sealing surfaces carefully. They must be free of oil and grease.
is n

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- -> Apply a thin even coat of sealant onto the clean camshaft housing sealing surface. See hatched area on
ole,

illustration.
spec
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Note:
The sealant must not be applied too thick otherwise excess sealant can enter the oil channels and cause
damage to the engine.
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1.2 - Removing and installing camshaft housing 61

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- -> Ensure all roller rocker fingers contact the valve ends -1- correctly and they are clipped into their respective
support elements -2-.
- Screw two studs (M6 x 70) into cylinder head before installing camshaft housing.

- -> Carefully fit the camshaft housing vertically onto the cylinder head studs and dowel pins -arrows- from
above.

Note:

◆ Ensure that no oil residue can drip onto the coated sealing surfaces.
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- Tighten camshaft housing new securing bolts (evenly by Vfrom inside to outside using cross-over
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Ensure that camshaft housing is not canted. auth eo
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Tightening torque: 10 Nm + 1/4 turn (90 °) sfurther.
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Note:

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◆ Sealant must be left dry for approx. 30 minutes after installing camshaft housing.

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Installing toothed belt and adjusting timing => Page 24 , Removing, installing and tensioning toothed belt.
hole

spec
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The rest of the assembly is basically a reverse of the dismantling sequence.

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62 15 - Cylinder head, Valve gear

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4-Cyl. injection
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1.3 - Removing and installing cylinder head
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Special tools, workshop equipment, test and measuring appliances and auxiliary items required

◆ 3415/1 Bolts
◆ 3415 Counter support
◆ T 10014 Retainer
◆ T 10016 Camshaft locking device

1.3 - Removing and installing cylinder head 63

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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◆ V.A.G 1306 Drip tray rrectness o
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f
◆ V.A.G 1331 Torque wrench (5...50 Nm)
inform

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

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◆ V.A.G 1921 Pliers for spring-type clips or VAS 5024 assembly tool for spring-type clips
atio
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◆ D 188 003 A1 Sealant

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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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- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding. cted agen
Prote AG.
- With the ignition switched off disconnect battery earth strap.
- First remove main drive toothed belt
=> Page 24 .
- Remove camshaft housing
=> Page 60 .
- 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.
- Open and close the expansion tank sealing cap to release pressure in cooling system.
- Drain coolant => Page 107 .
- Loosen hose clips and pull coolant hoses off coolant thermostat housing.
- Remove oil dipstick tube.

64 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- Disconnect fuel supply and fuel return pipes at fuel rail.

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.

- Loosen or separate the following components:

- The hose from crankcase breather
- The hose from activated charcoal filter system to throttle valve control unit
- The vacuum hose from brake servo to intake manifold
- The vacuum hose from exhaust gas recirculation valve to brake servo vacuum hose junction piece
- The 2 pin connector from knock sensor (rear of cylinder block) and the 4 pin connector from intake
manifold pressure sender (front right under intake manifold).

- The connector from engine speed sender below oil dipstick tube bracket, and pull connector out from
retainer
- The connector from coolant temperature sender, oil pressure switch and exhaust gas recirculation valve
- Injector connectors
Remove front exhaust pipe from exhaust manifold.
Unbolt bracket from exhaust manifold on cylinder block => Page 148 ; Item 6 .
Pull the clamps which secure the coolant pipe to coolant pump off the thermostat housing.

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- -> Loosen socket head bolts in the sequence given and then remove completely.
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- Carefully lift cylinder head off.

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Installing
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Notes:
t to the co

◆ Only remove the new cylinder head gasket from its packing immediately before installing.
◆ Handle the new gasket with extreme care. Damaging will lead to leaks.
rrectness of i
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- Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and
piston.
- Carefully clean cylinder head and cylinder block sealing surfaces. Thereby ensuring that no scoring or
nform
ercia

scratches are formed (when using abrasive paper the grade must not be less than 100).
- Carefully remove metal particles, emery remains and cloths.
m

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- Set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly.
ion
c

- Fit new cylinder head gasket. Lettering (Part No.) must be readable.
in t
or

- Place cylinder head on. When doing this observe the centralizing pins in cylinder block.
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1.3 - Removing and installing cylinder head 65

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
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- Fit new cylinder head bolts and tighten hand tight.
- -> Tighten cylinder head in tightening sequence as follows:

rrectness of i
- Tighten all bolts to 30 Nm.
- Then tighten all bolts a 1/4 turn (90 °) further using a rigid wrench.
l purpos

- Then tighten all bolts again a 1/4 turn (90 °) further.

- Insert support element in cylinder head and fit roller rocker finger onto respective valve stem end and support
element.

nform
ercia

- Install camshaft housing,

m

=> Page 60 .

at
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The rest of the assembly is basically a reverse of the dismantling sequence.

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Filling with new coolant => Page 107 .

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66 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.4 - Checking compression pressures

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Special tools, workshop equipment, test and measuring appliances and auxiliary items required
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◆ 3122 B Spark plug spanner

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◆ V.A.G 1331 Torque wrench (5...50 Nm)

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◆ V.A.G 1763 Compression tester

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1.4 - Checking compression pressures
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
• Engine oil temperature must be at least 30 °C.

Work sequence

- -> Remove cover above camshaft housing -arrows-.

- Take off H.T. wiring with spark plug connectors first.
- Unscrew spark plugs with spark plug spanner 3122 B.

- -> Pull 4 pin connector off ignition transformer -arrow-.

- Use a second mechanic to fully depress accelerator pedal.
- Check compressions with compression tester V.A.G 1381 or V.A.G 1763.

Note:

See relevant test unit operating instructions for instructions on how to use test unit.
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- Operate starter until tester shows no further yV
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Compression pressure: utho
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New: 10...15 bar
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Wear limit: 7 bar

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Permissible difference between all cylinders: 3 bar

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68 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

2 - Servicing valve gear

2.1 - Servicing valve gear
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1 20 Nm + 1/4 turn (90 °) further

◆ Renew
◆ Use camshaft locking tool T 10016 to loosen and tighten=>Page 75 , Fig. 1
2 Camshaft sprocket
◆ Note position when installing the toothed belt
=> Page 24
3 Oil seal
◆ Only replace with camshaft installed
◆ Lightly oil sealing lip of oil seal
◆ Renewing=> Page 79
4 Coupling drive toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing and installing
=> Page 24

2.1 - Servicing valve gear 69

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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5 Camshaft housing
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◆ Removing and installing Cop py
=> Page 60
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◆ Remove sealant remnants cop Vo
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◆ Coat with AMV 188 003 before fitting cted agen
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◆ When installing fit vertically from above onto studs and dowel pins
6 10 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Tighten from centre outwards
7 Sealing cap/ignition transformer retainer
8 10 Nm
9 Roller rocker finger
◆ Check roller bearing
◆ Oil contact surface
◆ Use securing clip to clip onto support element when installing

70 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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12 20 Nm
13 Lifting eye
14 Non-return valve, 6 Nm
◆ Do not overtighten, otherwise the valve can stick
◆ Clean threads and insert with
D 154 102 A1
15 Support element
◆ Check oil spray drillings
◆ With hydraulic valve clearance compensation
◆ Do not interchange
◆ Before installing check camshaft axial clearance => Page 76 , Fig. 3
◆ Oil contact surface

2.1 - Servicing valve gear 71

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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16 Upper valve spring plate

17 Valve spring
◆ Removing and installing:
Cylinder head
removed: with valve spring compressor 3362
installed: => Page 83 , Renewing valve stem seals
18 Valve stem seal
◆ Renewing=> Page 83
19 Service part - valve guide
◆ With collar
20 Valve guide
◆ Checking => Page 81
21 Valves
◆ Do not rework only grinding-in is permitted
◆ Valve dimensions => Fig. 5

72 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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22 Cylinder head
ss

◆ Reworking valve seats

o
cial p

f i

=> Page 77
nform

◆ Reworking sealing surface

mer

=> Fig. 2
atio
om

23 20 Nm
c

i
or

n thi

24 Tensioner
te

sd
va

◆ Checking => Page 30

i

o
pr

cum
r
fo

◆ Tensioning toothed belts

en
ng

t.
=> Page 24 op
yi Co
py
25 Sealing plug, 45 Nm
. C rig
ht ht
rig by
◆ Insert with D 154 102 A1 copy Vo
by lksw
◆ Must not be screwed in too far cted agen
Prote AG.
◆ Maximum permitted insertion depth from top of plug to camshaft housing surface = 2 mm

2.1 - Servicing valve gear 73

 Polo Estate 1998 ➤
n AG. Volkswagen AG do
4-Cyl. injection engine (4 valve), Mechanics - Editionlkswage
11.1999 es n
o o t gu
yV
db ara
ir se nte
ho eo
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ss c

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e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

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f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

26 Camshafts
◆ Checking axial clearance => Fig. 3
◆ Coat with oil before inserting (also axle bearing shoulder)
◆ Identification and valve timing
=> Page 76 , Fig. 4
◆ After installing, replace seals
◆ Renewing seals=> Page 79
27 O-ring
◆ Renew
◆ Coat with oil before inserting

74 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
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un

pt
an
d
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ab
ility
ot p

-> Fig. 1 Locking both camshaft sprockets with camshaft locking tool T 10016

wit
is n

h re
- Guide both locking pins through camshaft sprocket locking pin holes onto stop in camshaft housing fitting
ole,

spec
holes.
urposes, in part or in wh

t to the co
Note:

Both locking pins are inserted correctly when the ends -D- align with line -A-.

rrectne
- Slide retainer -B- onto stop on inlet camshaft sprocket -C-.

ss
- When both camshaft sprockets are locked in the fitting holes the camshaft pulleys can be loosened or

o
cial p

f
tightened.

inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

-> Fig. 2 Reworking cylinder head sealing surface

Cylinder head reworking dimension:

a = At least 108.25 mm

2.1 - Servicing valve gear 75

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
-> Fig. 3 Checking camshaft axial clearance

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ VW 387 Universal dial gauge bracket

◆ Dial gauge

Perform measurements with camshaft housing removed and sealing cover fitted.

Wear limit: max. 0.40 mm

-> Fig.4 Camshaft identification, valve timing

Identification between cam pairs

Cyl. 1 & 2 n AG. Volkswagen AG do
wage
Inlet shaft -E- "036AC" y Vo lks es n
ot g
b ua
Exhaust shaft -A- "036AA"o
ir se
d ran
te
th eo
au ra
c
Valve timing at 1 mm valve lift ss ce
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un

pt
an
d
itte

Inlet opens after TDC 19.1 °

y li
rm

ab

Inlet closes after BDC 15.1 °

pe

ility
ot

wit

Exhaust opens before BDC 20.2 °

, is n

h re

Exhaust closes before TDC 15.3 °

hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

76 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
-> Fig. 5 Valve dimensions

Note:
Valves must not be reworked. Only lapping-in is permitted.

Dimension Inlet valve Exhaust valve

øa mm 29.5 26.0
øb mm 5.973 5.953
c mm 100.9 100.5
α <° 45 45

2.2 - Reworking valve seats

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Depth gauge
◆ Valve seat refacing tool

Notes:
◆ When repairing engines with leaking valves, it is not sufficient to replace or renew valve seats and valves.
It is also necessary to check the valve guides for wear. This particularly important on high mileage engines
=> Page 81 . n AG. Volkswagen AG do
lkswage es n
◆ The valve seats should only be reworked by Vjust enough to produce a perfect
o ot g seating pattern. The maximum
ua
permissible reworking dimension must o
ir se be calculated before reworking commences.
d ran
tee If the reworking dimen‐
sion is exceeded, the function ofathe
uth hydraulic tappets can no longer be guaranteed or and the cylinder head
ac
should be renewed. ss

ce
le
un

pt
The max. permissible reworking dimension is calculated as follows:
an
d
itte

y li
erm

ab
- Insert valve and press firmly against seat.
ility
ot p

wit
is n

Note: h re
ole,

spec
urposes, in part or in wh

If the valve is to be renewed as part of a repair, use a new valve for the calculation.
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
- -> Measure distance between end of valve stem and upper edge of cylinder head. . Cop py
- Calculate max. permissible reworking dimension from measured distance and minimum dimension.
t rig
gh ht
pyri by
Vo
co lksw
by
Minimum dimension:
cted agen
Prote AG.
Inlet valve 7.6 mm
Exhaust valve 7.6 mm

Measured distance minus minimum dimension

2.1 - Servicing valve gear 77

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
= max. permissible reworking dimension.

Example:

- Measured distance 8.0 mm

Minimum dimension 7.6 mm
= max. perm. rework dimension* 0.4 mm
AG. Volkswagen AG d
agen oes
ksw not
*) The max. permissible reworking dimension
by Vol
is shown on illustrations forgureworking
ara
valve seats as
dimension "b". rise
d
nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
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wit
is n

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spec
urposes, in part or in wh

t to the co
rrectness o
-> Reworking inlet valve seat
cial p

f inform
mer

a = 28.7 mm ø

atio
m

b = Max. permissible reworking dimension*

o

n
c

c = 1.5...1.8 mm

i
or

n thi
Z = Cylinder head lower edge
te

sd
a

α = 45 °valve seat angle

iv

o
pr

β = 30 °upper correction angle cum

r
fo

en
ng

γ = 60 °lower correction angle

t.
yi Co
Cop py
t. rig
gh
Reworking exhaust valve seat
ht
pyri by
Vo
co lksw
by
cted agen
Prote
a = ø25.0 mm
AG.

b = Max. permissible reworking dimension*

c = approx. 1.8 mm
Z = Cylinder head lower edge
α = 45 °valve seat angle
β = 30 °upper correction angle
γ = 60 °lower correction angle

*) Calculating max. permissible reworking dimension => Page 77 .

78 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

2.3 - Replacing camshaft oil seals

AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
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nl

pt
du

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itte

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erm

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ility
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wit
, is n

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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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n in
or c

thi
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sd
iva

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cu
o

Special tools, workshop equipment, test and measuring appliances and auxiliary items required
f

en
ng

t.
yi Co
Cop py
◆ T 10015 Puller
t. rig
gh ht
yri
◆ T 10018 Seal extractor p by
co Vo
lksw
◆ T 10016 Camshaft locking device
by
cted agen
Prote
◆ V.A.G 1331 Torque wrench (5...50 Nm)
AG.

Removing

- First remove both toothed belts

=> Page 24 .
- Turn crankshaft back slightly.

Note:

The camshaft sprockets must be locked into the camshaft housing fitting holes by bolt pins of locking device T
10016.

- Remove camshaft sprockets. Hold camshaft sprockets with locking device T 100 16 to loosen bolts.

2.3 - Replacing camshaft oil seals 79

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

- Unscrew inner part of oil seal extractor T 10018 two turns (approx. 3 mm) out of the outer part and lock in
position with knurled screw. AG. Volkswagen AG d
swagen oes
k not
- Oil threaded head of oil seal extractor. by
Vol gu
ara
- -> Screw puller T 10018 forcibly as far as possible
rised
into oil seal. nte
- Loosen knurled screw and turn inner part au
t of extractor against camshaft until oil seal has
ho e o been extracted.
ra
ss c

ce
Installing
e
nl

pt
du

an
itte

y li
- Lightly oil sealing lip of oil seal.
erm

ab
ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

at
om

- -> Place the guide sleeve T 10015/2 onto the camshaft journal. ion
c

in t
or

- Slide oil seal over the guide sleeve.

his
ate

- Press oil seal in onto stop with press sleeve T 10015/1 and bolt T 10015/3.
do
priv

- Fit camshaft sprockets.

um
for

en
ng

t.
yi Co
Note: Cop py
t. rig
gh ht
yri by
Observe position of camshaft sprockets to camshaft keyways.
op Vo
by c lksw
cted agen
Prote AG.
- Hold the respective camshaft sprocket with locking device T 10016 and tighten new bolts to
20 Nm
and then turn bolt
1/4 turn (90°) further.

When installing toothed belt => Page 24 .

The rest of the assembly is basically a reverse of the dismantling sequence.

80 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

2.4 - Checking valve guides

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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un

pt
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d
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ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

rrectne
◆ VW 387 Universal dial gauge bracket
◆ Dial gauge

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Test sequence

- -> Insert new valve into guide until end of valve stem is flush with end of guide. Due to the slight difference
in stem dimensions, ensure that only an inlet valve is used in the inlet guide and an exhaust valve in the
exhaust guide.
- Determine rock.
Wear limit: 0.8 mm

2.5 - Renewing valve guides

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ 3360 Driver
◆ 3363 Hand reamer and cutting fluid

Removing

- First check whether the valve seat insert rings and if necessary the cylinder head sealing surface can be
reworked. If this is not the case then the valve guide should not be replaced.
- Press the worn valve guides out with drift 3360 from the camshaft side.

2.4 - Checking valve guides 81

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Note:

If repair version guides are already fitted in the cylinder head, these must be pressed out from the combustion
chamber side. To do this the cylinder head can be supported on the valve spring seats with sleeve VW 421
and press piece VW 447h.

Installing

- Coat the new valve guides with oil and press with drift 3360 into cold cylinder head from the camshaft side
until the shoulder makes contact.

Note:

When the shoulder on guide makes contact, the pressure must not exceed 1.0 t otherwise shoulder may break
off.

- Ream guides out with hand reamer 3363 using plenty of cutting fluid.
- Rework valve seats => Page 77 .

2.6 - Renewing valve stem seals

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un

pt
an
d
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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

82 15 - Cylinder head, Valve gear

op Vo
by c lksw
cted agen
Prote AG.
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

Special tools, workshop equipment, test and measuring appliances and auxiliary items required
◆ 3122B Spark plug spanner
◆ 3362 Valve spring compressor with 3362/1 press piece
◆ 3364 Puller
◆ 3365 Fitting tool
◆ VW 653/3 Pressure hose

Removing
(with cylinder head fitted)
- First remove main drive toothed belts
=> Page 24 .
- Then remove camshaft housing
=> Page 60 .

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
e
nl

pt
du

an
itte

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erm

ab
ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
- Remove roller rocker arms and place onto a clean surface. Ensure that roller rocker arms are not inter‐
changed.
- Remove spark plugs with spark plug spanner 3122B.

rrectness of i
- Set piston of appropriate cylinder to "bottom dead centre".
l purpos

- -> Mount fitting tool 3362 with press piece 3362/1.

- Screw pressure hose VW 653/3 into the spark plug thread.
- Connect pressure hose to compressed air system supplying nf
ercia

at least 6 bar
orm

and remove valve springs.

m

atio
m

- Pull off valve stem seals with puller 3364.

o

n in
or c

thi
e

Installing
t

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.

2.6 - Renewing valve stem seals 83

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- -> Place the plastic sleeve supplied on the appropriate valve stem. This will prevent the new valve stem seal
being damaged.
- Place new valve stem seal in fitting tool 3365.
- Oil valve stem seal sealing lip and press carefully onto the valve guide.

Installing camshaft housing => Page 60 .

- Install toothed belt and tension => Page 24 .

AG. Volkswagen AG d
agen oes
The rest of the assembly is basically a reverse of the dismantling
yV
osequence.
lksw not
gu
b ara
ed nte
oris eo
th
au ra
c
ss

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

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
o
by c lksw
cted agen
Prote AG.

84 15 - Cylinder head, Valve gear

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

17 - Lubrication

1 - Removing and installing parts of the lubrication system

1.1 - Removing and installing parts of the lubrication system

Note:
The oil level must not be above the max. mark - danger of damaging catalyst!
Marks => Page 90 , Fig. 1 .
n AG. Volkswagen AG do
Checking oil pressure => Page l95 kswage es n
o ot g
Oil system capacity1): d byV ua
ran
ir se
with oil filter 3.2 ltr. tho tee
or
u
1) Up-to-date figures:ss
a ac
=> Exhaust emissions test binder

ce
e
nl

pt
du

Engine oil specifications:

an
itte

y li
Use engine oil to VW standard 500 00, 501 01 or 502 00. Only in exceptional cases: Multi-grade oils corre‐
erm

ab
ility
sponding to API-SF or SG.
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.1 - Removing and installing parts of the lubrication system 85

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
1 0.3...0.7 bar oil pressure switch (F1),
25 Nm
◆ Checking => Page 95
◆ If sealing ring is leaking nip open and replace.
2 10 Nm
3 Oil separator
4 To air cleaner
5 Cap
◆ Renew seal if damaged
6 Dipstick
◆ The oil level must not be above the max. mark!
◆ Markings => Fig. 1
7 Guide
◆ Pull off to extract oil

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

8 Guide tube
9 Main drive toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Toothed belt routing
=> Page 21 , Fig. 1
◆ Removing, installing and tensioning

86 17 - Lubrication
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
=> Page 24
10 Idler roller
11 Oil filter
◆ Loosen at hexagon bolt head
◆ Tighten by hand
◆ Observe installation instructions on oil filter
12 Oil pump
◆ Only renew complete
◆ When installing note follower on crankshaft
=> Page 89 , item 29
◆ Must be located on dowel sleeves
◆ Removing and installing
=> Page 92

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
ss c
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un

pt
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d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

13 12 Nm
◆ Renew
ss o

14 Toothed belt guard - upper part

cial p

f inform

15 Toothed belt guard - lower part

mer

atio

16 90 Nm + 1/4 turn (90 °) further

om

n
c

◆ Renew
i
or

n thi

◆ Oil threads
te

sd
va

◆ The turning further can be done in several stages

i

o
pr

cum

◆ The turning further angle can be measured with a commercial protractor e.g. Hazet 6690
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht

87
py by
co Vo
1.1 - Removing and installing parts of the lubrication system
by lksw
cted agen
Prote AG.
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

17 Belt pulley
◆ When installing note fixing arrangement
◆ Removing and installing ribbed belt => Page 21

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

18 Crankshaft toothed belt sprocket

◆ When installing note fixing arrangement
19 Seal
◆ Renewing => Page 37
20 Gasket
◆ Renew
◆ Must be located on dowel sleeves
21 Gasket
◆ Renew
22 Suction pipe
◆ Clean strainer if soiled
23 20 Nm
24 Tensioner
◆ Tensioning toothed belts
=> Page 24

88 17 - Lubrication
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

25 Sump
f

en
ng

t.
yi Co
◆ Removing and installing Cop py
=> Page 90
t. rig
gh ht
yri by
◆ Clean sealing surface before installing cop Vo
by lksw
◆ Install with silicone sealant cted agen
Prote AG.
D 176 404 A2
=> Page 90
26 Oil drain plug, 30 Nm
◆ With attached seal
◆ Renew
27 Cable guide
28 15 Nm
◆ Loosen and tighten only bolts on flywheel end with socket insert T10058
29 Driver
◆ Coat with oil before installing oil pump
30 O-ring
◆ Renew

1.1 - Removing and installing parts of the lubrication system 89

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

-> Fig. 1 Markings on oil dipstick

G. Volkswagen
1- max. mark ksw
agen
A AG do
es n
2- min. mark y Vol ot g
ua
d b
a- Area above hatched field up to max.ormark:ise Do not replenish with engine oil! rante
b- Oil level within hatched field: can abe
ut replenished with engine oil
h eo
ra
c- Area from min. mark up to hatched ss field: replenish with max. 0.5 ltr. of engine oil! c

ce
e
nl

pt
du

an
itte

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erm

ab
1.2 - Removing and installing oil sump

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
do
priv

cum
for

en
g

◆ T10058 Key
n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.

◆ V.A.G 1331 Torque wrench (5...50 Nm)

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

90 17 - Lubrication
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Work sequence
- Drain engine oil.
- Remove cable guide from sump.
- Unbolt right-hand drive shaft at gearbox.

=> Running gear; Repair group 40; Servicing front suspension; Removing and installing wheel bearing, sus‐
pension strut and drive shaft Servicing front suspension Removing and installing wheel bearing, suspension
strut and drive shaft
- Remove bolt from front wishbone mounting.

=> Running gear; Repair group 40; Servicing front suspension; Removing and installing wheel bearing, sus‐
pension strut and drive shaft Servicing front suspension Removing and installing wheel bearing, suspension
strut and drive shaft
- 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.

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- -> Remove sealant residue on the sump with a rotating brush, e.g. a hand drill with a plastic brush (wear
es, in part or in w

t to the co
eye protection).
- Clean sealing surface, must be free of oil and grease.

Installing rrectness of i
l purpos

Notes:
◆ Note the use by date of the sealant.
nform
ercia

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

◆ Sump can be offered up easier and with greater security if, for guide purposes, M6 studs are inserted into
m

at
om

the cylinder block flange at two positions.

on
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for

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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.

1.2 - Removing and installing oil sump 91

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- and run on inside of bolt holes -arrows-.

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

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es, in part or in w

t to the co
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c

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Cop py
.
Special tools, workshop equipment, test and measuring appliances and auxiliary items required
t rig
gh ht
pyri by
Vo
co lksw
by
◆ T10022 Sleeve cted agen
Prote AG.
◆ 3083 Oil seal fitting tool

92 17 - Lubrication
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
◆ V.A.G 1331 Torque wrench (5...50 Nm)

AG. Volkswagen AG d
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Removing
un

pt
an
d
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- Remove main drive toothed belt => Page 24 ; Removing, installing and tensioning toothed belt.
rm

ab
pe

ility
- -> Secure crankshaft toothed belt -1- to crankshaft with old securing bolt -2-.
ot

- Position crankshaft at TDC No. 1 cylinder:

wit
, is n

h re
hole

spec
The tooth ground down on the toothed belt sprocket must align with mark on the oil pump -arrow-.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
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tion in
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- -> Turn crankshaft/toothed belt sprocket three teeth anti-clockwise away from TDC:
n

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Cop py
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The third tooth -arrow- to the right of the tooth ground down -A- on the toothed belt sprocket must align with
ht
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TDC mark on the oil pump housing. by c lksw
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Prote AG.

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 main drive tensioning roller.

- Remove sump => Page 90 .
- Remove suction pipe => Page 88 , item 22 .
- Remove crankshaft toothed belt sprocket.
- Remove oil pump.
- Remove gasket.
- Remove sealant remnants on cylinder block with a flat scraper.
- Clean sealing surfaces, they must be oil and grease free.

1.3 - Removing and installing oil pump 93

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

Installing
Conditions
• -> One of the polygon cams -arrow- on the crankshaft is uppermost.

AG. Volkswagen AG d
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Work sequence by Vol
gu
ara
d
ise nte
- -> Fit sleeve T10022 and hexagon thor
socket head bolt from 3083 onto crankshaft e o and tighten hand tight.
- Fit new gasket onto guide pins
ss a -A-.
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c
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ot

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

- -> Position one of the oil pump inner rotor markings arrow -A- on installation position mark arrow -B- on oil
nform
ercia

pump housing cover.

- Coat the four crankshaft polygon cams with oil.
m

a
com

ti

- Lightly oil sealing lip of oil pump oil seal.

on in

- Guide oil pump carefully onto crankshaft polygon cams.

r
te o

thi

- Align inner rotor to crankshaft polygon cams by turning slightly if necessary.

s
iva

do

- Then slide oil pump carefully onto guide pins.

r
rp

cum

- Secure oil pump with new bolts.

fo

en
ng

Tightening torque: 12 Nm
t.
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op
- Remove sleeve T10022. C py
t. rig
- Install suction pipe => Page 88 , item 22 .
gh ht
pyri by
- Install sump => Page 90 .
co Vo
by lksw
cted agen
Prote AG.

94 17 - Lubrication
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- Install main drive tensioning roller, install toothed belt and tension => Page 24 , Removing, installing and
tensioning toothed belt.

1.4 - Checking oil pressure and oil pressure switch

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Special tools, workshop equipment, test and measuring appliances and auxiliary items required
h re
hole

spec
es, in part or in w

◆ V.A.G 1342 Oil pressure tester

t to the co

◆ V.A.G 1527 B Diode test lamp

◆ V.A.G 1594 A Adapter set
rrectness of i

Note:
l purpos

Functional check and servicing the optical and acoustic oil pressure warning:
nf
ercia

=> Current flow diagrams, Electrical fault finding and Fitting locations binder
orm
m

atio
om

n in
or c

thi
te

sd
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o
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rp

cu
o

m
f

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Cop py
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rig ht
py by

95
co Vo
by lksw
cted 1.3 - Removing and installing oil pump
agen
Prote AG.
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Test sequence

AG. Volkswagen AG d
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olksw not
V gu
d by ara
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- -> Remove oil pressure switch (F1) and screw
s aut into tester. ra
c
- Screw tester into the cylinder head in place
s of the oil pressure switch.

ce
e

- Connect brown wire of tester to earth (-).

nl

pt
du

an
- Connect diode test lamp V.A.G 1527 B using aux. cables from V.A.G 1594 A to battery positive (+) and oil
itte

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pressure switch.
erm

ab
- If the LED lights up, renew oil pressure switch (F1) .

ility
ot p

wit
, is n

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If the LED does not light up:
hole

spec
es, in part or in w

- Start engine and increase speed slowly.

t to the co
At
0.3...0.7 bar
the LED must light up, otherwise renew oil pressure switch.

rrectness of i
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.
l purpos

At higher engine speed the oil pressure must not exceed 7.0 bar.

nform
mercia

at
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for

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96 17 - Lubrication
 AG. Volkswagen AG d
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y V gu
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thor Polo Estate 1998
eo ➤
u ra
4-Cyl. injectionss aengine (4 valve), Mechanics - Edition 11.1999 c

ce
e
nl
19 - Cooling system

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ility
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1 - Removing and installing parts of cooling system

es, in part or in w

t to the co
1.1 - Removing and installing parts of cooling system

rrectness of i
l purpos
Notes:

◆ When the engine is warm the cooling system is under pressure. If necessary release pressure before com‐

nform
ercia

mencing repair work.

◆ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
m

at
om

i
◆ For fitting the spring-type clips, assembly tool VAS 5024 is recommended.

on
c

in t
or

his
e

Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/3 and
at

do
riv

V.A.G 1274/4.
p

cum
for

en
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t.
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Parts of cooling system body side =>Page 98 .
Co
Cop py
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Parts of cooling system engine side => 101 . p by
co Vo
by lksw
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Coolant hose connection diagram =>Page 106 .

Draining and filling with coolant=> Page 107 .

Coolant mixture ratios => Page 107 , draining and filling with coolant

1.1 - Removing and installing parts of cooling system 97

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.2 - Parts of cooling system body side

AG. Volkswagen AG d
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urposes, in part or in wh

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cial p

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mer

1 Clamp
atio
m

2 Radiator
o

n
c

i
or

◆ Removing and installing

thi
e

=>Page 109
t

sd
iva

◆ After replacing renew entire coolant

pr

cum
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3 8 Nm
en
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4 Lock carrier Cop py
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5 Radiator fan pyri by
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6 Additional fan Prote
cted AG.
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◆ Only with optional extras

7 Series resistance
◆ Only with optional extras
8 Double fan ring
◆ Only with optional extras

98 19 - Cooling system
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

n AG. Volkswagen AG do
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rrectness of i
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orm
m

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9 Connector
◆ For radiator fan
10 Cover
11 Expansion tank
12 To thermostat housing
◆ Coolant hose connection diagram =>Page 106
13 Cap
◆ Check with V.A.G 1274 and 1274/4
◆ Test pressure 1.4...1.6 bar
14 To thermostat housing
◆ Coolant hose connection diagram =>Page 106
15 Connector
◆ For radiator fan thermo-switch (F18)

1.2 - Parts of cooling system body side 99

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
V gu
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h
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hole

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es, in part or in w

16 Thermo-switch (F18), 35 Nm
t to the co

◆ For electric fan

◆ Switching temperatures:
rrectness of i

Stage 1
on: 92...97 °C
l purpos

off: 84...91 °C
Stage 2
on: 99...105 °C
nform
ercia

off: 91...98 °C
m

17 Lower coolant hose

com

tion in

◆ Coolant hose connection diagram =>Page 106

r
te o

thi

18 Rubber washer
s
iva

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19 Upper coolant hose

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◆ Coolant hose connection diagram =>Page 106

en
ng

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20 Air ducting Cop py
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pyri by
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by c lksw
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Prote AG.

100 19 - Cooling system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.3 - Parts of cooling system engine side

AG. Volkswagen AG d
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es, in part or in w

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l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

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t.
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Cop py
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by c lksw
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Prote AG.

Thermostat side

1 Retainer
◆ For connectors
2 Self-tapping bolt
3 From bottom of radiator
◆ Coolant hose connection diagram =>Page 106
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 101

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

n AG. Volkswagen AG do
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7 To top of expansion tank

h re
hole

spec
8 To heat exchanger
es, in part or in w

9 From expansion tank or ATF cooler

10 Retaining clip t to the co
11 From heat exchanger
rrectness of i

12 Coolant pump housing on cylinder block

l purpos

13 Seal
◆ Renew
nform
ercia

14 Coolant pipe
15 Thermostat housing
m

a
com

tio

16 10 Nm
n in
r
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cum
fo

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t.
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Cop py
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pyri by
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by
cted agen
Prote AG.

102 19 - Cooling system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
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ility
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spec
es, in part or in w

t to the co
17 Sealing plug/connection for ATF cooler
18 Coolant temperature sender (G62)
◆ With coolant temperature gauge sender (G2) rrectness of i
19 To top of radiator
l purpos

◆ Coolant hose connection diagram =>Page 106

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
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o

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t.
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Cop py
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rig ht
py by
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by lksw
cted agen
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1.3 - Parts of cooling system engine side 103

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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an
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rm

ab
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ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

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ng

t.
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Cop py
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Coolant pump side rig ht
py by
co Vo
by lksw
cted agen
1 Main drive toothed belt Prote AG.

◆ Mark D.O.R. before removing

◆ Check for wear
◆ Do not kink
◆ Toothed belt routing => Page 21 , Fig. 1
◆ Removing, installing and tensioning
=> Page 24
2 Coolant pump
◆ Check for ease of movement
◆ If damaged or leaking renew complete
◆ Removing and installing
=> Page 111
3 10 Nm
4 Rear toothed belt guard
5 Toothed belt guard - upper part
6 Toothed belt guard - lower part

104 19 - Cooling system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

7 Belt pulley
◆ When installing note fixing arrangement
◆ Removing and installing ribbed belt => Page 21
8 90 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Oil threads
◆ The turning further can be done in several stages
◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690
9 12 Nm
◆ Renew
10 20 Nm
11 Crankshaft toothed belt sprocket
◆ When installing note fixing arrangement

1.3 - Parts of cooling system engine side 105

 Polo Estate 1998 ➤AG. Volkswagen A
4-Cyl. injection agen G do
ksw engine (4 valve), Mechanics
es n - Edition 11.1999
Vol ot gu
by ara
ed
1.4 - Coolantthohose
ris connection diagram nte
eo
au ra
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
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

106 19 - Cooling system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.5 - Draining and filling cooling system

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c

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ility
ot

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es, in part or in w

t to the co
◆ V.A.G 1306 Drip tray

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
◆ VAS 5024 Assembly tool for spring-type clips
py by
co Vo
by lksw
◆ Anti-freeze tester
Prote
cted AG.
agen

Draining
- Remove cap from coolant expansion tank.
- Drain coolant from bottom radiator hose.

Note:
Observe disposal regulations!
Filling
Notes:
◆ Only use coolant additive G 12 in accordance with TL VW 774 F.
Distinguishing feature: coloured violet
◆ G 12 violet (in accordance with TL VW 774 F) can be mixed with the previous coolant additive G 12 red!
◆ G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage,
scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with
frost and corrosion protection additives.

◆ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in
countries with tropical climates.
◆ 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 107

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
◆ If radiator, heat exchanger, cylinder head or cylinder head gasketn AisGreplaced,
. Volkswagendo
A
not reuse old coolant.
age G do
ksw es n
Vol ot g
Recommended mixture ratios: ed
by ua
ran
oris tee
th or
Frost pro- tection Anti-freeze amount G 121) Water1) au ac
ss
to

ce
le
un

pt
-25 °C 40 % 2.25 l 3.35 l

an
d
itte

y li
-35 °C 50 % 2.8 l 2.8 l

rm

ab
pe

ility
ot
1) The quantity of coolant can vary depending upon the vehicle equipment.

wit
, is n

h re
hole

spec
With cooling system charging unit VAS 6096 es, in part or in w

t to the co
- Fill coolant circuit using cooling system charging unit VAS 6096.

=> Operating instructions for cooling system charging unit VAS 6096

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

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fo

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t.
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pyri by
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by c lksw
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Not using cooling system charging unit VAS 6096

- -> 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.

108 19 - Cooling system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.6 - Removing and installing radiator

n AG. Volkswagen AG do
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ility
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spec
es, in part or in w

t to the co
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nform
mercia

at
om

ion
c

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or

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ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Special tools, workshop equipment, test and measuring appliances and auxiliary items required
◆ V.A.G 1306 Drip tray
◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ VAS 5024 Assembly tool for spring-type clip
◆ Anti-freeze tester

Removing
- First remove radiator grille and trim.

=> General body repairs; Repair group 66; Trims; Removing and installing radiator grille and trim frame Trims
Removing and installing radiator grille and trim frame
Vehicles with air conditioning system:
- Observe additional information and removal work => Page 110 .

- Drain coolant => Page 107 .

- Pull coolant hoses off radiator.
- Pull connectors off thermo-switch.
- Remove radiator fan together with fan ring.

1.6 - Removing and installing radiator 109

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- Remove radiator securing bolts and take out radiator.

Installing

Installation is carried out in the reverse order, when doing this note the following:

- Filling with coolant => Page 107

- Electrical connections and routing:

=> Current flow diagrams, Electrical fault finding and Fitting locations

Additional information and removal work on vehicles with air conditioner

Warning!
The air conditioning system refrigerant circuit must not be opened.

Note: AG. Volkswagen AG d

agen oes
olksw not
To prevent damage to condenser by and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
V gu
d ara
e
not stretched, kinked or tbent.
ho
ris nte
eo
au ra
c
ss
- Removing lock carrier with attachments:
ce
le
un

pt
an
d
itte

=> General body repairs; Repair group 50; Lock carrier; Removing and installing lock carrier with grille Lock y li
rm

carrier Removing and installing lock carrier with grille ab

pe

ility
ot

wit
, is n

- Remove retaining clamp(s) from refrigerant pipes.

h re

- Unbolt condenser from radiator and secure to lock carrier.

hole

spec

- Secure condenser to body so that refrigerant pipes/hoses are not stressed.

es, in part or in w

t to the co

- Unbolt air conditioner fluid reservoir and allow to hang free.

- Remove radiator securing bolts.
- Pull radiator out carefully.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

110 19 - Cooling system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.7 - Removing and installing coolant pump

AG. Volkswagen AG d
agen oes
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byV gu
ara
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ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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cu
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f

en
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Cop py
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rig ht
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by lksw
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Prote AG.

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

◆ V.A.G 1306 Drip tray

◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ VAS 5024 Assembly tool for spring-type clip
◆ Anti-freeze tester

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 107

- First remove main drive toothed belt
=> Page 24 .

1.7 - Removing and installing coolant pump 111

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl

pt
du

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itte

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ab
ility
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hole

- -> Remove idler roller -6- by removing idler roller bolt -5-.

spec
- Remove bolts -1- and -4- and remove rear toothed belt guard -2- and coolant pump -3-.
es, in part or in w

t to the co
Installing

rrectness of i
Installation is carried out in the reverse order, when doing this note the following:
l purpos

- Insert coolant pump -3- in cylinder block and install securing bolt -4- together with rear toothed belt guard.
- Tighten securing bolts -4- to 20 Nm and -1- to 10 Nm.

nform
ercia

- Install idler roller -6- and tighten securing bolt -5- to 50 Nm.
- Install toothed belt and tension => Page 24 .
m

at
- Install ribbed belt => Page 21 .
om

ion
- Filling with coolant => Page 107
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

112 19 - Cooling system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

20 - Fuel supply system

1 - Removing and installing parts of fuel supply system

1.1 - Removing and installing parts of fuel supply system

Notes:

◆ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
◆ Fuel hoses in engine compartment must only beswsecuredagen with
AG. V spring-type
olkswagen AG
does clips. The use of clamp or screw-
type clips is not permissible. by
Volk not
gu
◆ For fitting the spring-type clips, assembly
ris
edtool VAS 5024 is recommended. ara
nt ee
tho or
au ac
Observe safety precautions=> Page s 124
s .

ce
le
un

pt
Observe rules for cleanliness => Page 124 .

an
d
itte

y li
erm

ab
Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate => Page 114 .

ility
ot p

wit
is n

h re
Removing and installing fuel tank with its attachments, Caddy => Page 119 .
ole,

spec
urposes, in part or in wh

Observe crash fuel shut-off => Page 128 .

t to the co
Checking electronic power control (EPC) => Page 136 .

rrectne
Servicing parts of the activated charcoal filter system => Page 143 .

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.1 - Removing and installing parts of fuel supply system 113

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.2 - Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate

AG. Volkswagen AG d
agen oes
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ility
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spec

1 Cap
es, in part or in w

2 Retaining ring
t to the co

3 Tank flap unit

◆ Removing and installing
rrectness of i

=> General body repairs; Repair group 55; fuel flap unit fuel flap unit
l purpos

4 Gravity/overflow valve
nf
ercia

◆ To remove, release locking lug and unclip valve upwards out of filler neck
orm

◆ Check valve for through-flow

m

atio
m

valve vertical: open,

o

n in
c

valve tilted 90 °: closed

or

thi
te

5 Earth connection
sd
iva

o
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rp

cu
o

m
f

en
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

114 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
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nl

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du

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itte

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erm

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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

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m

atio
om

n in
or c

thi
te

sd
iva

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f

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t.
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Cop py
ht. rig
rig ht
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by lksw
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6 10 Nm
7 Return pipe
◆ Blue
◆ From fuel manifold

=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail with injectors Servicing
injection system Dismantling and assembling fuel rail with injectors

8 Union nut
◆ Remove and install with spanner 3217
9 Fuel delivery unit
◆ Removing and installing
=> Page 125
◆ Checking fuel pump
=> Page 129
◆ Note fitting location on fuel tank
=> Page 124 , Fig. 1

1.2 - Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate

115
 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Polo Estate 1998 ➤ orise nte
e
h
4-Cyl. injection engines a(4 valve), Mechanics - Edition 11.1999 or ac
ut
s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
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10 Fuel gauge sender

◆ Removing and installing
=> Page 126
◆ Adjusting:

=> 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)

11 Sealing ring
◆ Renew if damaged
◆ Coat with fuel when installing
12 Fuel filter
◆ Fitting position: Arrow points in direction of flow
13 Supply pipe
◆ Black
◆ To fuel manifold

=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail with injectors Servicing
injection system Dismantling and assembling fuel rail with injectors

116 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

n AG. Volkswagen AG do
lkswage es n
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ility
ot p

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f i

14 3 Nm
nform
mer

15 Fuel tank
atio
m

◆ Removing and installing

o

n
c

=> Page 126

i
or

n thi

◆ Press clamping washer from heat shield tightly onto pins on vehicle floor
te

sd
iva

16 25 Nm
o
pr

cum
r
fo

17 Securing strap
en
ng

t.
yi Co
18 Vent pipe t. Cop py
rig
◆ To activated charcoal filter
gh ht
pyri by
=> Page 143 , item 1
co Vo
by lksw
cted agen
19 Sealing boot
Prote AG.

◆ After installing filler pipes fit over fuel tank connections, having turned boot inside out
20 Filler pipes
◆ With non-return valve

1.2 - Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate

117
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
21 Vent valve
or

n thi
te

sd
◆ Checking =>Page 124 , Fig. 2
iva

o
r

◆ To remove pull locking latch lightly to inside -arrow- and pull valve out
p

cum
r
fo

en

22 O-ring
ng

t.
yi Co
op
◆ Renew if damaged C py
t. rig
gh
23 Cup
ht
pyri by
Vo
o
by c lksw
◆ For filler pipes Prote
cted AG.
agen

118 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.3 - Removing and installing fuel tank with its attachments, Caddy

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt

1 Cap
an
d
itte

y li

2 Retaining ring
rm

ab
pe

3 Tank flap unit

ility
ot

wit

◆ Removing and installing

, is n

h re
hole

spec

=> General body repairs; Repair group 55; fuel flap unit fuel flap unit
es, in part or in w

t to the co

4 Vent pipe
5 Gravity/overflow valve
rrectness of i

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

valve vertical: open,

valve tilted 90 °: closed
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

119
Prote AG.
1.3 - Removing and installing fuel tank with its attachments, Caddy
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

6 Earth connection
nf
ercia

7 10 Nm
orm
m

8 Return pipe
atio
om

◆ Blue
n in
or c

◆ From fuel manifold

thi
te

sd
iva

o
r
rp

cu

=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail with injectors Servicing
o

m
f

injection system Dismantling and assembling fuel rail with injectors

en
ng

t.
yi Co
Cop py
. rig
9 Union nut
ht ht
rig by
py
◆ Remove and install with ring nut spanner 3217
co Vo
by lksw
cted agen
10 Fuel delivery unit
Prote AG.

◆ Removing and installing

=> Page 125
◆ Checking fuel pump
=> Page 129
◆ Note fitting position on fuel tank => Fig. 1

120 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

11 Fuel gauge sender

nf
ercia

or

◆ Removing and installing

m
m

atio

=> Page 126

om

n in

◆ Adjusting:
or c

thi
te

sd
iva

=> Electrical system self-diagnosis; Repair group 01; Self-diagnosis for dash panel insert; Checking fuel gauge
o
r
rp

cu

(adapting) Self-diagnosis for dash panel insert Checking fuel gauge (adapting)
o

m
f

en
ng

t.
yi Co
op
12 Sealing ring C py
ht. rig
ht
◆ Renew if damaged
rig by
opy Vo
◆ Coat with fuel when installing by c lksw
cted agen
Prote AG.
13 Fuel filter
◆ Fitting position: Arrow points in direction of flow
14 Supply pipe
◆ Black
◆ To fuel manifold

=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail with injectors Servicing
injection system Dismantling and assembling fuel rail with injectors

1.3 - Removing and installing fuel tank with its attachments, Caddy 121
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

15 3 Nm

spec
urposes, in part or in wh

16 Fuel tank

t to the co
◆ Removing and installing
=> Page 126
17 Heat shield
◆ Press clamping washer from heat shield tightly onto pins on vehicle floor rrectne

18 25 Nm
ss o

19 Vent pipe
cial p

f inform

◆ To activated charcoal filter

mer

=> Page 143 , item 1

atio
m

20 Sealing boot
o

n
c

i
or

◆ After installing filler pipes fit over fuel tank connections, having turned boot inside out
thi
te

sd
a

21 Filler pipes
iv

o
pr

cum
r

◆ With non-return valve

fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

122 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

22 Vent valve
thi
te

sd
a

◆ Checking =>Fig. 2
iv

o
pr

◆ To remove pull locking latch lightly to inside -arrow- and pull valve out
um
r
fo

en
ng

23 O-ring
t.
yi Co
op py
◆ Renew if damaged t. C rig
gh ht
yri
24 Cup
p by
o Vo
by c lksw
cted
◆ For filler pipes
agen
Prote AG.

1.3 - Removing and installing fuel tank with its attachments, Caddy 123
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
-> Fig. 1 Installation position of fuel delivery unit flange

Marking -2- on the flange must align with marking -1- on the fuel tank.

n AG. Volkswagen AG do
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d ran
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ab
ility
ot p

wit
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-> Fig. 2 Checking vent valve
hole

spec
es, in part or in w

t to the co
Lever in rest position: Closed

Lever pushed in direction of arrow: Open

rrectness of i
l purpos

1.4 - Safety precautions when working on the fuel supply system

nf
ercia

orm
m

atio
om

n in
Warning!
or c

Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
thi
te

sd
a

tion. Then release pressure by carefully pulling hose off connection.

iv

o
r
rp

cu
o

m
f

en
ng

t.
yi
When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel
Co
op py
tank the following must be observed: t. C rig
gh ht
pyri by
Vo
co lksw
◆ Before commencing work, switch on exhaust extraction system and place an extraction hose close to the
by
cted agen
Prote
sender opening in the fuel tank to extract escaping fuel fumes.
AG.

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.

124 20 - Fuel supply system

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ho
ir se tee Polo Estate 1998 ➤
t
u 4-Cyl. injection engine (4 valve), Mechanics or
a ac - Edition 11.1999
ss

ce
le
1.6 - Removing and installing fuel delivery unit

un

pt
an
d
itte

y li
rm

ab
pe

ility
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
◆ 3217 Ring nut spanner

s
iva

do
r
rp

cum
Removing
fo

en
ng

t.
yi Co
op
- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
C py
t. rig
gh
- Note safety precautions before starting work => Page 124
ht
pyri by
- With ignition switched off disconnect battery earth strap.
co Vo
by lksw
cted agen
Prote AG.

Caddy Van:
- Lift front, right load area floor covering.
- Now remove the right-hand load area floor piece.

=> General body repairs; Repair group 70; Removing and installing load compartment floor panel (Caddy)
Removing and installing load compartment floor panel (Caddy)
- Remove floor cover.

Caddy Kombi, Polo Classic, Polo Estate:

- Fold rear seat forwards.
- Remove floor cover.

When the floor cover is removed:

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.

- -> Pull connector -1- and supply and return pipes -2, 3- off flange.
- Separate breather pipe -4- and supply pipe -5- at connections.

1.6 - Removing and installing fuel delivery unit 125

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- Fit spanner 3217 on the three rounded ribs on the union nut and unscrew union nut from flange.

- Pull fuel delivery unit and seal out of the opening in fuel tank.

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

Notes:
◆ 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 124 , Fig. 1 .

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=> Page 125 .
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- -> Release and pull off the terminals for wires -3- and -4-.
om

ion
- Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge sender off downwards -arrow-.
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ate

Installing
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- Insert fuel gauge sender in the guides on the fuel delivery unit and push up until it engages.
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1.8 - Removing and installing fuel tank
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Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

126 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
◆ V.A.G 1331 Torque wrench (5...50 Nm)

Removing

- Note safety precautions before starting work

=> Page 124
- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With ignition switched off disconnect battery earth strap.

Caddy Van:

- Lift front, right load area floor covering.

- Now remove the right-hand load area floor piece.
olksw
=> General body repairs; Repair group 70; Removing and installingwagload
en AGcompartment
.V agen AG
dfloor
oes panel (Caddy)
Removing and installing load compartment floor panel (Caddy)Volks not
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- Remove floor cover. tho e or
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Caddy Kombi, Polo Classic, Polo Estate:

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- Unscrew securing bolts and remove tank flap unit.
erm

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urposes, in part or in wh

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atio
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- Fold rear seat bench forwards.

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c

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or

n
- Remove floor cover.

thi
te

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When the floor cover is removed:

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t.
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- -> Pull connector -1- and return pipe -3- off flange.
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- Separate breather pipe -4- and supply pipe -5- at connections.
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- Drain fuel tank, clean fuel filler neck and surrounding area.
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- -> Remove support bracket -1- from body.

- Remove all rear exhaust system mountings from body. Then lower the exhaust system slightly and secure
to body with wire.
- Remove rear right wheel.
- Detach filler pipe from body.

1.8 - Removing and installing fuel tank 127

 A n AG d G. Volkswage
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Polo Estate 1998 ➤ o lksw
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4-Cyl. injection engine
ised (4
b valve), Mechanics - Edition a11.1999
ran
r tee
ho
ut or
- Take filler cap off filler neck
ss
a and detach filler neck from cup. ac

ce
e
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Polo Classic, Polo Estate:

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ab
- Remove gravity/overflow valve and secure together with breather pipe on fuel tank. Removing gravity/over‐

ility
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flow valve => Page 114 , item 4 .

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- Remove filler neck.

h re
- Remove tensioning strap. When doing this support fuel tank with engine/gearbox jack V.A.G 1383 A if
hole

spec
necessary.
es, in part or in w

- Now the fuel tank can be removed together with the heat shield.

t to the co
Caddy:

rrectness of i
- Remove shock absorber upper securing nut and push securing bolt out inwards approx. 2 cm (Do not remove
l purpos

shock absorber).
- 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

nf
ercia

tank through 90°).

orm
m

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

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◆ Breather and fuel hoses are to be installed kink-free.

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◆ Do not interchange supply and return hose (return hose blue or with blue markings, supply hose black).
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1.9 - Crash fuel shut-off
Prote AG.

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.

When opening the fuel system:

Observe safety precautions=> Page 124 .

- Check fuel pump relay:

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

128 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.10 - Checking fuel pump ksw

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Prote AG.

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

◆ 3217 Spanner for union nut

◆ V.A.G 1318 Pressure gauge
◆ V.A.G 1318/1 Adapter
◆ V.A.G1318/7 Adapter
◆ V.A.G 1318/11 Adapter
◆ V.A.G 1318/13 Adapter

1.10 - Checking fuel pump 129

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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◆ V.A.G1318/17 Adapter
◆ V.A.G 1332 Torque wrench (40...200 Nm)
rrectne

◆ V.A.G 1348/3 A Remote control

◆ V.A.G 1348/3-2 Adapter cable
ss

◆ V.A.G 1527 B Diode test lamp

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cial p

◆ V.A.G 1594 A Adapter set

inform
mer

atio
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◆ V.A.G 1715 Multimeter

◆ Measuring container
◆ Current flow diagram

130 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Test conditions

• Battery voltage at least 11.5 V

• -> Fuse No. 40 O.K.

Checking function and voltage supply

Note:
Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
must be disconnected. Obtain radio code first if necessary.
Caddy Van:

- Lift front right section of load area floor covering.

- Remove right-hand load compartment floor panel.
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=> General body repairs;
d by V Repair group 70; Removing and
ua installing
ran load compartment floor panel (Caddy)
Removing andhinstalling
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load compartment floor panel (Caddy) tee
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- Remove floor cover.
ss
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Caddy Kombi, Polo Classic, Polo Estate:

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- Fold rear seat forwards.

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- Remove floor cover.

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spec

When the floor cover is removed:

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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:

rrectness of i
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mercia

at
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- Switch off ignition.
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- Remove cover in front of fuse holder.
- Pull fuse No. 40 out of fuse holder.

1.10 - Checking fuel pump 131

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
- -> Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 at contact 40b to fuel pump
and battery positive (+).
- Operate remote control.

Fuel pump runs:

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- Check activation of fuel pump relay: d byV gu
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=> Current flow diagrams, Electrical fault finding and ut
Fittings alocations ra
s c

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Fuel pump does not run:

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- -> Pull 4-pin connector -1- off fuel tank flange -2-.
erm

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es, in part or in w

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c

- -> Connect diode test lamp V.A.G 1527 using adapter cables from V.A.G 1594 to the outer contacts of the
or

thi
connector.
te

sd
a

- Operate remote control.

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LED must light up
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LED does not light up: C py
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- Locate and eliminate open circuit using current flow diagram
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LED lights up (voltage supply OK.):

- 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.

If not open circuit can be found:

- Fuel pump defective, renew fuel delivery unit =>Page 125 , Removing and installing fuel delivery unit.

Checking delivery rate

Test conditions

• The voltage supply for the fuel pump OK.

132 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
• Remote control V.A.G 1348/3A is still connected.

Test sequence

- Remove filler cap from fuel tank filler neck.

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.

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- -> Pull fuel supply hose (white marking) off fuel supply pipe -1-.

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
3 bar.

rrectness of i
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
adapter cables from V.A.G 1594 to the vehicle battery.
nform
ercia

- Operate remote control for

30 seconds
m

a
com

and measure battery voltage

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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.

1.10 - Checking fuel pump 133

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
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 AG. Volkswagen G d
agen to fuel supplyApipe.
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- Repeat delivery rate check. by
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If the minimum delivery rate is now attained: auth or
ac
ss

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le

- Replace the fuel filter.

un

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If the minimum delivery rate is again not attained:
rm

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ot

- Remove the fuel delivery unit and check the strainer filter for soiling.

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hole

Only when up to now no fault has been detected:

spec
es, in part or in w

t to the co
- Fuel pump defective, renew fuel delivery unit =>Page 125 , Removing and installing fuel delivery unit.

If the delivery rate has been attained but nevertheless you suspect a fuel supply system fault (e.g. intermittent

rrectness of i
failure of fuel supply system):
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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cum
fo

en
ng

t.
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rig ht
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Prote AG.
- Check the current draw of the fuel pump as follows:
- Reconnect all disconnected fuel pipes.
- -> Connect the multimeter V.A.G 1715 using the current clamp to the red/yellow wire from wiring harness.
- Start the engine and run at idling speed.
- Measure the current draw of the fuel pump.
Specification: max. 8 amps.

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

- Fuel pump defective, renew fuel delivery unit =>Page 125 , Removing and installing fuel delivery unit.

134 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Checking fuel pump non-return valve

Test conditions

• Remote control V.A.G 1348/3A is still connected.

• Pressure gauge V.A.G 1318 is still connected.

Test sequence

Note:

With this check the fuel supply pipe connections from the fuel delivery unit to the point at which the pressure
gauge V.A.G 1318 is connected will be checked for leaks at the same time.

- Close pressure gauge cut-off tap (lever at right angle to direction of flow).
- Operate remote control at short intervals until a pressure of
3 bar
has built up.

Warning! wage
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- If pressure builds up too
s auhigh, lower excess pressure by carefully opening r a the
c shut-off tap.
- Watch pressure drop. sAfter 10 minutes the pressure must not drop below

ce
e

2 bar.
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If the pressure drops further:

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ility
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- Check pipe connections for leaks.
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h re
hole

spec
If no fault is detected in the wiring:
es, in part or in w

t to the co
- Fuel pump defective, renew fuel delivery unit =>Page 125 , Removing and installing fuel delivery unit.
rrectness of i
l purpos

nf
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Prote AG.

1.10 - Checking fuel pump 135

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics g-enEdition
AG. Volksw11.1999
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2 - Checking electronic power control (EPC) yV
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2.1 - Checking electronic power control
ss (EPC) c

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un

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ility
ot

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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
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pyri by
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Prote AG.

1 Bracket
◆ Removing and installing

=> Running gear; Repair group 46; Brake, Assembly overview brake mechanism, brake pedal/mounting bracket
Brake, Assembly overview brake mechanism, brake pedal/mounting bracket

2 Accelerator pedal position sender (G79 and G185)

◆ Checking =>Page 139
◆ When removing remove dash panel and pedal cluster cover
3 10 Nm
4 Cable cam
◆ Installing
=>Page 137 , Fig. 1
5 Spring washer

136 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

6 Adjustment bolt
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7 20 Nm
um
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8 Accelerator pedal
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9 Hexagon bolt M8
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Prote AG.

-> 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

2.1 - Checking electronic power control (EPC) 137

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
c = Forwards

Note:

The cable cam eye must be parallel to the forward direction.

2.2 - Function of EPC system

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With the EPC system the throttle ir se valve is not operated by a cable. There
d ran is no
tee mechanical connection between
accelerator and throttle valve.
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or
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ss
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.

ility
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The throttle valve is operated over the complete revolution and load range by an electric motor (throttle valve

h re
ole,

positioner) in the throttle valve control part.

spec
urposes, in part or in wh

t to the co
The throttle valve is operated by the throttle valve positioner which is controlled by the engine control unit.

When the engine is running (under load) the engine control unit can open or close the throttle valve independ‐

rrectne
ently of the accelerator pedal position sender.

s
This means that the throttle valve can already be completely open even though the accelerator pedal is de‐

s o
pressed half way.
cial p

f inform
mer

This also gives vastly improved consumption and exhaust emission levels at certain load conditions.
atio
om

n
c

The torque required by the engine can be produced by the engine control unit by optimising the combination
i
or

n thi
e

of throttle valve cross-section and intake manifold pressure.

t

sd
iva

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pr

cum
r

It is incorrect to believe that the "EPC" is comprised of one or two components only. The EPC is a system,
fo

en
ng

which is comprised of all components which have an influence, control or monitor the position of the throttle
t.
yi Co
op
valve, e.g. the accelerator pedal position sender, the throttle valve control unit, the EPC warning lamp, the
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engine control unit.
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- Functional test of EPC warning lamp: Prote AG.

=> Repair group 01; General to self-diagnosis; Significance of EPC warning lamp (fault lamp for electronic
throttle operation) in dash panel insert. General to self-diagnosis Significance of EPC warning lamp (fault lamp
for electronic throttle operation) in dash panel insert.

Observe safety precautions=> Page 124 .

Observe rules for cleanliness => Page 124 .

138 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

2.3 - Checking accelerator pedal position sender

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Special tools, workshop equipment, test and measuring appliances and auxiliary items required
itte

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ab
pe

ility

◆ V.A.G 1526 Hand multimeter

ot

◆ V.A.G 1594 A Adapter set

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, is n

h re

◆ V.A.G 1598/31 Test box

hole

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
spec

◆ Current flow diagram

es, in part or in w

t to the co

Function
rrectness of i

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
l purpos

housing.
Test conditions
nform
ercia

• The battery voltage must be at least 11.5 V.

m

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com

tion in

Test sequence
r
te o

thi
s
iva

do

- Connect fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics control
r
rp

cum

unit with the "Address word" 01:

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139
Prote AG.
2.3 - Checking accelerator pedal position sender
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
=> Repair group 01; Self-diagnosis; Connecting fault reader V.A.G 1551 and selecting engine electronics con‐
trol unit Self-diagnosis Connecting fault reader V.A.G 1551 and selecting engine electronics control unit

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 6 and 2 for the "Display group number 62" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 62
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- Check specifications thorisof sender 1 (G79) at idling stop in display zone
nte
eo 3.
Specification:s a3...100 %
u ra
c
- Check specifications
s of sender 2 (G185) at idling stop in display zone 4.

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e
nl

Specification: 3...100 %

pt
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Note:
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The engine control unit calculates the voltage values of the angle sender in percent relative to 5 Volt and displays
, is n

these as a percentage figure (5 Volt supply voltage equates to 100 %). h re

hole

spec
es, in part or in w

- Operate the accelerator pedal slowly until fully depressed and observe the angle sender figures in display
t to the co

zones 3 and 4:

The percentage display in display zone 3 and 4 must rise evenly. The tolerance range of 3...100 % is not
rrectness of i

covered completely.
l purpos

End specification value not achieved:

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- -> If necessary, adjust accelerator pedal -2- with adjusting bolt -1-.

End specification value not achieved:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

If the display does not indicate as described:

- Check accelerator pedal position sender voltage supply and wiring connections =>Page 141 .

140 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Checking voltage supply and wiring to control unit
- Remove driver's stowage compartment:

=> General body repairs; Repair group 68; Dash panel; Removing driver's stowage compartment Dash panel
Removing driver's stowage compartment
- Disconnect 6-pin connector for accelerator pedal position sender.
- Switch ignition on.

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

- -> Connect multimeter to measure voltage at the following contacts of the connector:

pt
an
d

Contact 2 + earth
itte

y li
erm

Contact 2 + 3

ab
ility
Contact 5 + earth
ot p

wit
Contact 5 + 4
is n

h re
Specification: minimum 4.5 V
ole,

spec
urposes, in part or in wh

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

- Switch off ignition.

fo

en
ng

t.
yi Co
op
If the specifications are not obtained:
C py
t. rig
gh ht
yri by
- -> Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains discon‐
op Vo
by c lksw
nected. cted agen
Prote AG.

2.3 - Checking accelerator pedal position sender 141

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
G. Volkswage
- -> Check wiring between test lksw
abox
gen Aand connector for
n AG d
oesopen circuit according to current flow diagram.
not
Contact 1+ socket b35 yV
o gu
ara
Contact 2+ socket oris 73
ed
nte
Contact 3+ socket
aut
h 36 eo
ra
Contact 4+s socket 33
s c
Contact 5+ socket 72

ce
le
un

pt
Contact 6+ socket 34

an
d
itte

y li
Wire resistance: max. 1.5 ω
rm

ab
- Additionally check the wiring for short to battery positive or earth.
pe

ility
- Additionally check wires for short to one another.
ot

wit
, is n

h re
hole

If no fault is detected in the wiring:

spec
es, in part or in w

t to the co
- Renew accelerator pedal position sender
=> Page 136 , item 2

rrectness of i
l purpos

3 - Activated charcoal filter system

nform
ercia

3.1 - Activated charcoal filter system

m

a
com

tion in
r
te o

thi
s
iva

3.2 - Function
do
r
rp

cum
fo

en
ng

t.
yi Co
op py
Depending upon the air pressure and ambient temperature, fuel vapour will form above the level of fuel in the
t. C rig
gh ht
tank. pyri by
Vo
o
by c lksw
cted agen
Prote
The activated charcoal filter system prevents these HC emissions escaping to the atmosphere.
AG.

In limited quantities, fuel vapours pass through a gravity valve (which closes at an angle of 45 °) located at the
highest point in the tank and through a pressure retention valve into the activated charcoal filter.

The activated charcoal stores these vapours like a sponge.

When the Lambda control is active when driving (engine warm), the solenoid valve (N80, also called regener‐
ation 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 solenoid valve is closed and the activated charcoal filter will not be
purged.

Notes:

◆ Hose connections are secured with either spring-type or clamp-type clips.

◆ Always replace clamp-type clips with spring-type clips.
◆ For fitting the spring-type clips, assembly tool VAS 5024 is recommended.

Observe safety precautions=> Page 124 .

Observe rules for cleanliness => Page 124 .

142 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

3.3 - Servicing parts of the activated charcoal filter system

n AG. Volkswagen AG do
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a ac
ss
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un

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an
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itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

1 Activated charcoal filter

rrectne

◆ Location: in engine compartment, right

◆ Secured to body
s

◆ With solenoid valve 1 for activated charcoal filter (N80)

s o

◆ When the engine is warm the valve will be activated from the engine control unit (pulsed)
cial p

f in

◆ Checking:
form
mer

atio
m

=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐
o

n
c

forming final control diagnosis

i
or

n thi
te

sd
va

2 Pressure retention valve with connecting hose

i

o
pr

cum
r
fo

◆ Shuts-off the tank venting when the solenoid valve (N80) is open and intake manifold pressure is present
en
ng

t.
yi
3 Connector
Co
Cop py
. rig
◆ 2-pin
t
gh ht
yri by
◆ For solenoid valve 1 cop Vo
by lksw
cted agen
Prote AG.

3.3 - Servicing parts of the activated charcoal filter system 143

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

4 Breather pipe
◆ Check securely seated
s

◆ From gravity/overflow valve on fuel tank

s o
cial p

=> Page 117 , item 18

inform

5 Throttle valve control part

mer

atio

6 Vent pipe
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.

144 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

3.4 - Checking fuel tank breather

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ V.A.G 1368 Vacuum tester

wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
d by ara
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ris
utho eo
ra
a c
ss
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

◆ V.A.G 1390 Hand vacuum pump

Test conditions
ss o
cial p

f i

• Ignition must be switched off

nform
mer

atio

Test sequence
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.

- -> Pull breather pipe/hose -2- from activated charcoal filter -1- off at throttle valve control part -3-.
- Connect hand vacuum pump V.A.G 1390 to pipe/hose -2-.
- Pull breather pipe/hose -5- from fuel tank off activated charcoal filter and connect to -connection A- of vacuum
tester V.A.G 1368.
- Connect vacuum tester V.A.G 1368 -connection B- to breather pipe/hose -4-.
- Set vacuum tester to position -B-.
- Introduce final control diagnosis and select activated charcoal filter solenoid valve (N80):

3.4 - Checking fuel tank breather 145

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐
forming final control diagnosis

- Operate hand vacuum pump V.A.G 1390 several times.

Vacuum must not
build up.

If vacuum builds up:

- Check breather connection -6- on activated charcoal filter -1- for soiling, clean if necessary.

If vacuum does not build up:

- Remove fuel filler cap.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
- -> Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 -connection B-. ss c

ce
le

- Set vacuum tester to -A/B- position.

un

pt
- Operate V.A.G 1390 several times. Vacuum must

an
d
itte

y li
not build-up.
erm

ab
ility
ot p

If vacuum builds-up:

wit
is n

h re
ole,

- Check gravity/overflow valve => Page 114 , item 4

spec
urposes, in part or in wh

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

t to the co
If vacuum does not build up:

rrectne
- Refit fuel filler cap.
- Operate hand vacuum pump V.A.G 1390 several times.

s
Vacuum must not

s o
build up.
cial p

f inform
mer

Note:
atio
om

n
c

If the fuel level in the tank is low the hand vacuum must be operated at least 20...30 times.
i
or

n thi
te

sd
va

If vacuum builds up:

i

o
pr

cum
r
fo

en
ng

t.
- Replace fuel tank cap.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

146 20 - Fuel supply system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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

agenthe system is not under stress, and that it has sufficient
clearance from the bodywork. lIf n AG. Volkloosen
necessary,
sw
double
es nand single clamps and align silencer and exhaust
AG do
kswage
pipe so that sufficient clearance
y Vo is maintained to the bodywork
ot g and the support rings are evenly loaded.
ua
db
◆ Components marked owith rise * will be checked by self-diagnosis: ran
te
th eo
au ra
=> Repair group 01; sFault
memory; Interrogating and erasing engine control unit fault memory Fault memory
s c

ce
e

Interrogating and erasing engine control unit fault memory

nl

pt
du

an
itte

y li
◆ Renew self-locking nuts.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.1 - Removing and installing parts of exhaust system 147

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi
1 Warm air collector plate
Co
Cop py
t. rig
2 10 Nm pyri
gh by
ht

◆ Note tightening sequence

o Vo
by c lksw
cted agen
Page => 151 , Fig. 1 Prote AG.

3 Exhaust manifold with precatalyst

4 Gasket
◆ Renew
5 Lock nut, 25 Nm
6 Bracket

148 26 - Exhaust system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

7 Lambda probe after catalyst (G131)*, 50 Nm

◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
rrectne

◆ Remove and install with ring spanner 3337

◆ Checking:
ss o
cial p

=> Repair group 24; Checking function; Checking Lambda probe and Lambda regulation after catalyst Checking
inform

function Checking Lambda probe and Lambda regulation after catalyst

mer

atio
m

8 To silencer
o

n
c

i
or

9 Marking
thi
te

sd
va

◆ Three times on circumference

i

o
pr

cum
r
fo

10 Main catalyst
en
ng

t.
yi
11 25 Nm
Co
Cop py
.
12 Mounting
t rig
gh ht
pyri by
◆ Renew if damaged
co Vo
by lksw
cted agen
13 Front exhaust pipe with catalyst
Prote AG.

1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments 149
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

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
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

14 Flexible pipe
nform
ercia

15 40 Nm
m

16 Gasket
a
com

tion in

◆ Renew
r
te o

thi

17 Lambda probe before catalyst (G39)*, 50 Nm

s
iva

do

◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
r
rp

cum

◆ Remove and install with ring spanner 3337

fo

en
ng

◆ Checking:
t.
yi Co
Cop py
t. rig
gh ht
=> Repair group 24; Checking function; Checking Lambda probe and Lambda regulation before catalyst
yri
p by
o Vo
Checking function Checking Lambda probe and Lambda regulation before catalyst by c lksw
cted agen
Prote AG.

150 26 - Exhaust system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

-> Fig. 1 Tightening sequence, warm air collector plate on exhaust manifold.
1- Tighten bolt -1-, 10Nm
2- Tighten bolt -2-, 10Nm
3- Tighten bolts -3-, 10Nm

1.3 - Silencer with mountings

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

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments 151
 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
1 Front exhaust pipe with catalyst
2 Marking
◆ Three times on circumference
3 Double clamp
4 Dimension-a- = ca. 5 mm
5 Carriage bolt
AG. Volkswagen AG d
6 40 Nm agen oes
olksw not
V gu
7 Front silencer1) ed by ara
nte
ris
8 25 Nm ut
ho eo
ra
a
9 Mounting ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

10 Mounting
◆ Renew if damaged
11 Connecting piece
12 15 Nm
13 20 Nm + 1/4 turn (90 °) further
14 Rear silencer1)
15 Marking
◆ Visible from below
◆ For repair double clamp item - 16 -
16 Repair double clamp

152 26 - Exhaust system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
◆ Must be pushed on to the markings item - 15 -

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
urposes, in part or in wh

t to the co

17 Separating point
◆ For repair cases1)
rrectne

◆ Marked by impressions on connecting pipe

ss

1) Front and rear silencers are installed as a single component at the factory. In repair cases the front and
o
cial p

rear silencers are supplied individually and a repair double clamp item 16 is supplied as a joint. Cut through
inform

connecting pipe at separating point - 17 - with a body saw e.g. V.A.G 1523.
mer

atio
om

n
c

i
or

n thi

2 - Exhaust gas recirculation system

te

sd
iva

o
pr

cum
r
fo

2.1 - Exhaust gas recirculation system

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Notes:
co Vo
by lksw
cted agen
Prote AG.
◆ The activation of the exhaust gas recirculation system is undertaken by the engine control unit (J537) via
valve for exhaust gas recirculation (N18) to exhaust gas recirculation valve.
◆ Checking exhaust gas recirculation valve (N18).

1.3 - Silencer with mountings 153

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐
forming final control diagnosis
◆ The conical plunger in the mechanical exhaust gas recirculation valve ensures that various cross sectional
openings are possible at different plunger lifts.
◆ Pulsed control makes every conceivable valve position possible.
◆ Components marked with an * are checked via the self-diagnosis.

=> 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
◆ Components marked with ** are checked via the final control diagnosis.

=> Repair group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis

2.2 - Servicing parts of exhaust gas recirculation system

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 Gasket
◆ Renew
2 Intake connecting flange
3 10 Nm
4 Connecting pipe

154 26 - Exhaust system

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
tho PoloteeEstate
or 1998 ➤
au
4-Cyl. ssinjection engine (4 valve), Mechanics - Edition ac
11.1999

ce
le
un

pt
5 Filter

an
d
itte

y li
6 20 Nm

erm

ab
7 Exhaust gas recirculation valve (N18)*/** with potentiometer for exhaust gas recirculation (G212)

ility
ot p

wit
◆ Check EGR valve (N18):

is n

h re
ole,

spec
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐

urposes, in part or in wh
forming final control diagnosis

t to the co
◆ Check potentiometer for exhaust gas recirculation (G212) =>Page 156

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.

8 Adapter
9 20 Nm
10 Throttle valve control part (J338)*

2.2 - Servicing parts of exhaust gas recirculation system 155

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

2.3 - Checking potentiometer for exhaust gas recirculation (G212)

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
erm

ab
ility
ot p

Special tools, workshop equipment, test and measuring appliances and auxiliary items required
wit
is n

h re
ole,

◆ V.A.G 1598/31 Test box

spec
urposes, in part or in wh

◆ V.A.G 1527 B Diode test lamp

t to the co

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
◆ V.A.G 1594 A Adapter set
◆ V.A.G 1526 Hand multimeter
rrectne

◆ Current flow diagram

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

156 26 - Exhaust system

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999
Test conditions

• -> Fuse 30 must be OK.

Test sequence
olkswagen AG
en AG. V
- Remove 6-pin connector from valve for exhaust
olksgas recirculation => Page
wag does
no154
t
, item 7
yV gu
db ara
rise nte
tho eo
au ra
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
- -> Connect multimeter to contacts 2 and 4 of 6-pin connector for voltage measurement.
- Switch on ignition.
l purpos

Specification: min. 4.5 V

nf
ercia

If the specification is not attained: orm

m

atio
m

- Switch off ignition.

o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- -> Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains discon‐
nected.

2.3 - Checking potentiometer for exhaust gas recirculation (G212) 157

 Polo Estate 1998 ➤
4-Cyl. injection engine (4 valve), Mechanics - Edition 11.1999

- -> Check wiring for open circuit between test box and n6-pin
AG. Voconnector
lkswagen AG using current flow diagram.
Contact 2 and test box socket 98 lkswage does
not
Vo
Contact 4 and test box socket 108 ed by gu
ara
Contact 6 and test box socket 100 thoris nte
eo
Wire resistance: max. 1.5ω sa
u ra
c
- Additionally check wiring for short to one another, and for short to positive or earth.
s

ce
le
un

pt
an
d

If the specification is obtained:

itte

y li
erm

ab
ility
ot p

- Connect engine control unit to test box V.A.G 1598/31 and reconnect 6-pin connector to EGR valve.

wit
- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
is n

h re
with the "Address word" 01.
ole,

spec
urposes, in part or in wh

=> Repair group 01; Self-diagnosis general: Connecting fault reader V.A.G 1551 and selecting engine elec‐

t to the co
tronics control unit. Self-diagnosis general: Connecting fault reader V.A.G 1551 and selecting engine electronics
control unit.

rrectne
- Initiate final control diagnosis and select EGR valve (N18):

ss
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐

o
cial p

f
forming final control diagnosis

inform
mer

- Connect diode test lamp V.A.G 1527 B to test box socket 100 and earth using adapter from V.A.G 1594.
atio
m

The LED must flash.

o

n
c

i
- Proceed with final control diagnosis until completed.
or

n thi
e

- Press keys 0 and 6 for the "End data transfer" function and confirm input with the Q key.
t

sd
iva

- Switch off ignition.

o
pr

cum
r
fo

- Depending on conditions, renew following components:

en
ng

t.
yi Co
op py
LED flashes: t. C rig
gh ht
pyri by
Vo
co
- Renew EGR valve (N18) with potentiometer (G212).
by lksw
cted agen
Prote AG.

- Erase learnt values and re-adapt engine control unit

=> Repair group 24; Engine control unit; Erasing learnt values and adapting engine control unit to throttle valve
control part and EGR valve Engine control unit Erasing learnt values and adapting engine control unit to throttle
valve control part and EGR valve

If no wiring fault is detected and the LED does not flash:

- Renew engine control unit.

=> Repair group 24; Engine control unit; Renewing engine control unit Engine control unit Renewing engine
control unit

158 26 - Exhaust system