Volkswagen Polo 11/1990-08/1994 petrol free download

File name VW POLO 90-94 Repair handbook .pdf

Contents LIVING WITH YOUR VW POLO Introduction Safety first! Page 0.4 Page 0.5 Roadside repairs Introduction If your car won't start Jump starting Wheel changing Identifying leaks Towing Page 0.6 Page 0.6 Page 0.7 Page 0.8 Page 0.9 Page 0.9 Weekly checks Introduction Underbonnet check points Engine oil level Coolant level Brake fluid level Screen washer fluid level Wiper blades Battery Tyre condition and pressure Bulbs and fuses Page 0.10 Page 0.10 Page 0.11 Page 0.11 Page 0.12 Page 0.12 Page 0.13 Page 0.13 Page 0.14 Page 0.15 Lubricants, fluids and tyre pressures Page 0.16 MAINTENANCE Routine maintenance and servicing Maintenance schedule Maintenance procedures Page 1.1 Page 1.3 Page 1.5 Contents REPAIRS & OVERHAUL Engine and associated systems Petrol engine in-car repair procedures Engine removal and overhaul procedures Cooling, heating and ventilation systems Fuel/exhaust systems - single-point petrol injection models Fuel/exhaust systems - multi-point petrol injection models Exhaust and emission control systems Engine electrical - starting and charging systems Engine electrical - Ignition system Page 2A.1 Page 2B.1 Page 3.1 Page 4A.1 Page 4B.1 Page 4C.1 Page 5A.1 Page 5B.1 Transmission Clutch Manual transmission Driveshafts Page 6.1 Page 7.1 Page 8.1 Brakes and suspension Braking system Suspension and steering Page 9.1 Page 10.1 Body equipment Bodywork and fittings Body electrical systems Page 11.1 Page 12.1 Wiring diagrams Page 12.12 REFERENCE Dimensions and weights Conversion factors Buying spare parts and vehicle identification General repair procedures Jacking and vehicle support MOT test checks Fault finding Glossary of technical terms Page REF.1 Page REF.2 Page REF.3 Page REF.4 Page REF.5 Page REF.5 Page REF.12 Page REF.19 Index Page REF.24 0.4 Introduction The updated VW Polo range was introduced in November of 1990, with a choice of 1.05 litre (1043 cc) or 1.3 litre (1272 cc) petrol engines, with either single-point or multi-point fuel injection. During Spring 1991, the G40 model was launched, equipped with a supercharged version of the 1.3 litre engine. Three body shells are available - a three-door hatchback, a two-door saloon and a threedoor Coupe. All engines are derived from the well-proven units which have appeared in previous versions of the VW Polo. The engine is of fourcylinder overhead camshaft design, mounted transversely, with the transmission mounted on the left-hand side. All models have a four or five-speed manual transmission. All models have fully-independent front suspension and employ coilover-damper struts, transverse lower arms and an anti-roll bar. The rear suspension is semi-independent, utilising coil-over-damper struts and incorporating trailing arms located by a torsion beam axle. A rear anti-roll bar is fitted to certain models. A wide range of standard and optional equipment is available within the Polo range to suit most tastes, including a sliding sunroof, tinted glass, alloy wheels and rem