Introduction
This manual provides detailed service and repair information for Volkswagen Polo models produced between 1982 and October 1990. It is designed to assist both professional mechanics and DIY enthusiasts in performing various maintenance tasks and repairs.
The content is based on a complete stripdown and rebuild of the vehicle, ensuring accuracy and practicality. It covers various body styles including Hatchback, Coupe, Saloon/Classic, and specific engine displacements.
Image: Front cover of the Volkswagen Polo Service and Repair Manual. The cover features the title "VW POLO Hatchback, Coupe & Saloon/Classic 1982 to October 1990" and lists engine sizes 1043 cc, 1093 cc, and 1272 cc. A detailed cutaway illustration of a Volkswagen Polo is prominently displayed, showing internal components. The Haynes logo is visible in the top right corner.
Models Covered
This manual specifically covers the following Volkswagen Polo models:
- All VW Polo Hatchback, Saloon/Classic and Coupe models.
- Includes special and limited edition versions.
- Engine displacements: 1043 cc, 1093 cc, and 1272 cc.
Note: This manual does not cover the revised Polo range introduced in November 1990.
Image: Back cover of the Volkswagen Polo Service and Repair Manual. The cover displays several smaller images depicting various repair scenarios, including engine work, brake maintenance, and electrical diagrams. Text highlights that the manual covers mechanical features of Vans and explains that Haynes manuals include step-by-step procedures, hundreds of illustrations, hands-on experience, color wiring diagrams, and fault diagnosis sections.
General Information and Safety
Before commencing any work on your vehicle, it is crucial to read and understand all relevant sections of this manual. Always prioritize safety by using appropriate tools, wearing protective gear, and following recommended procedures. Disconnect the battery before working on electrical components.
Familiarize yourself with the vehicle's systems and components. If unsure about a procedure, consult a qualified mechanic.
Maintenance Procedures
Regular maintenance is essential for the longevity and reliable operation of your Volkswagen Polo. This section outlines routine service intervals and procedures.
Routine Checks
- Fluid Levels: Check engine oil, coolant, brake fluid, power steering fluid, and windshield washer fluid regularly.
- Tire Pressure: Verify tire pressure, including the spare, and inspect for wear and damage.
- Lighting: Ensure all exterior and interior lights are functioning correctly.
- Wipers: Check wiper blade condition and operation.
Scheduled Service
Refer to the detailed chapters for specific instructions on:
- Oil and filter changes.
- Air filter and fuel filter replacement.
- Spark plug inspection and replacement.
- Brake system inspection and pad replacement.
- Timing belt inspection and replacement (if applicable).
- Cooling system flush and refill.
Repair Procedures
This manual provides step-by-step instructions for various repair tasks, categorized by vehicle system.
Engine Overhaul and Repair
Detailed guidance on engine removal, disassembly, inspection, component replacement, and reassembly. Includes information on cylinder head, block, crankshaft, pistons, and valve train.
Transmission and Driveline
Instructions for servicing and repairing manual and automatic transmissions, clutch replacement, driveshafts, and differential components.
Braking System
Comprehensive coverage of disc and drum brakes, master cylinder, brake lines, and ABS (if equipped). Includes procedures for bleeding the system and component replacement.
Suspension and Steering
Guidance on front and rear suspension components, shock absorbers, springs, steering rack, power steering system, and wheel alignment.
Electrical System
Detailed wiring diagrams, component locations, and troubleshooting for the charging system, starting system, ignition, lighting, and auxiliary electrical components.
Troubleshooting Common Issues
This section helps diagnose common problems based on symptoms. It provides a systematic approach to identify the root cause of issues such as engine starting problems, poor performance, unusual noises, or electrical malfunctions.
- Engine won't start: Check battery, starter, fuel supply, ignition system.
- Overheating: Inspect coolant level, radiator, thermostat, water pump.
- Brake noise/vibration: Examine pads, rotors, calipers.
- Electrical failures: Check fuses, relays, wiring, specific components.
Specifications
This section contains critical technical data, including torque specifications for various fasteners, fluid capacities, and component dimensions. Always refer to these specifications when performing repairs to ensure proper assembly and operation.
| Category | Detail | Value |
|---|---|---|
| Engine Type | Petrol (Gasoline) | 1043cc, 1093cc, 1272cc |
| Fuel Type | Unleaded | |
| Transmission | Manual/Automatic | |
| Brake System | Front/Rear | Disc/Drum |
Note: Specific torque settings and fluid capacities are detailed within the relevant chapters of the manual.
Support and Additional Resources
For further assistance or if you encounter issues not covered in this manual, it is recommended to consult a certified Volkswagen service center or a professional mechanic.
This manual is published by Haynes Manuals Inc. For inquiries regarding the publication, please refer to the publisher's contact information.
- Publisher: Haynes Manuals Inc
- ISBN-10: 1850107548
- ISBN-13: 978-1850107545
- Publication Date: January 1, 1991
While this manual aims to be comprehensive, vehicle technology and repair techniques evolve. Always ensure you are using the most current and relevant information for your specific vehicle model and year.
