Volkswagen Polo 1990 – 1994 Haynes Service and Repair Manual

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 three-door Coupe.

All engines are derived from the well-proven units which have appeared in previous versions of the VW Polo. The engine is of four-cylinder 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 coil-over-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.

Your Polo manual

The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even if you choose to get it done by a garage). It will also provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads.

The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Tasks are described and photographed in a clear step-by-step sequence.

This manual is not a direct reproduction of the vehicle manufacturer’s data, and its publication should not be taken as implying any technical approval by the vehicle manufacturers or importers.


  • Introduction
  • Safety first!
  • Roadside repairs Introduction
  • If your car won’t start
  • Jump starting
  • Wheel changing
  • Identifying leaks
  • Towing
  • Weekly checks Introduction
  • Underbonnet check points
  • Engine oil level
  • Coolant level
  • Brake fluid level
  • Screen washer fluid level
  • W iper blades
  • Battery
  • Tyre condition and pressure
  • Bulbs and fuses
  • Lubricants, fluids and tyre pressures
  • Routine maintenance and servicing
  • Maintenance schedule
  • Maintenance procedures
  • 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
  • Transmission Clutch
  • Manual transmission
  • Driveshafts
  • Brakes and suspension Braking system
  • Suspension and steering
  • Body equipment Bodywork and fittings
  • Body electrical systems
  • Wiring diagrams
  • 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
  • Index

Language: English
Format: PDF
Pages: 182

Volkswagen Polo 1990 – 1994 Haynes Service and Repair Manual