1996 Volkswagen Polo Box Van engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt tensioner

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines


Central screws	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Otherwise	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCarburetion

expand_moreInjection nozzle (injector)


All Volkswagen diesel straight-4 1.9 Liters AEF engines	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m

expand_moreInjection pump pulley


One-part injection pump pulley	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Two-part injection pump pulley	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreCooling system

expand_moreCoolant pump


1.0 with gasoline straight-4 1.0 L 44 HP engine (1994.10–1999.12)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


All Volkswagen diesel straight-4 1.9 Liters AEF engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll other modifications

expand_moreNuts


First stage	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
Second stage	90°90°90°


Screws	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCylinder head screws

expand_moreAll other modifications

Figure 1. Cylinder head, Cylinder head screws, All other modifications.


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Screws must be replaced. See figure 1.
Second stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Third stage	90°90°90°
Fourth stage	90°90°90°

expand_moreValve cover


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-4 1.0 Liters AEV engines


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Second stage	90°90°90°

expand_moreAll other modifications

expand_moreM7


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreM8


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreCrankshaft central screws

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-4 1.0 Liters AEV engines


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Screws must be replaced.
Second stage	120°120°120°

expand_moreAll other modifications

expand_moreWith hexagon-head screws


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace the screws and lubricate lightly
Second stage	120°120°120°

expand_moreWith Torx-head screws


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace the screws and lubricate lightly
Second stage	90°90°90°

expand_moreCrankshaft pulley

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines


First stage	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Screws must be replaced.
Second stage	90°90°90°


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreFlywheel


First stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreMain bearing

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines


First stage	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Screws must be replaced.
Second stage	90°90°90°


All other modifications	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m

expand_moreVibration damper

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines


First stage	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Screws must be replaced.
Second stage	90°90°90°


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley


First stage	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreCamshaft timing gear


All Volkswagen diesel straight-4 1.9 Liters AEF engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All Volkswagen gasoline straight-4 1.0 Liters AEV engines	59 lbf⋅ft59 lbf⋅ft80 N⋅m

expand_moreAll other modifications


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Screws must be replaced.
Second stage	90°90°90°


Toothed belt guard at the bottom	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Toothed belt tensioning roller	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreEngine lubrication


Oil drain plug	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreOil filter housing


1.0 with gasoline straight-4 1.0 L 44 HP engine (1994.10–1999.12)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Oil sump	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreEngine management

expand_moreGlow plugs


All Volkswagen diesel straight-4 1.9 Liters AEF engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Knock sensor	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Lambda sensor	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket


All Volkswagen diesel straight-4 1.9 Liters AEF engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreEngine mounting

expand_moreOn chassis


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Bolts must be replaced.
Second stage	45°45°45°

expand_moreOn engine bracket


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Bolts must be replaced.
Second stage	90°90°90°


Strut	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreExhaust system


Exhaust manifold	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 1996 Volkswagen Polo Box Van user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Volkswagen warranty policy for your region. In some regions DIY service may invalidate your warranty.

Maintenance Items

Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Volkswagen Polo Box Van service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 1996 Volkswagen Polo Box Van you're not only saving money, but also also improving your technical skills and learning something new.

1996 Volkswagen Polo Box Van Third generation Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

Volkswagen Polo Box Van Third generation model years

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