2002 Volkswagen Polo Hatchback engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system


Induction-pipe flap control unit	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreIntake manifold


All Volkswagen diesel straight-3 1.4 Liters AMF engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
All Volkswagen diesel straight-4 1.9 Liters ATD engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen diesel straight-4 1.9 Liters AXR engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
All Volkswagen diesel straight-4 1.9 Liters BMT engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
All Volkswagen diesel straight-3 1.4 Liters BAY engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt deflection pulley


All Volkswagen gasoline straight-4 1.4 Liters AXU engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreAll other modifications


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreAuxiliary drive belt tensioner

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AUA engines


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

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AWY engines


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AXU engines


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

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AZQ engines


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-4 1.6 Liters BAH engines

expand_moreM8


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°


M10	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


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


Air-conditioning compressor	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAir-conditioning compressor bracket


All Volkswagen gasoline straight-4 1.6 Liters BAH engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreAll other modifications


M10 × 45 screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
M10 × 55 screws	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m


Air-conditioning compressor pressure line	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreAlternator


All Volkswagen diesel straight-3 1.4 Liters AMF engines	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m
All Volkswagen gasoline straight-4 1.6 Liters BAH engines	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m
All Volkswagen diesel straight-3 1.4 Liters BAY engines	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAlternator pulley


With freewheel	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Without freewheel	55.32 lbf⋅ft55.32 lbf⋅ft75 N⋅m

expand_moreGenerator bracket


All Volkswagen gasoline straight-4 1.4 Liters AUA engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters AUB engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Volkswagen gasoline straight-4 1.6 Liters BAH engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters BBY engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters BBZ engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters BKY engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Tighten crosswise from inside to outside.

expand_morePower steering pump bracket


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreHydraulic lines at the servo-steering pump


1.6 with gasoline straight-4 1.6 L 99 HP at 5750 RPM, 140 N⋅m at 3250 RPM engine (2002.8–2005.5)	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreVacuum pump


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

expand_moreAll other modifications


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCarburetion

expand_moreExhaust gas return cooler


Support	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Otherwise	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Seals must be replaced.


Exhaust gas return valve	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreExhaust recirculation pipe


All Volkswagen diesel straight-4 1.9 Liters BLT engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Sealing rings must be replaced.
All Volkswagen diesel straight-4 1.9 Liters ATD engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Sealing rings must be replaced.
All Volkswagen diesel straight-4 1.9 Liters AXR engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Sealing rings must be replaced.

expand_moreAll Volkswagen diesel straight-4 1.9 Liters BMT engines


Screws	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Nuts	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Nuts must be replaced.

expand_moreFuel-distributing pipe


All Volkswagen gasoline straight-4 1.4 Liters AXU engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreInjection hoses


1.9 SDI with diesel straight-4 1.9 L 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM engine (2001.10–2009.11)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreInjection nozzle (injector)


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

expand_moreAll other modifications


First stage	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Screws must be replaced.
Second stage	270°270°270°

expand_moreInjection pump


1.9 SDI with diesel straight-4 1.9 L 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM engine (2001.10–2009.11)	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreInjection pump pulley

expand_more1.9 SDI with diesel straight-4 1.9 L 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM engine (2001.10–2009.11)


Central nuts	Do not loosen the middle nut.

expand_moreWheel

Figure 1. Carburetion, Injection pump pulley, 1.9 SDI with diesel straight-4 1.9 L 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM engine (2001.10–2009.11), Wheel.


Variant 1	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
See figure 1.
Figure 2. Carburetion, Injection pump pulley, 1.9 SDI with diesel straight-4 1.9 L 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM engine (2001.10–2009.11), Wheel.

expand_moreVariant 2
See figure 2.


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

expand_moreCharging

expand_moreCharge air pipes


All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m


Turbo charger	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Screws must be replaced. Use mounting lubricant.

expand_moreTurbocharger bracket

expand_moreAll other modifications


At the turbocharger	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
On the engine block	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreTurbocharger oil feed line

expand_moreAll other modifications


At the oil filter	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
At the turbocharger	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Support	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreTurbocharger oil return line

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ATD engines


On the engine block	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
At the turbocharger	12.54 lbf⋅ft12.54 lbf⋅ft17 N⋅m

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AXR engines


On the engine block	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
At the turbocharger	12.54 lbf⋅ft12.54 lbf⋅ft17 N⋅m

expand_moreAll Volkswagen diesel straight-4 1.9 Liters BMT engines


At the turbocharger	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Sealing rings must be replaced.
On the engine block	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Sealing rings must be replaced.
Support at turbocharger	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreCooling system

expand_moreCoolant pump


All Volkswagen gasoline straight-4 1.4 Liters AUA engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters AUB engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-3 1.2 Liters AWY engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters AXU engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All Volkswagen gasoline straight-3 1.2 Liters AZQ engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen gasoline straight-4 1.6 Liters BAH engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters BBY engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters BBZ engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters BKY engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-3 1.2 Liters BMD engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen gasoline straight-3 1.2 Liters BME engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m


Coolant pump pulley	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Fan wheel	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Radiator mounting	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


All Volkswagen diesel straight-4 1.9 Liters ASY engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
First tighten bearing covers 2 and 4 alternately and in steps

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AWY engines


First stage	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
From inside to outside
Second stage	90°90°90°
Screws must be replaced.

expand_moreAll Volkswagen gasoline straight-4 1.6 Liters BAH engines

Figure 3. Cylinder head, Camshaft bearing, Volkswagen gasoline straight-4 1.6 Liters BAH.


First stage	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
See figure 3.
Second stage	90°90°90°

expand_moreAll other modifications


First stage	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Screws must be replaced.
Second stage	90°90°90°
First tighten bearing covers 2 and 3 alternately and in steps

expand_moreCylinder head screws

expand_moreAll Volkswagen diesel straight-3 1.4 Liters AMF engines

Figure 4. Cylinder head, Cylinder head screws, Volkswagen diesel straight-3 1.4 Liters AMF.


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Screws must be replaced. See figure 4.
Second stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Third stage	90°90°90°
Fourth stage	90°90°90°

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ASY engines


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Screws must be replaced. See figure 4.
Second stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Third stage	90°90°90°
Fourth stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AZQ engines

Figure 5. Cylinder head, Cylinder head screws, Volkswagen gasoline straight-3 1.2 Liters AZQ.


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
See figure 5.
Second stage	90°90°90°
Third stage	90°90°90°

expand_moreAll other modifications

Figure 6. Cylinder head, Cylinder head screws, All other modifications.


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced. See figure 6.
Second stage	90°90°90°
Third stage	90°90°90°

expand_moreCylinder head screws shank length (new)


All Volkswagen diesel straight-3 1.4 Liters AMF engines	6.54 in6.54 in166 mm
All Volkswagen diesel straight-4 1.9 Liters ASY engines	4.53 in4.53 in115 mm
All Volkswagen diesel straight-4 1.9 Liters ATD engines	6.54 in6.54 in166 mm
All Volkswagen gasoline straight-3 1.2 Liters AWY engines	6.22 in6.22 in158 mm
All Volkswagen diesel straight-4 1.9 Liters AXR engines	6.54 in6.54 in166 mm
All Volkswagen diesel straight-3 1.4 Liters BAY engines	6.54 in6.54 in166 mm
All Volkswagen gasoline straight-3 1.2 Liters BMD engines	6.22 in6.22 in158 mm
All Volkswagen diesel straight-4 1.9 Liters BMT engines	6.54 in6.54 in166 mm
All other modifications	5.43 in5.43 in138 mm

expand_moreRocker bridge


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Screws must be replaced.
Second stage	90°90°90°
First tighten crosswise inside, then outside

expand_moreValve cover

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AUA engines


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

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AWY engines


First stage	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
From inside to outside
Second stage	90°90°90°
Screws must be replaced.

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AXU engines


First stage	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Screws must be replaced.
Second stage	90°90°90°
Tighten from inside to outside.

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AZQ engines


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


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Tighten the screws cross-wise from inside to outside.

expand_moreEngine block

expand_moreBalance shaft gear wheel


First stage	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreConnecting rod bearing

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AUA engines


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

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AXU engines

expand_moreM7


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

expand_moreM8


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

expand_moreAll other modifications


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

expand_moreCrankshaft central screws

expand_moreAll Volkswagen diesel straight-3 1.4 Liters AMF engines


First stage	88.51 lbf⋅ft88.51 lbf⋅ft120 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ASY engines


First stage	88.51 lbf⋅ft88.51 lbf⋅ft120 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AXU engines

expand_moreWith threaded screw head


First stage	110.63 lbf⋅ft110.63 lbf⋅ft150 N⋅m
Screws must be replaced.
Second stage	180°180°180°

expand_moreOtherwise


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

expand_moreAll other modifications


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

expand_moreCrankshaft pulley

expand_moreCentral screws


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Second stage	90°90°90°


Wheel	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreDrive plate

expand_moreFlywheel


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


Flywheel cover	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
If fitted

expand_moreMain bearing


All Volkswagen gasoline straight-4 1.6 Liters BAH engines	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Screws must be replaced.

expand_moreAll other modifications


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

expand_moreVibration damper

expand_moreAll other modifications


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

expand_moreEngine control


Camshaft adjuster	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCamshaft drive belt deflection pulley

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ASY engines


M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreM10


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AUA engines


M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
M10	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m


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


Camshaft timing chain slip rail	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Camshaft timing chain tensioner	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
Camshaft timing chain tensioning rail	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCamshaft timing gear


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

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AWY engines


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AZQ engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-4 1.6 Liters BAH engines


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

expand_moreAll other modifications


Central camshaft screws	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
Wheel	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Chain tensioner	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Coupling drive tensioning roller	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Drive belt tensioner device	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreInlet camshaft wheel

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AXU engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AZQ engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	90°90°90°

expand_moreAll other modifications


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

expand_moreOil pump drive chain tensioner

expand_moreAll Volkswagen diesel straight-3 1.4 Liters AMF engines


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Screws must be replaced.
Second stage	90°90°90°


All other modifications	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOutlet camshaft wheel

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AXU engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AZQ engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	90°90°90°

expand_moreAll other modifications


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

expand_moreTiming case cover

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AXU engines


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M10	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreAll other modifications


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
M10	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


Toothed belt guard	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreToothed belt tensioning roller


All Volkswagen diesel straight-4 1.9 Liters ASY engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters AUA engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters AUB engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.6 Liters BAH engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Use new screws and nuts.
All Volkswagen gasoline straight-4 1.4 Liters BBY engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters BBZ engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters BKY engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll other modifications


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	45°45°45°

expand_moreEngine lubrication


Oil cooler	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Screws must be replaced.
Oil drain plug	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced.

expand_moreOil filter


First stage	Tighten by hand
Slightly oil sealing lips.
Second stage	14.75–17.7 lbf⋅ft14.75–17.7 lbf⋅ft20–24 N⋅m

expand_moreOil filter housing


Cap	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOn the engine block


First stage	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Screws must be replaced.
Second stage	90°90°90°
Tighten alternately starting from the top left


Oil pressure sensor	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOil pump


All Volkswagen diesel straight-3 1.4 Liters AMF engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters AXU engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen gasoline straight-4 1.6 Liters BAH engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All Volkswagen diesel straight-3 1.4 Liters BAY engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All other modifications	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOil pump chain wheel


All Volkswagen diesel straight-4 1.9 Liters ATD engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen diesel straight-4 1.9 Liters AXR engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen diesel straight-4 1.9 Liters BMT engines	18.44 lbf⋅ft18.44 lbf⋅ft25 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°

expand_moreOil sump


All Volkswagen gasoline straight-3 1.2 Liters AWY engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Volkswagen gasoline straight-3 1.2 Liters AZQ engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Tighten the screws in steps.

expand_moreAll Volkswagen gasoline straight-4 1.6 Liters BAH engines

expand_moreOil sump top part


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

expand_moreOil sump lower part


First stage	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Second stage	90°90°90°
Third stage	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
At the gearbox


All Volkswagen gasoline straight-3 1.2 Liters BMD engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Volkswagen gasoline straight-3 1.2 Liters BME engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Tighten the screws in steps.

expand_moreAll other modifications


At the gearbox	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
On the engine block	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Gradually tighten screws crosswise.

expand_moreEngine management

expand_moreCamshaft sensor


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Screws must be replaced.

expand_moreCharge air pressure sensor


All Volkswagen diesel straight-4 1.9 Liters BMT engines	2.21 lbf⋅ft2.21 lbf⋅ft3 N⋅m
All Volkswagen diesel straight-3 1.4 Liters BMS engines	2.21 lbf⋅ft2.21 lbf⋅ft3 N⋅m
All Volkswagen diesel straight-3 1.4 Liters BWB engines	2.21 lbf⋅ft2.21 lbf⋅ft3 N⋅m
All other modifications	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m

expand_moreCrankshaft sensor


All Volkswagen diesel straight-4 1.9 Liters ATD engines	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
All Volkswagen diesel straight-4 1.9 Liters BMT engines	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
All Volkswagen gasoline straight-4 1.4 Liters AXU engines	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
All Volkswagen diesel straight-3 1.4 Liters BMS engines	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
All Volkswagen diesel straight-3 1.4 Liters BWB engines	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m


Exhaust gas temperature sensor	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Use hot screw paste
Glow plugs	11.06 lbf⋅ft11.06 lbf⋅ft15 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

expand_more1.2 12V with gasoline straight-3 1.2 L 63 HP at 5400 RPM, 112 N⋅m at 3000 RPM engine (2001.10–2007.7)


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

expand_more1.2 with gasoline straight-3 1.2 L 54 HP engine (2002.1–2007.5)


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


1.4 16V with gasoline straight-4 1.4 L 74 HP at 5000 RPM, 126 N⋅m at 3800 RPM engine (2001.10–2008.5)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
1.4 16V with gasoline straight-4 1.4 L 74 HP at 5000 RPM, 126 N⋅m at 3800 RPM engine (2001.10–2008.5)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
1.4 16V with gasoline straight-4 1.4 L 74 HP engine (2001.10–2008.5)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
1.4 16V with gasoline straight-4 1.4 L 99 HP at 6000 RPM, 126 N⋅m at 4400 RPM engine (2001.10–2008.5)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
1.4 16V with gasoline straight-4 1.4 L 99 HP engine (2001.10–2008.5)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreEngine mounting

expand_moreAll Volkswagen diesel straight-3 1.4 Liters AMF engines

expand_moreOn chassis


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

expand_moreOn engine bracket


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

expand_moreAll other modifications

expand_moreOn chassis


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

expand_moreSubframe

expand_moreM10


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreM12


First stage	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreTorque arm

expand_moreAt the subframe


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

expand_moreAt the gearbox


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

expand_moreExhaust system

expand_moreCatalytic converter


All Volkswagen diesel straight-3 1.4 Liters AMF engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Nuts must be replaced.
All Volkswagen gasoline straight-4 1.6 Liters BAH engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Nuts must be replaced.
All Volkswagen diesel straight-3 1.4 Liters BAY engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Nuts must be replaced.


Catalytic converter bracket	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Diesel particulate filter	5.16 lbf⋅ft5.16 lbf⋅ft7 N⋅m
Sealing rings must be replaced.
Differential pressure sensor lines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Exhaust manifold	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace the nuts and use fitting paste

expand_moreExhaust manifold heat shields


All Volkswagen gasoline straight-4 1.6 Liters BAH engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Nuts must be replaced.

expand_moreExhaust pipe


All Volkswagen diesel straight-4 1.9 Liters ATD engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Nuts must be replaced.
All Volkswagen diesel straight-4 1.9 Liters AXR engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Nuts must be replaced.
All other modifications	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace the nuts and use fitting paste

expand_moreExhaust pipe bracket


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


Exhaust pipe rear	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreParticle filter bracket


Top	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m
Bottom	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Particulate filter heat protection plate	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m

expand_moreFuel supply

expand_moreFuel filter bracket


All Volkswagen gasoline straight-4 1.4 Liters AXU engines	2.21 lbf⋅ft2.21 lbf⋅ft3 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreIgnition system


Spark plugs	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreStart system

expand_moreStarter

expand_moreAll Volkswagen gasoline straight-4 1.4 Liters AUA engines


M8	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
M10	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AWY engines


M8	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
M10	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreAll Volkswagen gasoline straight-3 1.2 Liters AZQ engines


M8	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
M10	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreAll Volkswagen gasoline straight-4 1.6 Liters BAH engines

expand_moreM8


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreM10


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	45°45°45°


All other modifications	59 lbf⋅ft59 lbf⋅ft80 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2002 Volkswagen Polo Hatchback 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 Hatchback 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 2002 Volkswagen Polo Hatchback you're not only saving money, but also also improving your technical skills and learning something new.

2002 Volkswagen Polo Hatchback generations

In 2002 Volkswagen offered 2 generations of the Polo Hatchback. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

Third generation facelift

A03

Type 6N2

2002 Volkswagen Polo Hatchback Fourth generation Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

2002 Volkswagen Polo Hatchback generations

Third generation facelift

Volkswagen Polo Hatchback Fourth generation model years

Suggest edit