1994 Volkswagen Polo Hatchback engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


All Volkswagen gasoline straight-4 1.6 Liters AEA engines	14.01–15.49 lbf⋅ft14.01–15.49 lbf⋅ft19–21 N⋅m
Tighten screws from the inside outwards.
All Volkswagen gasoline straight-4 1.6 Liters AEE engines	14.01–15.49 lbf⋅ft14.01–15.49 lbf⋅ft19–21 N⋅m
Tighten screws from the inside outwards.
All Volkswagen gasoline straight-4 1.6 Liters AHS engines	14.01–15.49 lbf⋅ft14.01–15.49 lbf⋅ft19–21 N⋅m
Tighten screws from the inside outwards.
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


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 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_moreAuxiliary drive belt tensioner


All Volkswagen diesel straight-4 1.9 Liters AEF engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Left-hand thread
All other modifications	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


Air-conditioning compressor	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreAir-conditioning compressor bracket


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

expand_moreAll other modifications


Aluminium engine block	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Grey cast-iron engine block	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


Air-conditioning compressor pressure line	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Alternator	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreGenerator bracket


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

expand_moreAll other modifications


Aluminium engine block	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Grey cast-iron engine block	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


Hydraulic lines at the servo-steering pump	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Servo pump pulley	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Servo steering pump	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Vacuum pump	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCarburetion


Fuel-distributing pipe	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Injection hoses	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreInjection nozzle (injector)


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


Injection pump	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreInjection pump pulley


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

expand_moreCooling system

expand_moreCoolant pump


All Volkswagen diesel straight-4 1.9 Liters AEF engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


Coolant pump pulley	18.44 lbf⋅ft18.44 lbf⋅ft25 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
First tighten bearing covers 2 and 4 alternately and in steps

expand_moreAll other modifications

expand_moreNuts


First stage	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
First tighten bearing covers 2 and 4 alternately and in steps
Second stage	90°90°90°


Screws	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCylinder head screws

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines

Figure 1. Cylinder head, Cylinder head screws, Volkswagen diesel straight-4 1.9 Liters AEF.


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_moreAll other modifications

expand_moreAluminium engine block


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced. See figure 1.
Second stage	90°90°90°
Third stage	90°90°90°

expand_moreGrey cast-iron engine block


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_moreCylinder head screws shank length (new)


All Volkswagen diesel straight-4 1.9 Liters AEF engines	4.53 in4.53 in115 mm
All Volkswagen gasoline straight-4 1.0 Liters AEV engines	3.78 in3.78 in96 mm
All other modifications	4.33 in4.33 in110 mm

expand_moreValve cover


All Volkswagen diesel straight-4 1.9 Liters AEF engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreAll other modifications


First stage	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreAll Volkswagen gasoline straight-4 1.3 Liters ADX engines

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_moreAll Volkswagen gasoline straight-4 1.6 Liters AEA engines

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_moreAll other modifications


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

expand_moreCrankshaft central screws

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_moreDrive plate


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

expand_moreFlywheel


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

expand_moreFlywheel cover


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

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


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

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley


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

expand_moreCamshaft timing gear


All Volkswagen diesel straight-4 1.9 Liters AEF engines	33.19 lbf⋅ft33.19 lbf⋅ft45 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_moreInlet camshaft wheel


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

expand_moreOutlet camshaft wheel


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


Toothed belt guard	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 cooler	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Oil drain plug	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Oil filter	Tighten by hand
Oil filter housing	hand-screwed

expand_moreOil pump

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 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_moreOil sump


All Volkswagen diesel straight-4 1.9 Liters AEF engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
All other modifications	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Gradually tighten screws crosswise.

expand_moreEngine management

expand_moreCrankshaft sensor


All Volkswagen diesel straight-4 1.9 Liters AEF engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


Glow plugs	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Knock sensor	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Lambda sensor	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket


All Volkswagen gasoline straight-4 1.6 Liters AEA engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All Volkswagen gasoline straight-4 1.6 Liters AEE engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All Volkswagen diesel straight-4 1.9 Liters AEF engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All Volkswagen gasoline straight-4 1.6 Liters AHS engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreAll other modifications


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

expand_moreEngine mounting

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines

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°

expand_moreAll other modifications

expand_moreOn chassis


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


On engine bracket	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Screws must be replaced.
On engine mounting	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Screws must be replaced.

expand_moreSubframe


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

expand_moreTorque arm

expand_moreAt the subframe

expand_moreAll Volkswagen diesel straight-4 1.9 Liters AEF engines


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


All other modifications	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m


At the gearbox	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreExhaust system


Catalytic converter	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Exhaust manifold	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace the nuts and use fitting paste
Exhaust pipe	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace the nuts and use fitting paste

expand_moreFuel supply


Fuel filter bracket	2.21 lbf⋅ft2.21 lbf⋅ft3 N⋅m

expand_moreIgnition system

expand_moreSpark plugs


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

expand_moreStart system

expand_moreStarter


All other modifications	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 1994 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 1994 Volkswagen Polo Hatchback you're not only saving money, but also also improving your technical skills and learning something new.

1994 Volkswagen Polo Hatchback generations

In 1994 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.

Second generation facelift

A02

Type 86C, Type 80

1994 Volkswagen Polo Hatchback Third generation Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

1994 Volkswagen Polo Hatchback generations

Second generation facelift

Volkswagen Polo Hatchback Third generation model years

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