2008 Volkswagen Polo Sedan engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system


Intake manifold	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt tensioner

expand_moreVolkswagen diesel straight-4 1.9 Liters ASY 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM


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

expand_moreVolkswagen gasoline straight-4 1.6 Liters BAH 99 HP at 5750 RPM, 140 N⋅m at 3250 RPM

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

expand_moreAll other modifications

expand_moreM8


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


Air-conditioning compressor bracket	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Alternator	16.96 lbf⋅ft16.96 lbf⋅ft23 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


Generator bracket	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreVacuum pump


1.9 SDI with diesel straight-4 1.9 L 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM engine (2002.9–)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCarburetion


Fuel-distributing pipe	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreInjection nozzle (injector)


1.9 SDI with diesel straight-4 1.9 L 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM engine (2002.9–)	14.75 lbf⋅ft14.75 lbf⋅ft20 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 (2002.9–)


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 (2002.9–), 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 (2002.9–), 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_moreCooling system


Coolant pump	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


Volkswagen diesel straight-4 1.9 Liters ASY 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreVolkswagen gasoline straight-4 1.6 Liters BAH 99 HP at 5750 RPM, 140 N⋅m at 3250 RPM

Figure 3. Cylinder head, Camshaft bearing, Volkswagen gasoline straight-4 1.6 Liters BAH 99 HP at 5750 RPM, 140 N⋅m at 3250 RPM.


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
Tighten new screws in inside-to-outside order.
Second stage	90°90°90°

expand_moreCylinder head screws

expand_moreVolkswagen diesel straight-4 1.9 Liters ASY 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM

Figure 4. Cylinder head, Cylinder head screws, Volkswagen diesel straight-4 1.9 Liters ASY 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM.


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 other modifications


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced. See figure 4.
Second stage	90°90°90°
Third stage	90°90°90°


Valve cover	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreVolkswagen gasoline straight-4 1.4 Liters BBY 74 HP at 5000 RPM, 126 N⋅m at 3800 RPM


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

expand_moreCrankshaft central screws


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_moreAll Volkswagen diesel straight-4 1.9 Liters ASY engines


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

expand_moreAll Volkswagen gasoline straight-4 1.6 Liters BAH engines

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_moreWith automatic gearbox


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
Second stage	90°90°90°


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

expand_moreMain bearing

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ASY engines


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


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

expand_moreVibration damper

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ASY engines


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

expand_moreAll Volkswagen diesel straight-3 1.4 Liters BAY engines


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

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley


All Volkswagen diesel straight-3 engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll Volkswagen diesel straight-4 engines


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

expand_moreAll other modifications


Bottom	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Top	18.44 lbf⋅ft18.44 lbf⋅ft25 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 diesel straight-3 1.4 Liters BAY engines


Central camshaft screws	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
Wheel	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°


Coupling drive tensioning roller	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreDrive belt tensioner device

expand_more1.4 TDI with diesel straight-3 1.4 L 74 HP at 4000 RPM, 195 N⋅m at 2200 RPM engine (2003.7–)


With hydraulic tensioning device	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

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

expand_moreToothed belt tensioning roller

expand_moreAll Volkswagen diesel straight-3 engines


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


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Use new screws and nuts.

expand_moreEngine lubrication


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

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

expand_moreVolkswagen diesel straight-4 1.9 Liters ASY 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM


First stage	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Second stage	90°90°90°


Volkswagen gasoline straight-4 1.4 Liters BBY 74 HP at 5000 RPM, 126 N⋅m at 3800 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Volkswagen gasoline straight-4 1.4 Liters BKY 74 HP at 5000 RPM, 126 N⋅m at 3800 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Volkswagen gasoline straight-4 1.4 Liters BBZ 99 HP at 6000 RPM, 126 N⋅m at 4400 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Oil pressure sensor	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Oil pump	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreOil sump

expand_moreVolkswagen gasoline straight-4 1.6 Liters BAH 99 HP at 5750 RPM, 140 N⋅m at 3250 RPM

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

expand_moreEngine management


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

expand_moreGlow plugs


1.9 SDI with diesel straight-4 1.9 L 63 HP at 4000 RPM, 125 N⋅m at 1600 RPM engine (2002.9–)	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


All Volkswagen diesel straight-3 engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All Volkswagen diesel straight-4 engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All other modifications	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreEngine mounting

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_moreOn chassis

expand_moreAll Volkswagen diesel straight-3 1.4 Liters BAY engines


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Screws must be replaced.
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_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


Catalytic converter	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Nuts must be replaced.
Exhaust manifold	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Nuts must be replaced.
Exhaust manifold heat shields	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Exhaust pipe	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Exhaust pipe bracket	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreIgnition system

expand_moreSpark plugs


Volkswagen gasoline straight-4 1.4 Liters BBZ 99 HP at 6000 RPM, 126 N⋅m at 4400 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreStart system

expand_moreStarter

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°

expand_moreAll other modifications


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

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2008 Volkswagen Polo Sedan 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 Sedan 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 2008 Volkswagen Polo Sedan you're not only saving money, but also also improving your technical skills and learning something new.

2008 Volkswagen Polo Sedan generations

In 2008 Volkswagen offered 2 generations of the Polo Sedan. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

Third generation facelift

A03

Type 6KV2

2008 Volkswagen Polo Sedan Fourth generation facelift Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

2008 Volkswagen Polo Sedan generations

Third generation facelift

Volkswagen Polo Sedan Fourth generation facelift model years

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