PDF Volkswagen Caddy Kasten Kombi 1996 Polo Classic 1996 Polo Variant 1998 Maintenace Manual

Service

Maintenance

Caddy Kasten/Kombi 1996 ➤ Polo Classic 1996 ➤ Polo Variant 1998 ➤ n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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Service Department. Technical Information

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Edition 03.2018

Service Maintenance

Heading 1. Engine list 2. Service work 3. General information 4. Descriptions of work: 5. Exhaust emissions test

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Copyright © 2018 Volkswagen AG, Wolfsburg

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No reproduction without prior agreement from publisher.

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

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4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25 4.26 4.27 4.28 4.29 4.30 4.31 4.32

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4.12 4.13 4.14 4.15 4.16

Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil change service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional work based on time or distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising vehicle with lifting platform and trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Countries where diesel has a high sulphur content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attaching “Your next service” sticker: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Descriptions of work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing engine compartment cover (noise insulation) . . . . . . . . . . . . . . . .

Driver and front passenger airbags: visual check of airbag units . . . . . . . . . . . . . . . . . . . .

Self-diagnosis: reading fault memories of all systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Door arrester and securing pins: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sunroof: checking function, cleaning and greasing guide rails . . . . . . . . . . . . . . . . . . . . . .

Electric windows: initialising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clock: setting to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio: activating anti-theft coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Window wash/wipe system and headlight washer system: checking function and settings ........................................................................

Windscreen wiper blades: checking park position, if wiper blades judder: checking setting angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel securing bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tyres: checking condition, wear pattern, inflation pressure, tread depth . . . . . . . . . . . . . .

Engine oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil: Draining or extracting and replenishing; renewing oil filter . . . . . . . . . . . . . . . .

Engine and components in engine compartment: inspecting for leaks and damage (from above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-belt: checking condition and tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Poly V-belt: checking condition and tensioning belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boots: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual gearbox/final drive: checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic gearbox: checking final drive oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake system: inspecting for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front and rear brake pads/linings: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Underbody protection: visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . .

Swivel joints: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system: checking coolant level and frost protection . . . . . . . . . . . . . . . . . . . . . . . .

Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dust and pollen filter: renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft drive belt: checking (petrol engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Toothed belt: checking for wear (SDI/TDI engines ►2000) . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft drive toothed belt: checking condition and tension (diesel engine with engine code ALH and automatic gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ht rig py Co t.

4.11

Contents

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1 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ra Caddy Kasten/Kombi ➤ a c s s Maintenance - Edition 03.2018

Contents

1 6 6 7 9 14 16 19 19 20 23 23 24 24 24 25 26 27 28 28 30 34 53 54 54 54 55 56 61 64 66 71 72 76 77 78 80 80 82 83 83 86 86 87 87 89 95 97 98 99

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

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ii Contents

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5.3 5.4 6

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4.36 4.37 4.38 4.39 4.40 4.41 4.42 4.43 4.44 4.45 4.46 4.47 5 5.1

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4.35

Toothed belt: checking condition and tension (diesel engine with engine code 1Y) . . . . . . 102 Toothed belt: renewing (diesel engine with engine codes AGP, AGR, ALH, AQM, ASK, ASV and AYQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Toothed belt: renewing (diesel engine with engine codes AEY, AFN, AHB, AHU, AKW and ALE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Fuel filter: renewing (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Fuel filter: draining water (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Automatic gearbox: checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Power assisted steering: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Brake fluid level (dependent upon brake pad/lining wear): checking . . . . . . . . . . . . . . . . . . 123 Battery: checking battery terminal clamps for secure seatingen A.G.. V. o. lk.s.w.ag. e.n.A.G. . . . . . . . . . . 124 do ag Battery: checking . . . . . . . . . . . . . . . . . . . . . . . . . .V.ol.ks.w. . . . . . . . . . . . . . . . . .es. n.o.t g. . . . . . 126 y u b Idling speed: checking . . . . . . . . . . . . . . . . . .ris.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an. t . . 126 e o Headlight adjustment: checking . . . . . . . . a.ut.h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.or a126 c s Carry out road test . . . . . . . . . . . . . . . . .s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Exhaust emissions test for vehicles with petrol engine without OBD with Fehlerauslesegerät V.A.G. 1551 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Exhaust emissions test for vehicles with petrol engine without OBD with emissions testing station VAS 6300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Exhaust emissions test for vehicles with petrol engine and OBD . . . . . . . . . . . . . . . . . . . . 151 Exhaust emissions test for diesel engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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4.33 4.34

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

1

Engine list

(VIGG001140; Edition 03.2018) This chapter provides information on the following subjects: ♦ Petrol engines ⇒ page 1 ♦ Diesel engines ⇒ page 3 Note

To ease the search for an engine, the engine codes are listed in alphabetical order.

Petrol engines 1) Unleaded RON 91 also permitted, but with reduced output.

2) Austria: Reduced output by a baffle in catalytic converter

Engines →

Petrol engine

Petrol engine

1.8 ADZ

Petrol en‐ gine 1.6 AEE

1.6 AEH

1.4 AEX

No. of cylinders/valves per cylinder Power kW at rpm

4/2 66/5500

4/2 55/4800

4/2 74/5600

2) 2

Torque

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Nm at rpm ∅ mm mm

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4/2

4/2

4/2

44/4700 120/3000

74/5600 145/3800

76.5 75.6 10.4

81.0 77.4 10.3

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Petrol engine 1.6 AKL

74/5800 140/3500 81.0 77.4 10.3

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∅ mm mm

Petrol engine 1.4 AKK

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Bore Stroke Compression ratio

Petrol engine 1.6 AFT

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No. of cylinders/valves per cyl‐ inder Power kW at rpm Torque Nm at rpm

10.0 9.8 10.3 10.2 Mono-Motronic 1AV Simos 2.2 Motronic MP 9.0 min. 95 super unleaded 95 super un‐ 95 super unlea‐ 95 super unlea‐ 1) 1 leaded 1) 1 ded 1) 1 ded 1) 1 EU 2 no no no no yes yes yes yes yes yes yes yes yes yes yes yes no no no no no no no no

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Displacement Engine code

Engines → l

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Exhaust emissions fulfil EPC system Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged

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Bore Stroke Compression ratio Injection/ignition RON

4/2

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Displacement Engine code

Petrol engine

4/2

44/4700 116/2800 to 3200 76.5 75.6 10.2 1. Engine list

1

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

Displacement Engine code

Engines → l

Petrol engine 1.6 AFT

Petrol engine 1.6 AKL

Petrol engine 1.4 AKV

Simos

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Motronic ME Simos 2.2 Motronic MP 07/05/2010 9.0 RON min. 95 super unlea‐ 95 super unleaded 95. V super 95 unleaded1) 1 olkswaunleaded ge 1) 1 1) 1 n AG do gen AG a ded 1) 1 e w s no ks tg Vol by 2 d Exhaust emissions fulfil EU D3 standard D3uastandard ran ir se te o h t EPC system no yes no noe or a u a c ss Self-diagnosis yes yes yes yes Catalytic converter yes yes yes yes Lambda regulation yes yes yes yes Exhaust gas recirculation no no no no Turbocharged no no no no

Petrol engine 1.6

Petrol engine 1.4

Petrol engine 1.4

Petrol engine 1.4

ALM

ANW

ANX

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No. of cylinders/valves per cylinder Power kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Injection/ignition

2 1. Engine list

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Engines → l

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Displacement Engine code

min. 95 super unlea‐ ded 1) 1 D3 standard no yes yes yes no no

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Exhaust emissions fulfil EPC system Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged

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RON

4/2 4/2 4/4 44/4700 40/4700 55/5000 120/3000 116/3000 126/3800 76.5 76.5 76.5 75.6 75.6 75.6 10.4 10.2 10.5 Motronic ME Motronic MP Motronic ME 07/05/2010 9.0 07/05/2010 95 super unlea‐ 95 super unlea‐ 95 super un‐ ded 1) 1 ded 1) 1 leaded 1) 1 D4 standard D4 standard yes no yes yes yes yes yes yes yes yes yes yes yes no yes no no no

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No. of cylinders/valves per cylinder 4/2 Power kW at rpm 55/4800 Torque Nm at rpm 135/2800 to 3600 Bore ∅ mm 75.0 Stroke mm 86.9 Compression ratio 9.8 Injection/ignition 1 AV

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Engines → l

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Displace‐ ment Engine code

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Injection/ignition

Petrol engine 1.4 AKK

Petrol engine 1.6 APF

Petrol engine 1.4 APQ

Petrol engine 1.4 AQQ

4/2 74/5600 145/3800 81.0 77.4 10.3 Simos 3.3

4/2 44/4700 116/2800 to 3200 76.5 75.6 10.2 Motronic MP 9.0

4/4 74/6000 128/4500 76.5 75.6 10.5 Magneti Marelli 4LV

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Engines → l

Displacement Engine code RON

Petrol engine 1.6 APF

Petrol engine 1.4 APQ

Petrol engine 1.4 AQQ

min. 95 super unleaded 95 super unlea‐ 1) 1 ded 1) 1 D4 standard D3 standard yes no yes yes yes yes yes yes no no no no

Exhaust emissions fulfil EPC system Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged

95 super unleaded 1) 1 D4 standard yes yes yes yes no no

Engines → Petrol engine Petrol engine n AG. Volkswagen AG do e g a es n w l 1.4 1.4 ot olks

Petrol engine 1.6

Petrol engine 1.6

AUA

AUR

1F

4/2

4/2

74/5600 145/3800 81.0 77.4 10.3 Simos 3.3

55/5500 125/2600 81.0 77.4 9.0 Mono-Motronic

95 unleaded1) 1

91 unleaded

Displace‐ yV ment db ise r ho Engine code ut

a ss No. of cylinders/valves per

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1

EU4 standard yes

EU4 standard yes

no

yes yes yes yes yes no

yes yes yes yes no no

yes yes yes yes no no

yes yes yes no no

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Exhaust emissions fulfil Exhaust emissions warning lamp EPC system Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged

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4/4 4/2 cylinder Power kW at rpm 55/5000 44/4700 Torque Nm at rpm 126/3900 116/3000 Bore ∅ mm 76.5 76.5 Stroke mm 75.6 75.6 Compression ratio 10.5 10.4 Injection/ignition Magneti Marelli Motronic ME 4LV 07/05/2010 RON min. 95 unleaded1) 1 95 unleaded1)

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Diesel engines 3) only France

Engines → Displacement Engine code

l

Diesel engine

Diesel engine

Diesel engine

1.9 AEY

1.9 AFN

1.9 AGP

Diesel en‐ gine 1.9 AGR

4/2 81/4150 235/1900

4/2 50/4200 133/2200 to 2600

4/2 66/4000 210/1900

No. of cylinders/valves per cylinder 4/2 Power kW at rpm 47/4200 Torque Nm at rpm 125/2200 to 2800

1. Engine list

3

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

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79.5 95.5 19.5 TDI 49 EU 2 yes yes yes no yes yes yes

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79.5 95.5 19.5 SDI 49 EU 2 yes yes yes no yes no no

Engines → Diesel engine l

AHB

No. of cylinders/valves per cylinder Power kW at rpm Torque Nm at rpm Bore Stroke Compression ratio Injection/ignition CN Exhaust emissions fulfil EPC system Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged Charge air cooling

Displacement Engine code

∅ mm mm

min.

3) 1

1.9 AHU

1.7 AKW

4/2 42/4200 112/2200 to 2600 79.5 86.4 19.5 SDI 49 yes yes yes no yes no no

4/2 66/4000 202/1900

4/2 44/4250 112/2000 to 3000 79.5 86.4 19.5 SDI 49 yes yes yes no yes no no

79.5 95.5 19.5 TDI 49 yes yes yes no yes yes yes

Engines → Diesel engine Diesel engine l 1.9 1.9 ALH AQM

No. of cylinders/valves per cylinder Power kW at rpm Torque Nm at rpm

4 1. Engine list

1.7

Diesel engine

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Displacement Engine code

Diesel engine

4/2 66/3750 210/1900

4/2 50/4200 133/2200 to 2600

Diesel en‐ gine 1.9 ALE

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79.5 95.5 19.5 TDI 49 yes yes yes no yes yes yes

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79.5 95.5 19.5 SDI 49 yes yes yes no yes no no

AG.

∅ mm mm

1.9 AGP

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1.9 AEY

Diesel en‐

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Bore Stroke Compression ratio Injection/ignition CN Exhaust emissions fulfil EPC system Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged Charge air cooling

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Displacement Engine code

Diesel engine

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Engines →

4/2 66/4000 202/1900

79.5 95.5 19.5 TDI 49 D3 standard yes yes yes no yes yes yes

Diesel engine 1.9 ASK

Diesel engine 1.9 ASV

4/2 81/4150 235/1900

4/2 81/4000 235/1900

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Engines → Diesel engine Diesel engine l 1.9 1.9 ALH AQM

Displacement Engine code Bore Stroke Compression ratio Injection/ignition CN Exhaust emissions fulfil EPC system Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged Charge air cooling

∅ mm mm

79.5 95.5 19.5 TDI min.

49 D3 standard yes yes yes no yes yes yes

Engines → l

Displacement Engine code

79.5 95.5 19.5 SDI 49 D3 standard yes yes yes no yes no no

Diesel engine 1.9 ASK

Diesel engine 1.9 ASV

79.5 95.5 19.5 TDI 49 D3 standard no yes yes no yes yes yes

79.5 95.5 19.5 TDI 49 D3 standard no yes yes no yes yes yes

Diesel engine 1.9 AYQ

Diesel engine 1.9 1Y

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No. of cylinders/valves per cylinder 4/2 4/2 Power kW at rpm 47/4200 47/4400 Torque Nm at rpm 128/2200 to 2750 124/2000 to 3000 Bore ∅ mm 79.5 79.5 Stroke mm 95.5 95.5 Compression ratio 19.5 22.5 . Volkswagen AG gen AG does a w s Injection/ignition SDI SD not olk gu yV ara db e CN min.

49 49 nte ris eo ho t ra Exhaust emissions fulfil s au EU 3 c s EPC system yes no Self-diagnosis yes yes Catalytic converter yes yes Lambda regulation no no Exhaust gas recirculation yes yes Turbocharged no no Charge air cooling no no

1. Engine list

5

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

2

Service work

This chapter provides information on the following subjects: ♦ Service tables ⇒ page 6 ♦ Oil change service ⇒ page 7 ♦ Inspection service ⇒ page 9 ♦ Additional work based on time or distance ⇒ page 14 ♦ Delivery inspection ⇒ page 16

2.1

Service tables

VW engine oil standards ⇒ page 6 Filter change intervals ⇒ page 6 Toothed belt change intervals ⇒ page 7 Service intervals ⇒ page 7

2.1.1

VW engine oil standards CADDY Van/Kombi 9K and POLO Classic/Estate 6V VW ENGINE OIL STANDARDS

PETROL ENGINES 4-cylinder engines

VW 500 00, VW 502 00, VW 504 001or VW 501 01 lksw n AG. Vo wage s k l Vo

Filter change intervals

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2.1.2

CADDY Van/Kombi 9K and POLO Classic/Estate 6V FILTER CHANGE INTERVALS ENGINE OIL FILTER All engine types

Every 15,000 km or 1 year

AIR FILTER

DUST AND POLLEN FILTER

6 2. Service work

r fo ng

Drain water Every 7,500 km Every 15,000 km

Prote cted by

Change Drain water Change Every Every Every 30,000 km 15,000 km 15,000 km Every Every Every 60,000 km 30,000 km 30,000 km

Biodiesel (RME) conforming to EN 14214 Change Drain water Every Every 15,000 km 7,500 km Every Every 30,000 km 15,000 km AG.

1997►

Diesel not conforming to EN 590

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►1996

Diesel conforming to EN 590

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FUEL FILTER All diesel engines

Every 30,000 km or 2 years Every 60,000 km or 2 years Every 60,000 km or 4 years

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►1996 1997 to 1999 2000►

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1Combination product: VW 504 00/507 00

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DIESEL ENGINES 4-cylinder engines

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 CADDY Van/Kombi 9K and POLO Classic/Estate 6V FILTER CHANGE INTERVALS All engine types

2.1.3

Every 30,000 km or 2 years

Toothed belt change intervals CADDY Van/Kombi 9K and POLO Classic/Estate 6V TOOTHED BELT CHANGE INTERVALS AG. Volkswagen A

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Every 90,000 km Every 90,000 km

Every 120,000 km

Service intervals

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2.1.4

Idler roller

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DIESEL ENGINES y Volks b ed ris Engine code o h t AKW au ss Engine codes AHB, AEY, AHU, ALE and AFN Engine code AGP, AQM, ALH, AGR, ASK, ASV and AYQ ►2001 Engine code AGP, AQM, ALH, AGR, ASK, ASV and AYQ 2002►

Every 120,000 km

CADDY Van/Kombi 9K and POLO Classic/Estate 6V SERVICE INTERVALS

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2.2

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Since introduction Diesel, in countries where the sulphur content Oil change service in fuel is high every 7,500 km or 1 year Since introduction For all vehicles Oil change service every 15,000 km Since introduction For all vehicles Inspection every 12 months Since introduction For all vehicles Inspection every 30,000 km

Oil change service

Oil change service according to flexible service interval display ⇒ page 7 Oil change service every 15,000 km ⇒ page 8

2.2.1

Oil change service according to flexible service interval display

Note

Inform the customer if faults are found during service and repair measures are necessary.

2. Service work

7

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Caution

♦ If RME fuel (biodiesel) is used, always note the information on RME fuel (biodiesel) ⇒ page 25 . ♦ When using RME (biodiesel) according to “EN 14214”, the fuel filter must be renewed every 15,000 km.

Caution

♦ In countries where the diesel has a high sulphur content, change oil every 7,500 km. Affected countries with a high sulphur content ⇒ page 24 .

– Ask if customer requires: New wiper blades

•

Replenish Windscreen Clear G 052 164 (cleanser and antifreeze).

– Check if first aid box storage life date has been exceeded.

– Removing and installing engine compartment cover -bottom(noise insulation tray)

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The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid unnecessary interruptions in the work.

Vehicles with diesel engine code 1Y – Fuel filter: drain water

⇒ page 112

Engine oil: drain or extract, renew oil filter Front and rear brake pads/linings: check thickness Engine oil: replenish Service interval display: reset Enter date of next service on sticker and attach sticker to driver side door pillar (B-pillar). r fo ng

– – – – –

AG.

Prote cted by

Oil change service every 15,000 km

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2.2.2 Note

Inform the customer if faults are found during service and repair measures are necessary.

Caution

♦ If RME fuel (biodiesel) is used, always note the information on RME fuel (biodiesel) ⇒ page 25 . ♦ When using RME (biodiesel) according to “EN 14214”, the fuel filter must be renewed every 15,000 km.

8 2. Service work

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Only applies to vehicles 1996►

⇒ page 72 ⇒ page 83 ⇒ page 72 ⇒ page 34 ⇒ page 26

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 . Volkswage

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change oil every 7,500 km. Affected countries with a high sulphur content ⇒ page 24 .

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– Ask if customer requires: •

New wiper blades

•

Replenish Windscreen Clear G 052 164 (cleanser and antifreeze).

– Check if first aid box storage life date has been exceeded.

– Removing and installing engine compartment cover -bottom(noise insulation tray) The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid unnecessary interruptions in the work. r te o iva r rp fo ng

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Only valid for vehicles with diesel engine ►2000 AG.

– Fuel filter: drain water

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– Toothed belt: check for wear

in t his d o cu m en

Vehicles with petrol engine Vehicles with diesel engine (not engine code 1Y)

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•

Only valid for vehicles with diesel engine ►1996

– – – – –

Engine oil: drain or extract; renew oil filter Front and rear brake pads/linings: check thickness Engine oil: replenish Service interval display: reset Enter date of next service on sticker and attach sticker to driver side door pillar (B-pillar).

2.3

⇒ page 98

⇒ page 112

⇒ page 72 ⇒ page 83 ⇒ page 72 ⇒ page 34 ⇒ page 26

Inspection service

Inspection service every 12 months ⇒ page 9 Inspection service every 30,000 km ⇒ page 12

2.3.1

Inspection service every 12 months

Note

Inform the customer if faults are found during service and repair measures are necessary.

Caution

♦ If RME fuel (biodiesel) is used, always note the information on RME fuel (biodiesel) ⇒ page 25 . ♦ When using RME (biodiesel) according to “EN 14214”, the fuel filter must be renewed every 15,000 km.

2. Service work

9

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Caution

♦ In countries where the diesel has a high sulphur content, change oil every 7,500 km. Affected countries with a high sulphur content ⇒ page 24 .

– Ask if customer requires: •

New wiper blades

•

Replenish Windscreen Clear G 052 164 (cleanser and antifreeze).

– Check if first aid box storage life date has been exceeded.

– Removing and installing engine compartment cover -bottom(noise insulation tray) The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid unnecessary interruptions in the work.

Work to be completed for inspection service every 12 months Electrics

Work to be completed for inspection service every 12 months Vehicle exterior – Door arrester and securing pins: grease – Window wash/wipe system and headlight washer system: check function and settings – Wiper blades: check for damage; check park position; only if wiper blades “judder”: check setting angle

– Front left wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear left wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear right wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Front right wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Spare wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm

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10 2. Service work

⇒ page 53 ⇒ page 56 ⇒ page 61

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Work to be completed for inspection service every 12 months Tyres

⇒ page 28 ⇒ page 30 ⇒ page 34

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– Front lights – side lights, dipped beam, main beam, fog lights, turn signals, hazard warning lights: check function – Rear lights - brake lights (including 3rd brake light), tail lights, reversing lights, rear fog light, number plate light, turn signals, hazard warning lights, luggage/load com‐ AG. Volkswagen AG d partment lights: check function agen oes ksw not l o V cigarette lighter, warning lamps gu and horn: y – Interior and glove compartment lights, b ara d nte ise check function r o eo h t u ra a airbag: visual check of airbag units for exterior damage – Driver and front passenger c s s – Self-diagnosis: read fault memories of all systems – Service interval display: reset

⇒ page 66 ⇒ page 66 ⇒ page 66 ⇒ page 66 ⇒ page 66

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Work to be completed for inspection service every 12 months Tyres – Tyre pressure on all 4 wheels and spare wheel: check, if necessary correct

⇒ page 66

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Work to be completed for inspection service every 12 months Engine compartment

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eo th – Engine oil: ra au drain or extract; renew oil filter c ss – Engine and components in engine compartment: inspect for leaks and damage – Gearbox, final drive and drive shaft boots: inspect for leaks and damage.

– Brake system: inspect for leaks and damage.

– Front and rear brake pads/linings: check thickness – Exhaust system: inspect for leaks, firm seating and damage.

– Track rod ends: check clearance, firm seating and boots – Swivel joints: visual check of swivel joint boots for leaks and damage

AG.

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Only valid for SDI/TDI engines ►2000

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– Engine oil: replenish – Engine and components in engine compartment: visual check for leaks and damage (from above) – Windscreen wash/wipe system: replenish Windscreen Clear with antifreeze G 052 164 – Cooling system: check anti-freeze concentration and level of coolant; Specification -25°C (in countries with arctic climate -35°C) actual value (measured value): ____°C – Toothed belt: check for wear

– Fuel filter: drain water •

⇒ page 80 ⇒ page 83 ⇒ page 83 ⇒ page 86 ⇒ page 87

⇒ page 72 ⇒ page 76 ⇒ page 56 ⇒ page 87 ⇒ page 98

⇒ page 112

Only valid for vehicles with diesel engine ►1996

– Brake fluid level (dependent upon brake pad/lining wear): check – Battery: visual check – Idling speed: check •

⇒ page 72 ⇒ page 76

⇒ page 123 ⇒ page 126 ⇒ page 126

Only valid for vehicles with diesel engine and engine code 1Y, when no exhaust emissions test has been performed.

Work to be completed for inspection service every 12 months Final checks – Headlights: check adjustment – Enter date of next service on sticker and attach sticker to driver side door pillar (B-pillar).

– Carry out road test

⇒ page 126 ⇒ page 26 ⇒ page 130

2. Service work

11

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

2.3.2

Inspection service every 30,000 km

Note

Inform the customer if faults are found during service and repair measures are necessary.

G. Volkswagen AG do es n ot g ua ran tee or ac

♦ When using RME (biodiesel) according to “EN 14214”, the fuel filter must be renewed every 15,000 km.

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♦ If RME fuel (biodiesel) is used, always note the information on RME fuel (biodiesel) ⇒ page 25 .

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nA wage olks V by ed ris Caution o th au ss

Caution

♦ In countries where the diesel has a high sulphur content, change oil every 7,500 km. Affected countries with a high sulphur content ⇒ page 24 .

– Ask if customer requires: •

New wiper blades

•

Replenish Windscreen Clear G 052 164 (cleanser and antifreeze). r fo ng

– Removing and installing engine compartment cover -bottom(noise insulation tray)

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– Check if first aid box storage life date has been exceeded. ht rig py Co t.

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Scope of work in conjunction with inspection every 30,000 km Electrics – Front lights – side lights, dipped beam, main beam, fog lights, turn signals, hazard warning lights: check function – Rear lights - brake lights (including 3rd brake light), tail lights, reversing lights, rear fog light, number plate light, turn signals, hazard warning lights, luggage/load com‐ partment lights: check function – Interior and glove compartment lights, cigarette lighter, warning lamps and horn: check function – Driver's and passenger airbag: visual check of airbag units for external damage – Self-diagnosis: read fault memories of all systems – Service interval display: reset

⇒ page 28 ⇒ page 30 ⇒ page 34

Scope of work in conjunction with inspection every 30,000 km Vehicle exterior – Door arrester and securing pins: grease – Sunroof: check function, clean guide rails and lubricate with special grease -G 000 450 02– Window wash/wipe system and headlight washer system: check func‐ tion and settings

12 2. Service work

⇒ page 53 ⇒ page 54 ⇒ page 56

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Scope of work in conjunction with inspection every 30,000 km Vehicle exterior – Windscreen wiper blades: check for damage; check park position; only if wiper blades “judder”: check setting angle

⇒ page 61

Scope of work in conjunction with inspection every 30,000 km Tyres – Front left wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear left wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear right wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Front right wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Spare wheel: check condition and wear pattern of tyre; enter tread depth: _______ mm – Tyre pressure on all 4 wheels and spare wheel: check, if necessary cor‐ rect

Scope of work in conjunction with inspection every 30,000 km Underside of vehiclegen AG. Volkswagen AG d a lksw

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Only valid for engines without automatic tensioning roller

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⇒ page 66 ⇒ page 66 ⇒ page 66 ⇒ page 66 ⇒ page 66

⇒ page 72 ⇒ page 76 ⇒ page 77 ⇒ page 78

⇒ page 80 ⇒ page 80 ⇒ page 83 ⇒ page 83 ⇒ page 86

⇒ page 86 ⇒ page 87

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– Gearbox, final drive and drive shaft boots: inspect for leaks and dam‐ age.

– Manual gearbox/final drive: check oil level – Brake system: inspect for leaks and damage.

– Front and rear brake pads/linings: check thickness – Underbody: visual check for damage to underbody sealant and under‐ body panels – Exhaust system: inspect for leaks, firm seating and damage.

– Track rod ends: check clearance, firm seating and boots – Swivel joints: visual check of swivel joint boots for leaks and damage

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o o – Engine oil: y Vdrain or extract; renew oil filtert gua db ran e s teeinspect for leaks and ri and components in engine compartment: – Engine o h or ut ac a damage ss – V-belt: check condition and tension – Poly V-belt: check condition and tension belt

⇒ page 66

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– Engine oil: replenish – Engine and components in engine compartment: visual check for leaks and damage (from above) – Windscreen wash/wipe system: replenish Windscreen Clear with an‐ ti-freeze G 052 164

⇒ page 72 ⇒ page 76 ⇒ page 56

2. Service work

13

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Prote cted by

Scope of work in conjunction with inspection every 30,000 km Engine compartment – Cooling system: check anti-freeze concentration and level of coolant; specification -25°C (in countries with arctic climate -35°C) actual val‐ ue (measured value): ____°C – Toothed belt: check for wear Only valid for SDI/TDI engines ►2000

– Camshaft drive toothed belt and tensioning roller: check •

⇒ page 99

Only valid for vehicles with automatic gearbox and engine code ALH

– Fuel filter: renew •

⇒ page 98

⇒ page 111

Only valid for vehicles with diesel engine ►1996

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⇒ page 112

•

Only valid for vehicles with diesel engine 1997►

– – – –

Power assisted steering: check fluid level Brake fluid level (dependent upon brake pad/lining wear): check Battery: visual check Idling speed: check

•

Only valid for vehicles with diesel engine and engine code 1Y, when no exhaust emissions test has been performed.

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– Fuel filter: drain water

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⇒ page 87

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⇒ page 119 ⇒ page 123 ⇒ page 126 ⇒ page 126

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Scope of work in conjunction with inspection every 30,000 km Final checks – Headlights: check adjustment – Enter date of next service on sticker and attach sticker to driver side door pillar (B-pillar).

– Carry out road test

2.4

⇒ page 126 ⇒ page 26 ⇒ page 130

Additional work based on time or dis‐ tance

♦ Depending on conditions under which the vehicle is used and vehicle equipment, extra service measures must be performed in addition to the inspection service or oil change service. ♦ It is also possible, to perform additional work outside the serv‐ ice intervals with regard to the entries in the service schedule or service sticker: “Your next service dates”.

Every 30,000 km – Air filter: clean housing and renew filter element •

Only applies to vehicles ►1996

•

Only valid for vehicles driving more than 30,000 km in 2 years

– Dust and pollen filter: renew filter element •

Only valid for vehicles driving more than 30,000 km in 2 years

14 2. Service work

⇒ page 106

⇒ page 95

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

Every 60,000 km – Toothed belt: renew •

⇒ page 105

Only valid for vehicles with diesel engine and engine code AKW

– Poly V-belt: check condition •

⇒ page 78

Only valid for vehicles with automatic tensioning roller

– Air filter: clean housing and renew filter element •

Only valid for vehicles from 1997 up to 1999

•

Only valid for vehicles driving more than 60,000 km in 2 years

⇒ page 106

– Air filter: clean housing and renew filter element • •

⇒ page 106

Only applies to vehicles 2000►

AG. Volkswagen AG d agen oes ksw not l o V gu bykm in 4 years Only valid for vehicles driving more than 60,000 ara d e nte is r o eo h utdrive r a ⇒ page 82 a Automatic gearbox: check oil level of final c s s

– – Automatic gearbox: check ATF level.

– Fuel filter: renew

– Spark plugs: renew

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Only applies to vehicles 1997►

⇒ page 89

•

On vehicles ►1999 without time limit

•

Valid for vehicles 2000► driving more than 60,000 km in 4 years

Every 90,000 km – Toothed belt: renew

⇒ page 105

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Only valid for vehicles with diesel engine and engine codes: AEY, AFN, AHB, AHU and ALE

– Camshaft drive toothed belt: renew.

⇒ page 105

Only valid for vehicles with diesel engine and engine codes: AGP, AGR, ALH, AQM, ASK, ASV and AYQ

Only valid for diesel engine with engine code 1Y

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– Toothed belt: check condition and tension

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⇒ page 112 ⇒ page 111

⇒ page 102

Every 90,000 km, then every 30,000 km – Camshaft drive toothed belt: check.

•

⇒ page 97

Only valid for vehicles with petrol engine without prescribed change interval

Every 2 years – Brake fluid: change

⇒ page 120 2. Service work

15

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Air filter: cleaning housing and renewing filter element •

Only applies to vehicles ►1996

•

Only valid for vehicles driving less than 30,000 km in 2 years

⇒ page 106

– Air filter: cleaning housing and renewing filter element •

Only valid for vehicles from 1997 up to 1999

•

Only valid for vehicles driving less than 60,000 km in 2 years

⇒ page 106

– Dust and pollen filter: renew filter element •

⇒ page 95

Only valid for vehicles driving less than 30,000 km in 2 years

3 years after initial registration and then every 2 years – Exhaust emissions test (EET): perform.

⇒ page 131

Every 4 years – Spark plugs: renew

⇒ page 89

•

Only applies to vehicles 2000►

•

Only valid for vehicles driving less than 60,000 km in 4 years

– Air filter: clean housing and renew filter element

⇒ page 106

•

Only applies to vehicles 2000►

•

Only valid for vehicles driving less than inG4 years gen A . Volkswakm en AG60,000

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♦ For stock vehicles and vehicles in storage perform measures according to ⇒ Service for stock vehicles and vehicles in stor‐ age from ELSA ⇒ maintenance tables .

Work to be completed for delivery inspection Vehicle interior

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16 2. Service work

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– Door handles, door locks, central locking and windows: check func‐ tion and ease of movement – Check function and number of keys, if necessary remove grease – Fuse(s) (in ashtray): fit – All switches, electrical consumers, gauges and other controls: check function – Service interval display: reset – Electric windows: initialise – Clock: set to correct time – Radio: activate anti-theft coding, store local radio stations to station buttons – Radio card (part of radio operating instructions): stick radio serial number and fixed code number sticker onto radio card.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

♦ The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid un‐ necessary interruptions in the work.

⇒ page 34 ⇒ page 54 ⇒ page 54 ⇒ page 55

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Work to be completed for delivery inspection Vehicle interior – Check vehicle interior for cleanliness: front and rear seats, interior trim, carpets/mats, windows – Seat and carpet protective coverings: remove.

Work to be completed for delivery inspection Vehicle exterior – All equipment which has been packed inside vehicle (mats, wiper arms, spoilers, roof aerial, wheel trims/hub caps, tyre valve exten‐ sions): install – Edge protection on doors (plastic film): remove.

– Check vehicle exterior for cleanliness: paintwork, decorative parts, windows, wiper blades – Wheel securing bolts: tightening to specified torque

⇒ page 64

Work to be completed for delivery inspection Tyres – – – – –

Rear left wheel: check condition and inflation pressure of tyre Front left wheel: check condition and inflation pressure of tyre Rear right wheel: check condition and inflation pressure of tyre Front right wheel: check condition and inflation pressure of tyre Spare wheel: check condition and inflation pressure of tyre

⇒ page 66 ⇒ page 66 ⇒ page 66 ⇒ page 66 ⇒ page 66

n AG. Volkswagen AG do es n wage s k l ot g o Work to be completed for delivery inspection yV ua b d ran e s i Underside of vehicle tee r o h t or u ac 76 a – Vehicle from below (without removing ⇒ page ss engine noise insulation): en‐ pe rm itte d

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gine, joint protective bellows, brake system, steering, axles, gear‐ box/final drive, hoses, fluid reservoir – Carrying out visual check for leaks and damage: engine, joint pro‐ tective bellows, brake system, steering, axles, gearbox/final drive, hoses, fluid reservoir – Vehicle underside (floor pan): visual check for damage

⇒ page 86

Work to be completed for delivery inspection Engine compartment ⇒ page 124 ⇒ page 126 ⇒ page 56

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– Battery: check battery terminals by hand for tightness – Battery: check – Window wash/wipe system and headlight washer system: check function and settings; replenish Windscreen Clear with anti-freeze G 052 164 to maximum.

– Engine oil level: check – Engine and components in engine compartment: visual check for leaks and damage (from above) – Coolant level: check it is at maximum – Power assisted steering: check fluid level.

– Brake fluid level: check level is at maximum

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⇒ page 71 ⇒ page 76

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⇒ page 83

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⇒ page 87 ⇒ page 119 ⇒ page 123

2. Service work

17

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

Work to be completed for delivery inspection Final checks

⇒ page 130

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18 2. Service work

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– Service sticker “Your next service”: Enter date for next service (in‐ cluding brake fluid change) on sticker and apply sticker to driver side door pillar (B-pillar) – Service schedule: enter delivery inspection.

– Vehicle literature: check literature is complete and prepare for handover to customer – Carry out road test

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

3

General information

♦ Raising vehicle with lifting platform and trolley jack ⇒ page 19 ♦ Connecting vehicle diagnostic tester ⇒ page 20 ♦ Vehicle data sticker ⇒ page 23 ♦ Engine code and engine number ⇒ page 23 ♦ Vehicle identification number ⇒ page 24 ♦ Type plate ⇒ page 24 ♦ Countries where diesel has a high sulphur content ⇒ page 24 ♦ RME fuel (biodiesel) ⇒ page 25 ♦ Attaching “Your next service” sticker ⇒ page 26

3.1

Raising vehicle with lifting platform and trolley jack

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte Lifting points for lifting platform and trolley jack ⇒ page 20 ise r o eo h t u ra a c s s

Safety information ⇒ page 19

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Safety information

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♦ Before driving onto a lifting platform, ensure that there is sufficient clearance between low-lying vehicle compo‐ nents and lifting platform. ♦ Before driving a vehicle onto a lifting platform it must be ensured that the vehicle weight does not exceed the per‐ missible lifting capacity of the platform. ♦ Vehicle may be lifted only at points indicated in figure to avoid damaging vehicle floor pan or tipping vehicle. ♦ Never start engine and engage a gear with vehicle lifted as long as even one driven wheel has contact with the floor! Disregarding these warnings risks the danger of an accident!

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♦ If work is to be performed under vehicle, it must be sup‐ ported by suitable jack stands.

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WARNING

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3.1.1

3. General information

19

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

3.1.2

Lifting points for lifting platform and trol‐ ley jack

Front (all vehicles) Position support plate at cross reinforcement -1- of floor pan.

WARNING

The vehicle must not be lifted on vertical reinforcement of side member, otherwise serious damage may occur to the vehicle.

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Rear (Caddy)

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Note

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Position support plate on vertical reinforcement of side member at area marked -1-. The centre of the support plate must align with marking for the jack -arrow-.

Ensure that side member reinforcement seats centrally on sup‐ port plate of hoist mounting and the side member is not damaged.

Rear (Polo Classic, Polo Estate)

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♦ -Fehlerauslesegerät V.A.G. 1551-

20 3. General information

AG.

Special tools and workshop equipment required

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Connecting vehicle diagnostic tester

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Position support plate at mounting bracket at marked area -1-.

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♦ Diagnostic cable - V.A.G 1551/3A-

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♦ Diagnostic cable - VAS 5051/6A-

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♦ Vehicle diagnosis, testing and information system - VAS 5051B-

♦ Vehicle diagnostic and service information system - VAS 5052-

3. General information

21

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Diagnostic cable, 2 m - VAS 5052/3-

♦ Or subsequent units Note

Ensure that the fault reader is only used with the respective di‐ agnostic cable.

WARNING

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AG. Volkswagen AG d agen oes ksw not l o V gu y b and measuring equipment on the ara Always secure testing d nte ise r rear seat duringthoa road test. eo u ra a c s s Only a passenger may operate these devices while the

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Connecting selected fault reader – Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral.

With ignition switched off connect fault reader as follows: Vehicles ►09.99 – Open stowage compartment on driver side and unhook.

– Connect diagnosis cable connector to diagnostic connection.

– Switch on ignition.

– Pull ashtray insert out of centre console.

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Vehicles 10.99►

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– Connect diagnosis cable connector to diagnostic connection.

– Switch on ignition.

22 3. General information

AG.

– Switch on tester.

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– Switch on tester.

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– Carry out following procedure:

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

Vehicle data sticker

On the delivery van the data sticker is attached on the left roof side member near the wing door and on the Kombi behind the left side trim in luggage compartment. The vehicle data sticker is also found in the service schedule for the customer.

Polo Classic and Polo Variant The vehicle data sticker -1- is located in rear of vehicle on the left in spare wheel recess. The vehicle data sticker is also found in the service schedule for the customer.

The sticker contains the following data of the vehicle 1 - Production control number 2 - Vehicle identification number 3 - Model identification number r fo ng

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5 - Engine and gearbox code letters

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7 - Optional equipment identification number

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6 - Paint number/interior equipment identification number

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4 - Model explanation/engine output

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3.3

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Now follow screen display to start desired functions.

Engine code and engine number

Engine code and engine number can be found quickest by check‐ ing the sticker -arrow- on toothed belt guard.

Note

The “engine code” can be found also on the vehicle data sticker.

The data sticker can be found in the customer service schedule and on the Caddy delivery van on left roof side member near the wing door and on the Kombi behind the left side trim in luggage compartment. On the Polo Classic and Polo Variant the data sticker is attached on the floor pan left next to the spare wheel recess in luggage compartment.

3. General information

23

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

3.5

Vehicle identification number

The vehicle identification number is located in plenum chamber It is visible through a window -arrow- in the plenum chamber cover.

Significance of vehicle identification number:

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Model

Filler charac‐ ters

Model year 2000/2001

Type plate

The type plate -arrow- is secured to the plenum chamber in the engine compartment near the right suspension turret.

Vehicles for certain export countries have no type plate.

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Production location

Serial number

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3.6

Filler charac‐ ters

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Manufactur‐ er code

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o e h ut ZZZ 6K Z Y/1 or a a c s s

For vehicles with diesel engines an oil change service must always be performed »every 7,500 km« in the following coun‐ tries: Egypt Armenia Bahrain Bangladesh Chile Dominican Republic El Salvador Ecuador Ghana Guatemala Honduras

24 3. General information

Jordan Yugoslavia4) Cambodia Kazakhstan Kenya Columbia Cuba Kuwait Lebanon Madagascar Malawi

Macedonia Moldova Mozambique Myanmar New Caledonia Nigeria Oman Pakistan Panama Papua New Guinea Peru

South Africa Surinam Tajikistan Tanzania Turkey Ukraine Uruguay Uzbekistan Venezuela United Arab Emirates Vietnam

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indonesia Iraq Iran Jamaica

Malaysia Mali Morocco Mauritius

Russia (East & West) Saudi Arabia Zimbabwe Sri Lanka

4) Yugoslavia = Serbia, Montenegro, Vojvodina, Kosovo

3.8

RME fuel (biodiesel)

RME fuel may be used only for vehicles which have been ap‐ proved for this purpose by Volkswagen in the standard version.

Caution . Volkswagen AG gen AG d

wa is not suitable for oes n ♦ When RME fuel is used and yourVvehicle ot g olks y ua b this, the fuel system can be damaged. ra ed

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RME fuel must conform to EN 14214 (FAME). ♦ RME means “Rapeseed Methyl Ester”. ♦ EN means “Euro standard”. ♦ FAME means “Fatty Acid Methyl Ester”.

Characteristics of RME fuel ♦ Performance can slightly be lower when using biodiesel. ♦ Fuel consumption can slightly be higher when using biodiesel. ♦ RME can be used in winter at temperatures to approx. -10°C

changing the fuel filter ⇒ page 6 .

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♦ When using biodiesel observe the changed intervals for

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♦ At ambient temperatures below -10°C we recommend using winter diesel fuel.

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♦ When biodiesel is used which does not conform to the re‐ quired standard, the fuel filter can become blocked.

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th ♦ When filling the tank with au biodiesel, only use RME fuel ss (FAME)! conforming to EN 14214

AG.

♦ If it is planned not to use the vehicle for approx. two weeks, it

is recommended to fill the tank with original diesel beforehand and drive approx. 50 km, to prevent damage to the fuel injec‐ tion system.

3. General information

25

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

3.9

Attaching “Your next service” sticker:

– Service sticker “Your next service”: Enter a cross in position for next oil change service or inspection service (next service due) and enter date and mileage.

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26 3. General information

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– Attach sticker to driver door pillar (B-pillar).

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 . Volkswagen AG gen AG does not gu ara d e nte s i r In this chapter you will obtain information on the following sub‐ o eo h ut ra a jects: c s s

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♦ Driver and front passenger airbags: visual check of airbag units ⇒ page 28

♦ Automatic gearbox: checking final drive oil level ⇒ page 82

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♦ Swivel joints: inspecting ⇒ page 87 ♦ Automatic gearbox: checking ATF level ⇒ page 112 ♦ Tyres: checking condition, wear pattern, inflation pressure, tread depth ⇒ page 66 ♦ Brake system: inspecting for leaks and damage ⇒ page 83 ♦ Front and rear brake pads/linings: checking thickness ⇒ page 83 ♦ Brake fluid: changing ⇒ page 120 ♦ Brake fluid level (dependent upon brake pad/lining wear): checking ⇒ page 123

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♦ Boots: inspecting ⇒ page 80

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♦ Electric windows: initialising ⇒ page 54

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♦ Self-diagnosis: reading fault memory of all systems ⇒ page 30

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♦ Battery: checking ⇒ page 126

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♦ Battery: checking battery terminal clamps for secure seating ⇒ page 124

♦ V-belt: checking condition and tension ⇒ page 77 ♦ Poly V-belt: checking condition and tension belt ⇒ page 78 ♦ Cooling system: checking coolant level and frost protection ⇒ page 87 ♦ Fuel filter: renewing (diesel engine) ⇒ page 111 ♦ Fuel filter: draining water (diesel engine) ⇒ page 112 ♦ Air filter: cleaning housing and renewing filter element ⇒ page 106 ♦ Idling speed: checking ⇒ page 126 ♦ Engine oil level: checking ⇒ page 71 ♦ Engine oil: draining or extracting and replenishing; renewing oil filter ⇒ page 72 ♦ Engine and components in engine compartment: inspecting for leaks and damage (from above and below) ⇒ page 76 ♦ Engine compartment cover (noise insulation): removing and installing ⇒ page 28 ♦ Road test: carrying out ⇒ page 130 ♦ Radio: activating anti-theft coding ⇒ page 55 ♦ Wheel securing bolts: tightening to specified torque ⇒ page 64 ♦ Service interval display: resetting ⇒ page 34 ♦ Sunroof: checking function, cleaning and greasing guide rails ⇒ page 54

4. Descriptions of work:

27

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Window wash/wipe system and headlight washer system: checking function and settings ⇒ page 56 ♦ Windscreen wiper blades: checking park position if wiper blades judder: checking setting angle ⇒ page 61 ♦ Manual gearbox/final drive: checking oil level ⇒ page 80 ♦ Track rod ball joints: checking clearance, attachment and boots ⇒ page 86 ♦ Dust and pollen filter: renewing filter element ⇒ page 95 ♦ Power assisted steering: checking fluid level ⇒ page 119 ♦ Headlight adjustment: checking ⇒ page 126 ♦ Door arrester and securing pins: lubricating ⇒ page 53 ♦ Clock: setting to correct time ⇒ page 54 ♦ Underbody protection: visual check for damage ⇒ page 86 ♦ Spark plugs: renewing ⇒ page 89 ♦ Camshaft drive belt: checking (petrol engine) ⇒ page 97 ♦ Toothed belt: checking for wear (SDI/TDI engines ►2000) ⇒ page 98 ♦ Camshaft drive toothed belt: checking condition and tension (diesel engine code ALH with automatic gearbox) AG. Volkswagen AG d ⇒ page 99 agen o w olks

yV ♦ Toothed belt: checking condition eand d b tensioning (diesel en‐ is r gine code 1Y) ⇒ page 102 ho

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4.1

Removing and installing engine com‐ partment cover (noise insulation)

Carry out following procedure: – Remove hexagon combi bolts and hexagon nuts -arrows-, swing engine compartment cover down and unhook.

– Remove engine compartment cover downwards.

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4.2

Driver and front passenger airbags: vis‐ ual check of airbag units

4.2.1

Driver side airbag vehicles ►09.99

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Airbag recognition, is via the inscription “AIRBAG” on the steering wheel padded plate.

28 4. Descriptions of work:

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Install in reverse order of removal.

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♦ Toothed belt: renewing (diesel engine codes AEY, AFN, AHB, AHU, AKW, ALE) ⇒ page 105

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♦ Toothed belt: renewing (diesel ss engine codes AGP, AGR, ALH, AQM, ASK, ASV and AYQ) ⇒ page 105

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Carry out visual check of padded plate -1- for exterior damage.

WARNING

♦ The steering wheel padded plate surface must not have stickers attached or be covered or eotherwise be modified. n AG. Volkswagen AG do es n wag of the airbag is guar‐ This ensures that the future function s k l ot g o y V is aware of these instruc‐ ua anteed. Ensure the customer b ran ed s i tee r tions. o h ut

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Front passenger side airbag vehicles ►09.99

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4.2.2

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a ♦ The steering wheel ss padded plate must only be cleaned with a dry cloth or a cloth moistened with water.

Airbag recognition by the inscription “AIRBAG” on the right-hand side of dash panel (front passenger side).

– Carry out visual check of the airbag module surface -2- for exterior damage.

WARNING

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Driver side airbag vehicles 10.99► AG.

4.2.3

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♦ The surface of the airbag module must only be cleaned with a dry cloth or a cloth moistened with water.

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♦ The surface of the front passenger airbag module must not have stickers attached or be covered or be otherwise modified. This ensures that the future function of the air‐ bag is guaranteed. Ensure the customer is aware of these instructions.

Airbag recognition, is via the inscription “AIRBAG” on the steering wheel padded plate.

– Carry out visual check of padded plate -1- for exterior damage.

WARNING

♦ The steering wheel padded plate surface must not have stickers attached or be covered or otherwise be modified.

This ensures that the future function of the airbag is guar‐ anteed. Ensure the customer is aware of these instruc‐ tions. ♦ The steering wheel padded plate must only be cleaned with a dry cloth or a cloth moistened with water.

4.2.4

Front passenger side airbag vehicles 10.99►

Airbag recognition by the inscription “AIRBAG” on the right-hand side of dash panel (front passenger side).

4. Descriptions of work:

29

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Carry out visual check of dash panel surface -2- for exterior damage.

WARNING

♦ The surface of the front passenger airbag module must not have stickers attached or be covered or be otherwise modified. This ensures that the future function of the air‐ en AG of these bag is guaranteed. Ensure the customer isagaware AG. Volksw does agen ksw not l instructions. o V g y db

ss

Reading fault memory can be performed using two methods: ♦ With fault reader - V.A.G 1551- ⇒ page 30 ♦ Vehicle diagnosis, testing and information system - VAS 5051B- or subsequent units ⇒ page 31 WARNING

♦ If the vehicle diagnostic tester is placed in the deployment area of an airbag during a road test, there is the risk of heavy or fatal injuries when the airbag is triggered! ♦ During the road test take another person with you who can operate the vehicle diagnostic tester from the rear seat. r fo ng

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Reading fault memory of all systems us‐ ing fault reader - V.A.G 1551AG.

4.3.1

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♦ Always secure testing and measuring equipment on the rear seat during a road test.

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Self-diagnosis: reading fault memories of all systems

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e risairbag module must only be cleaned ♦ The surface of the ho t with a dry clothau or a cloth moistened with water.

– Connect fault reader ⇒ page 20 .

Reading fault memory – Start engine and run it at idling speed.

– Switch on printer with Print button (warning lamp in button lights up).

Indicated on display: or

V.A.G - SELF DIAGNOSIS HELP 1 - Rapid data transfer V.A.G - SELF DIAGNOSIS HELP 2 - Flash code output

Appears alternately – Press button 1 to select “Rapid data transfer” mode.

Indicated on display:

Rapid data transfer HELP Select function XX

– Press button 0 and 0 to select address word “Automatic test sequence”.

Indicated on display:

30 4. Descriptions of work:

Rapid data transfer Q 00 - Automatic test sequence

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Confirm entry with Q button. -V.A.G 1551- transmits all known address words one after the other.

When a control unit responds with its identification, the number of stored faults or “No fault detected” appears on the display.

Any system faults that are stored will be displayed one after the other and printed out. The -V.A.G 1551- will then transmit the next address word.

The automatic test sequence is completed when following is in‐ dicated on display:

V.A.G - SELF DIAGNOSIS HELP 1 - Rapid data transfer

or

V.A.G - SELF DIAGNOSIS HELP 2 - Flash code output

Appears alternately – Switch off ignition.

If faults are stored, repairs are necessary. The fault log must ac‐ company vehicle to repair.

Note

The fault reader must remain connected if service interval display is to be reset and if emissions test is to be carried out.

4.3.2

Reading fault memories of all systems using vehicle diagnosis, testing and in‐ formation system - VAS 5051B- or sub‐ sequent units

Note

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Observe actual operating is instructions for Vehicle diagnosis, test‐ r o h t ing and informationausystem - VAS 5051B- or subsequent units e or a c s display after selecting the functions Adminwhich are shownson

WARNING

♦ If the vehicle diagnosis, testing and information system VAS 5051B- or subsequent units are placed in the de‐ ployment area of an airbag during a road test, there is the risk of heavy or fatal injuries when the airbag is triggered! ♦ During the road test take another person with you who can operate the vehicle diagnosis, testing and information sys‐ tem - VAS 5051B- or subsequent units from the rear seat. ♦ Always secure testing and measuring equipment on the rear seat during a road test.

– Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”. ht rig py Co t.

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– Manual gearbox: gear lever in neutral.

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istration and Operating manual .

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Connect vehicle diagnosis, testing and information system - VAS 5051B- or subsequent units with ignition switched off ⇒ page 20 . agen lksw Vo by

AG.

– Switch on ignition.

4. Descriptions of work:

31

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display: Selecting operating mode – Select operating mode Vehicle self-diagnosis on display -arrow-.

Indicated on display: Selecting vehicle system – Press 00 - Reading fault memory of all systems on display -arrow-.

– The fault reader sends all known address words one after the other.

When a control unit responds with its identification, the number of stored faults or “No fault detected” appears on the display.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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C op yi

32 4. Descriptions of work:

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Any system faults that are stored will be displayed one after the other. The fault reader will then transmit the next address word.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 The automatic test sequence is completed when following is in‐ dicated on display: – Press Print button -1- on display and then press Screen in the print menu.

The fault reader prints out all the faults or “0 faults detected”. Ifswagen AG. k Vol faults are stored, repairs are necessary. The fault log must by ac‐ d e company vehicle to repair. ris un le pe rm itte d

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Caution

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Volkswagen AG does not gu ara nte eo ra c

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Static faults

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The vehicle must always be delivered to the customer with fault memory cleared.

If one or more static faults are stored in the fault memory, it is recommended in agreement with the customer to rectify these faults (repair measure).

Sporadic faults

If only sporadic faults or notes are stored in the fault memory and the customer has no complaints in conjunction with the electronic vehicle system, clear fault memory.

Clearing fault memory

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♦ Clear fault memory by selecting individual control units:

AG.

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♦ Clearing fault memory via function Collection services :

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– Select the respective control unit in overview and select func‐ tion Read fault memory and then Clear fault memory

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There are two ways to clear the fault memory:

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– Start operating mode Vehicle self-diagnosis in the sys‐ tem start mask of fault reader

– Touch the function Collection services on the screen and follow instructions on display of fault reader to clear the fault memory.

Note ♦ If all faults have been cleared, it is confirmed on display. ♦ The diagnosis log can be sent automatically »online«.

– Press the GoTo button on display -2-.

4. Descriptions of work:

33

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press the End button on display -arrow-.

– Press End button in End menu.

– Switch off ignition and separate diagnosis connections.

Note

The vehicle diagnosis, testing and information system - VAS 5051B- or subsequent units must remain connected if service in‐ terval display is to be reset.

4.4

Service interval display: resetting

Vehicles with diesel engine code 1Y are equipped with a flexible service interval display. The other vehicles are equipped with a non-flexible display.

Flexible display Function: With the flexible service interval display, in addition to the odom‐ eter and clock, the thermal load and soot load of engine oil are monitored electronically and used for calculating the service in‐ tervals.

Depending on vehicle operating conditions (driving style and en‐ gine load) the next oil change service may be due at distances AG. Volkswagen AG d between 7,500 km and 15,000 km or periods between 8 and 12 agen oes ksw not l o months.

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After the ignition is switched on, the display appears for a few seconds in place of the odometer display in the distance display.

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Function:

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If service is not required, INSP-0 will be indicated.

Non-flexible display

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ri On the flexible service interval display other display contents ho will ut a be indicated compared with the non-flexible service interval dis‐ ss play.

The service interval display electronics is comprised of, amongst other items: ♦ a time recorder and ♦ two distance recorders.

The electronics evaluates both recorders so that the customer

Prote cted by

34 4. Descriptions of work:

AG.

If service is not required, IN-00 will be indicated.

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After the ignition is switched on, the service interval display ap‐ pears for a few seconds in place of the odometer display in the distance display.

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♦ after a predetermined distance is reached

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or

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♦ after a predetermined time period is exceeded or

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.4.1

Vehicles ►09.99: resetting non-flexible display

Vehicles 10.99► ⇒ page 36 Resetting flexible display for vehicles ►09.99 with engine code 1Y ⇒ page 35 After switching on the ignition (engine does not operate) the dis‐ play -arrow C- appears for a few seconds in place of the odometer display in the speedometer. If service is not required, IN 00 will be indicated.

If a service is due, also after starting the engine the following dis‐ play flashes for approx. 3 seconds (service): OIL IN 01 IN 02

Engine oil change or Inspection service every 12 months or Inspection service every 30,000 km

After a service has been performed, service types which appear in the display before that one, must also be called-up individually . Volkswagen AG gen AG and reset: does swa k Vol

y d bperformed, OIL, IN 01 ♦ If the inspection service IN 02 has been ise r and IN 02 must be reset. tho au

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s ♦ If the inspection service IN 01 shas been performed, OIL and IN 01 must be reset.

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Reset the display as follows:

rrectness o f i t to the co n f orm spec atio h re n wit

– With ignition switched on press button -arrow A- below the speedometer and hold.

– Switch off ignition and release button. The inscription “OIL” is indicated in the display.

– Press the lower of both buttons -arrow B- of digital clock until five dashes are indicated (- - - - -). Only then the service is reset.

– By pressing the button again -arrow A-, below the speedom‐ eter, the other services are indicated and can be reset indi‐ vidually.

Vehicles ►09.99 with engine code 1Y: resetting flexible display

Type of Service: AG.

or: INSP-2

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alternately OIL or INSP or: INSP-1

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Indicated on display:

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If a service is due, also after starting the engine the following dis‐ play flashes for approx. 3 seconds (service):

in t his d o cu m en

4.4.2

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– Switch on ignition and if “IN 00” appears, switch off.

Engine oil change

Inspection service every 12 months Inspection service every 30,000 km

4. Descriptions of work:

35

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 After a service has been performed, also the previous type of service must be called-up individually and reset. ♦ If the inspection service INSP-2 has been performed OIL, INSP 1 and INSP 2 must be reset. ♦ If the inspection service INSP-1 has been performed OIL and INSP 1 must be reset. . Volkswagen AG gen AG

does wa not olks gu yV b ara d e nte is r o eo With ignition switched uon th press button -arrow A- below the ra a c speedometer and hold. s s

Reset the display as follows:

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– Switch off ignition and release button. The inscription “OIL” is indicated in the display. es, in part or in w l purpos hole ercia , is n m ot com

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Press the lower of both buttons -arrow B- of digital clock until five dashes are indicated (- - - - -). Only then the service is reset.

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–

– By pressing the button again -arrow A-, below the speedom‐ eter, the other services are indicated and can be reset indi‐ vidually.

– Switch on ignition and if “IN 00” appears, switch off.

4.4.3

Vehicles 10.99►

Between services, only the total distance and distance travelled (trip recorder) is shown in the distance display -2-.

♦ with ignition switched off “service”.

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Note

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♦ after the ignition is switched on and up to 3 minutes after the engine is started the type of service (service table).

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If a service is due, the following is indicated in the distance display -2- below the total mileage:

After the engine is started the display switches back to “service” after 3 minutes.

Service table Indicated on display:

Type of Service:

Mileage and service OIL or: Mileage and service INSP

Oil change service every 15,000 km

One or both service types must be reset depending on which service was completed, therefore: ♦ If a “service OIL” (oil change service every 15,000 km) is car‐ ried out, only “service OIL” must be reset. ♦ If “service INSP” (inspection service every 12 months or every 30,000 km) has been performed “service INSP” and “service OIL” must be reset.

36 4. Descriptions of work:

Inspection service every 12 months or every 30,000 km (whichever occurs first)

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ If a “service INSP” (inspection service every 12 months or ev‐ ery 30,000 km) without an oil change has been performed, then only “service INSP” must be reset.

The service interval display can be reset using one of three meth‐ ods: ♦ With adjustment button for the distance display on dash panel insert ⇒ page 37 , ♦ With fault reader - V.A.G 1551- ⇒ page 37 ♦ Vehicle diagnosis, testing and information system - VAS 5051B- or subsequent units ⇒ page 44

4.4.4

Resetting service interval display with AG. Volkswagen adjustment button for distance agen display AG does ksw not l o V gu on dash panel insert by ara d e

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th reset (adapted) during The service interval display mustaube es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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♦ delivery inspection ♦ every oil change service

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♦ every inspection

service interval display must be reset.

Note

♦ For delivery inspection it is not possible to reset the service

interval display with the adjustment button for the trip recorder in dash panel insert.

♦ Each service must be reset individually as only the distance

recorder and time counter of the actual service can be reset.

Reset the display as follows: – Switch off ignition.

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– Switch off ignition.

c o p yri gh t.

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– Release button -1-.

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– Switch on ignition and hold button -1- depressed (min. 10 sec‐ onds) until three dashes (- - -) or the next service appears in the display. Only then the service is reset.

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– Press and hold button -1- below the distance display.

After resetting the service interval display the previous trip re‐ corder display is indicated again.

Note ♦ Note that only the actual service type indicated on display can

be reset.

♦ To reset a further service, repeat these steps.

4.4.5

Resetting service interval display with fault reader - V.A.G 1551-

The service interval display must be reset during ♦ delivery inspection

4. Descriptions of work:

37

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ AG. Volkswagen AG d Maintenance - Edition 03.2018 agen o ♦ every oil change service

Connecting fault reader - V.A.G 1551- ⇒ page 20 – Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral.

Indicated on display: or Appears alternately – Switch on ignition.

V.A.G - SELF DIAGNOSIS HELP 1 - Rapid data transfer V.A.G - SELF DIAGNOSIS HELP 2 - Flash code output

– Press button 1 to select “Rapid data transfer” mode.

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Indicated on display:

AG.

– Press keys 1 and 7 . “17” enters the address word “dash panel insert”.

Rapid data transfer HELP Enter address word XX

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Indicated on display:

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– Switch on printer with Print button (warning lamp in button lights up).

Rapid data transfer Q 17 Dash panel insert

– Confirm entry with Q button.

Indicated on display:

9K0919860 Dash panel insert MM0 V27 -> Coding 00141 WSC 00000

The control unit identification and the coding will be displayed: ♦ Top line Part No. of control unit, system designation dash pan‐ el insert, manufacturer's code version number ♦ Lower line code number 5) dealership number 6) 5) Dependent on engine, gearbox, additional equipment and country version 6) Is automatically stored in control unit when entering system.

Will be indicated on display:

Control unit does not answer! HELP

– By pressing the HELP key a list of possible fault causes is printed out.

– After rectifying faults again enter address word 17 for dash panel insert and confirm with Q key.

Indicated on display:

9K0919860 Dash panel insert MM0 V27 -> Coding 00141 WSC 00000

– Press → button.

Indicated on display:

Rapid data transfer HELP Select function XX

– Press keys 1 and 0 . (10 selects the function “Adaption”.)

Indicated on display:

38 4. Descriptions of work:

Rapid data transfer Q 10 - Adaption

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Carry out following procedure:

ss

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(adapted).

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♦ every inspection

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Confirm entry with Q key.

Indicated on display:

Adaption Enter channel number XX

– Select adaption channel of service to be reset: ♦ for display “service OIL” channel 10 ♦ for display “service INSP” channel 10, 11 and 12 Adaption table Adaption channel

Counter content

Adaption value to reset

service OIL service INSP service INSP

10 11 12

Distance in 100s of km Distance in 100s of km Time in days

00150 00300 00360

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Service

is only possible in steps of 100 km. Therefore this is shown on the display in 100 km.

for adaption value 150 this equates to a distance of 15,000 km to next service).

♦ The entered values count down to 0 km. ♦ The procedure is the same for vehicles with a distance display

in miles. This means that the same adaption figures (numbers) should be entered as for a distance display in kilometres.

♦ The counter for “INSP service” can be adapted to max. 360

days.

♦ It is only possible to make direct entries using the keyboard of

the fault reader!

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♦ When entering an incorrect value the function “Adaption” is

ended and must be restarted again!

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♦ The adaption value entered must contain 5-digits (e.g. 00150

in t his d o cu m en

Resetting service interval display “service OIL” (oil change serv‐ ice) agen lksw Vo by

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Indicated on display:

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♦ Entering the relevant adaption values for the distance recorder

Rapid data transfer HELP Select function XX

AG.

– Press keys 1 and 0 . (10 selects the function “Adaption”.)

Indicated on display:

Rapid data transfer Q 10 - Adaption

– Confirm entry with Q key.

Indicated on display:

Adaption Enter channel number XX

– Press keys 1 and 0 .

Indicated on display:

Adaption Q Enter channel number 10

– Confirm entry with Q key.

Indicated on display: The actual reading of the distance recorder is displayed for “service OIL” (e.g. here 0 equates to 0 km), i.e. the oil change service must be performed.

Channel 10 Adaption 0 -> Actual value oil in 100 km <-13->

4. Descriptions of work:

39

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Press → button.

Indicated on display:

Channel 10 Adaption 0 Enter adaption value XXXXX

To reset the service interval display for “service OIL” the distance recorder must be reset to 150 (equates to 15,000 km): Note

The procedure is the same for vehicles with a distance display in miles. This means that the same adaption figures (numbers) should be entered as for an distance display in kilometres.

– Enter adaption value 00150.

Indicated on display: – Confirm entry with Q key.

AG. Volkswagen AG d agen oes Channel ksw n t 10 Adaption 0 Q l o Enter oadaption value 00150 gu yV b ara d nte ise r eo tho ra au c s s

Channel 10 Adaption 150 Q Actual value oil in 100 km <-13->

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Indicated on display after entering adaption value 00150:

Channel 10 Adaption 150 Q Save modified value?

– Confirm entry with Q key.

Indicated on display: – Press → button.

Indicated on display: – End output.

Channel 10 Adaption 150 -> Modified value is saved

Rapid data transfer HELP Select function XX

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Rapid data transfer HELP Select function XX

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Rapid data transfer Q 10 - Adaption

AG.

Indicated on display:

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– Confirm entry with Q key.

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– Press keys 1 and 0 . (10 selects the function “Adaption”.)

Indicated on display:

in t his d o cu m en

Reset service interval display: “service INSP” (inspection every 12 months) Indicated on display:

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Indicated on display:

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– Confirm entry with Q key.

Adaption Enter channel number XX

– Press keys 1 and 2 .

Indicated on display:

Adaption Q Enter channel number 12

– Confirm entry with Q key.

Indicated on display: The actual reading of the time recorder is displayed for “service INSP” (e.g. here 0 equates to 0 days), this means the inspection service must be performed.

Channel 12 Adaption 0 -> Actual value Insp. in 1 days <-1 3->

– Press → button.

Indicated on display:

40 4. Descriptions of work:

Channel 12 Adaption 0 Enter adaption value XXXXX

. Volkswage

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an e tee ris ho t or u interval display for “service INSP” the time To reset the service ac a s s recorder must be reset to 360 (equates to 360 days): es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

– Enter adaption value 00360 Indicated on display:

rrectness of i t to the co nform spec at i h re o n wit in t his

Channel 12 Adaption 0 Q Enter adaption value 00360

– Confirm entry with Q key.

Indicated on display after entering adaption value 00360:

Channel 12 Adaption 360 Q Actual value Insp. in 1 days <-1 3->

– Confirm entry with Q key.

Indicated on display:

Channel 12 Adaption 360 Q Save modified value?

– Confirm entry with Q key.

Indicated on display:

Channel 12 Adaption 360 -> Modified value is saved

– Press → button. r fo ng

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Note

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Indicated on display:

Rapid data transfer HELP Select function XX

♦ If an inspection service with oil change service has been per‐

formed the “service OIL” service must also be reset.

♦ If an inspection service without oil change service has been

performed, the output must be terminated.

Reset service interval display: “service INSP” (inspection every 30,000 km) Indicated on display:

Rapid data transfer HELP Select function XX

– Press keys 1 and 0 . (10 selects the function “Adaption”.)

Indicated on display:

Rapid data transfer Q 10 - Adaption

– Confirm entry with Q key.

Indicated on display:

Adaption Enter channel number XX

– Press keys 1 and 1 .

Indicated on display:

Adaption Q Enter channel number 11

– Confirm entry with Q key.

Indicated on display: The actual reading of the distance recorder for “service INSP” is displayed (e.g. here 0 equates to 0 km), this means the inspection service must be performed.

Channel 11 Adaption 0 -> Actual value Insp. in 100 km <-1 3->

– Press → button.

Indicated on display:

Channel 11 Adaption 0 Enter adaption value XXXXX

To reset the service interval display for “service INSP” the dis‐ tance recorder must be reset to 300 (equates to 30,000 km):

4. Descriptions of work:

41

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note

The procedure is the same for vehicles with a distance display in miles. This means that the same adaption figures (numbers) should be entered as for an distance display in kilometres.

– Enter adaption value 00300.

Indicated on display:

Channel 11 Adaption 0 Q Enter adaption value 00300

– Confirm entry with Q key.

Indicated on display after entering adaption value 00300:

Channel 11 Adaption 300 Q Actual value Insp. in 100 km <-1 3->

– Confirm entry with Q key.

Indicated on display:

Channel 11 Adaption 300 Q Save modified value?

– Confirm entry with Q key.

Indicated on display:

Channel 11 Adaption 300 -> Modified value is saved

– Press → button.

Indicated on display:

Rapid data transfer HELP Select function XX

– Press keys 1 and 0 . (10 selects the function “Adaption”.)

Indicated on display:

Rapid data transfer Q 10 - Adaption

– Confirm entry with Q key.

Indicated on display:

pe rm itte d

Adaption Q Enter channel number 12

Indicated on display: The actual reading of the time recorder is displayed for “service INSP” (e.g. here 0 equates to 0 days), this means the inspection service must be performed.

– Press → button.

Indicated on display:

Channel 12 Adaption 0 -> Actual value Insp. in 1 days <-1 3->

Channel 12 Adaption 0 Enter adaption value XXXXX

To reset the service interval display for “service INSP” the time recorder must be reset to 360 (equates to 360 days):

r te o iva r rp fo ng

Indicated on display after entering adaption value 00360:

Channel 12 Adaption 360 Q Actual value Insp. in 1 days <-1 3->

AG.

Prote cted by

42 4. Descriptions of work:

c o p yri gh t.

C op yi

– Confirm entry with Q key.

in t his d o cu m en

– Confirm entry with Q key.

Channel 12 Adaption 0 Q Enter adaption value 00360

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Indicated on display:

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– Enter adaption value 00360

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– Confirm entry with Q key.

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Indicated on display:

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– Press keys 1 and 2 .

AG. Volkswagen AG d agen oes ksw not l Adaption o V gu y Enter channel number XX b ara d nte ise r o eo h t u ra a c s s

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display:

Channel 12 Adaption 360 Q Save modified value?

– Confirm entry with Q key.

Indicated on display:

Channel 12 Adaption 360 -> Modified value is saved

– Press → button.

Indicated on display:

Rapid data transfer HELP Select function XX

– Press keys 1 and 0 . (10 selects the function “Adaption”.)

Indicated on display:

Rapid data transfer Q 10 - Adaption

– Confirm entry with Q key.

Indicated on display:

Adaption Enter channel number XX

– Press keys 1 and 0 .

Indicated on display:

Adaption Q Enter channel number 10

– Confirm entry with Q key.

Indicated on display: The actual reading of the distance recorder is displayed for “service OIL” (e.g. here 0 equates to 0 km).

Channel 10 Adaption 0 -> Actual value oil in 100 km <-13->

– Press → button.

Indicated on display:

Channel 10 Adaption 0 Enter adaption value XXXXX

To reset the service interval display for “service OIL” the distance lkswagen AG AG. Voto recorder must be reset to 150w(equates 15,000 km): doe agen Note

s no t gu ara nte eo ra c

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The procedure is the same for vehicles with a distance display in miles. This means that the same adaption figures (numbers) should be entered as for an distance display in kilometres.

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– Enter adaption value 00150.

Indicated on display:

Channel 10 Adaption 0 Q Enter adaption value 00150

– Confirm entry with Q key.

Indicated on display after entering adaption value 00150:

Channel 10 Adaption 150 Q Actual value oil in 100 km <-13->

– Confirm entry with Q key.

Indicated on display:

Channel 10 Adaption 150 Q Save modified value?

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– Confirm entry with Q key.

Indicated on display:

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Indicated on display:

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– Press → button.

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Channel 10 Adaption 150 -> Modified value is saved

Rapid data transfer HELP Select function XX

4. Descriptions of work:

43

AG.

Prote cted by

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 End output – Press keys 0 and 6 . (06 selects the function “End output”.)

Indicated on display:

Rapid data transfer Q 06 End output

– Confirm entry with Q key.

Indicated on display:

Rapid data transfer HELP Enter address word XX

– Observe distance display in dash panel insert.

– Switch off ignition and separate diagnosis connections.

– Switch on ignition.

After the ignition is switched on, the type of service is no longer displayed in the distance display in the dash panel insert.

The service interval display is now reset.

– Switch off ignition.

– Install ashtray insert.

4.4.6

Resetting service interval display using vehicle diagnosis, testing and informa‐ AG. Volkswagen AG d tion system - VAS 5051B- or subse‐ agen oes ksw not l o V gu y quent units b ara d e

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is or

th (adapted) during The service interval display must be reset au

Note

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.

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♦ every inspection

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♦ every oil change service

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♦ delivery inspection

Observe actual operating instructions for Vehicle diagnosis, test‐ ing and information system - VAS 5051B- or subsequent units which are shown on display after selecting the functions Administration and Operating manual .

– Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral. c o p yri gh t.

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44 4. Descriptions of work:

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With ignition switched off connect fault reader as follows:

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Connecting vehicle diagnosis, testing and information system VAS 5051B- or subsequent units ⇒ page 20

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Pull ashtray insert out of centre console.

– Switch on ignition.

Selecting operating mode – Select operating mode Vehicle self-diagnosis on display -arrow-.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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Indicated on display:

Indicated on display:

Selecting vehicle system

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The control unit identification and coding are displayed -arrow-.

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Indicated on display:

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– Press 17 - Dash panel insert on display -arrow-.

4. Descriptions of work:

45

AG.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display:

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–

AG. Volkswagen AG d agen oes ksw not l o gu Press 10 - Adaption y Von display -arrow-. b ara d e nte is r o eo h ut ra a c s s

Indicated on display: – Press the adaption channel for the service which is to be reset on the display number block -arrow-: ♦ for display “service OIL” on dash panel insert channel 10 ♦ for display “service INSP” on dash panel insert channel 10, 11 and 12 r te o iva r rp fo ng

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Adaption channel

Counter content

10 11 12

Distance in 100s of km Distance in 100s of km Time in days

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AG.

service OIL service INSP service INSP

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Service

Note ♦ Entering the relevant adaption values for the distance recorder

is only possible in steps of 100 km. Therefore this is shown on the display in 100 km.

♦ The entered values count down to 0 km. ♦ The procedure is the same for vehicles with a distance display

in miles. This means that the same adaption figures (numbers) should be entered as for a distance display in kilometres.

♦ The counter for “INSP service” can be adapted to max. 360

days.

46 4. Descriptions of work:

in t his d o cu m en

Adaption table

Adaption value to reset 150 300 360

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Resetting service interval display “service OIL” (oil change serv‐ ice) Indicated on display: – Press buttons 1 and 0 on display number block -arrow-.

– Confirm entry with Q key on display number block.

Indicated on display: – Move the position indicator -arrow- on the display until 150 is displayed over the scroll bar -1- (equates to 15,000 km).

Note ♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Note

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Indicated on display:

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The procedure is the same for vehicles with a distance display in miles. This means that the same adaption figures (numbers) should be entered as for an distance display in kilometres.

– Press the Accept button on display -arrow-.

– End output.

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r fo ng

Reset service interval display: “service INSP” (inspection every 12 months)

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4. Descriptions of work:

47

AG.

Prote cted by c o py rig ht .

C op yi

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press buttons 1 and 2 on display number block -arrow-.

– Confirm entry with Q key on display number block.

Indicated on display: – Move the position indicator -arrow- on the display until -1- 360 is displayed over the scroll bar (equates 360 days).

Note ♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number. n AG. Volkswagen AG do e wage ks Vol

y left -3- of the position in‐ bthe ♦ Pressing the scroll bar briefly on ed

ris dicator moves the value to tthe ho previous number. au ss

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– Press the Save button on display -4-.

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Indicated on display:

If an inspection service was performed without oil change, end output.

If an inspection service was performed with an oil change, con‐ tinue as follows:

Indicated on display:

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AG.

Prote cted by

c o p yri gh t .

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48 4. Descriptions of work:

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r te o iva r rp fo ng

– Press < -arrow- on display.

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– Press the Accept button on display -arrow-.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press 10 - Adaption on display -arrow-.

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d Indicated on display: nte ise r o eo h t u ra – Press buttons 1 and 0 on display a number block -arrow-. c s s

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Indicated on display:

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– Confirm entry with Q key on display number block.

– Move the position indicator -arrow- on the display until 150 is displayed over the scroll bar -1- (equates to 15,000 km).

Note

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

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c o p yri gh t.

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– Press the Save button on display -4-.

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indicator moves the value to the next number.

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♦ Pressing the scroll bar briefly to the right -2- of the position

Note

The procedure is the same for vehicles with a distance display in miles. This means that the same adaption figures (numbers) should be entered as for an distance display in kilometres.

Indicated on display: – Press the Accept button on display -arrow-.

– End output.

Reset service interval display: “service INSP” (inspection every 30,000 km)

4. Descriptions of work:

49

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press buttons 1 and 1 on display number block -arrow-.

– Confirm entry with Q key on display number block.

pe rm itte d

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displayed over the scroll bar -1- (equates to 30,000 km).

♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Note

Indicated on display: ht rig py Co t.

– Press the Accept button on display -arrow-.

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For the inspection every 30,000 km, also the inspection service every 12 months and the oil change service must be reset as fol‐ lows:

50 4. Descriptions of work:

AG.

– Press < -arrow- on display.

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Indicated on display:

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The procedure is the same for vehicles with a distance display in miles. This means that the same adaption figures (numbers) should be entered as for an distance display in kilometres.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

Note

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e Indicated on display: nte is r o eo th u ac a – Move the sposition indicator -arrow- on the display until 300 ris s

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press 10 - Adaption on display -arrow-.

Indicated on display: – Press buttons 1 and 2 on display number block -arrow-.

– Confirm entry with Q key on display number block.

Indicated on display: G. Volkswagen

nA G do agedisplay – Move the position indicator -arrow- on the until -1-A360 es n w ot g olks V is displayed over the scroll bar (equates 360 days). ua by

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♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number. es, in part or in w l purpos hole ercia , is n m ot com

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♦ Pressing the scroll bar briefly on the left -3- of the position in‐

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Note

ed ris ho t au

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Indicated on display:

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– Press the Accept button on display -arrow-.

4. Descriptions of work:

51

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AG.

Prote cted by c o py rig ht .

C op yi

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display:

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

pe rm itte d

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Indicated on display:

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– Press < -arrow- on display.

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Indicated on display:

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– Press 10 - Adaption on display -arrow-.

– Confirm entry with Q key on display number block.

Prote cted by

♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Note

The procedure is the same for vehicles with a distance display in miles. This means that the same adaption figures (numbers) should be entered as for an distance display in kilometres.

52 4. Descriptions of work:

AG.

Note

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c o p yri gh t.

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– Move the position indicator -arrow- on the display until 150 is displayed over the scroll bar -1- (equates to 15,000 km).

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Indicated on display:

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– Press buttons 1 and 0 on display number block -arrow-.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press the Accept button on display -arrow-.

– End output.

End output

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Indicated on display:

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pe rm itte d

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– Press the GoTo button on display -arrow-.

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Indicated on display:

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– Press the End button on display -arrow-.

– Press End button in End menu.

Prote cted by

4.5

AG.

– Install ashtray insert.

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– Switch off ignition.

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The service interval display is now reset.

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After the ignition is switched on, the type of service is no longer displayed in the distance display in the dash panel insert.

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– Switch on ignition.

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– Switch off ignition and separate diagnosis connections.

Door arrester and securing pins: lubri‐ cating

Carry out following procedure: – Grease door arrester and securing pin at points shown -arrows-.

– Grease door arrester in side area -arrow A- with grease -G 000 400- .

– Grease securing pin -arrow B- with lock cylinder lubricant spray -G 000 400 01- .

4. Descriptions of work:

53

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.6

Sunroof: checking function, cleaning and greasing guide rails

Carry out following procedure: – Check function of sunroof.

– Clean guide rails -arrows-, and lubricate them with special grease -G 000 450 02- .

Electric windows: initialising pe rm itte d

Note

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

The automatic opening and closing features for the electric win‐ dows do not function after disconnecting and reconnecting the vehicle battery. The electric windows must be initialised before a new vehicle is delivered. The vehicle battery must not be discon‐ nected after initialisation.

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4.7

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

WARNING

After vehicle battery has been disconnected and reconnected the roll-back function of the electric window regulators is disa‐ bled. Severe pinching injuries could result!

– Close all doors and windows completely.

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– Unlock vehicle.

– Lock vehicle again from outside at driver door or front pas‐ senger door. Hold key in lock position for at least 1 second.

Clock: setting to correct time

4.8.1

Vehicles ►09.99

Carry out adjustment as follows:

54 4. Descriptions of work:

AG.

4.8

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– Lock vehicle from outside at driver door or front passenger door.

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Carry out the following procedure to initialise the electric windows:

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 To set the time there are two press buttons -arrow B- in lower right of dash panel insert. The hours are set with the upper button, the minutes are set with the lower button.

Setting hours – Press briefly, preferably with a ball pen on upper button, to advance the time one hour. Pressing the button continuously speeds up selection of hours.

Setting minutes – Press briefly, preferably with lower button, to lkswapen Voball gen Aon .a G dobutton continu‐ gen AG Pressing aminute. advance the time one the es n w s k ot g Vol ously speeds dup ua by selection of minutes. ran t

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ee ho button the clock can be set exactly to the second With the minute or ut ac

sa

4.8.2

Vehicles 10.99►

Carry out adjustment as follows: Setting hours – Press briefly, preferably with a ball pen on button -1-, to ad‐ vance the time one hour. Pressing the button continuously speeds up selection of hours.

Setting minutes – Press briefly, preferably with a ball pen on button -2-, to ad‐ vance the time one minute. Pressing the button continuously speeds up selection of minutes.

With the minute button the clock can be set exactly to the second. r fo ng

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Radio: activating anti-theft coding agen lksw Vo by

4.9

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– Press button until time is one minute before time to be set.

Turn button at the moment when the seconds indicator of ac‐ curate clock shows a full minute.

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– Press sbutton until time is one minute before time to be set.

Turn button at the moment when the seconds indicator of ac‐ curate clock shows a full minute.

The radio units and radio-navigation systems are supplied with a fixed code. Fixed code means that each unit with an anti-theft coding is programmed with its own code number. This fixed code is not active when leaving the factory.

AG.

Activate fixed code on “alpha” radio units as follows: The security coding of the ready to play radio is not activated until the fixed code is entered. The fixed code is to be activated as follows: – Switch radio unit on.

– “SAFE” appears on digital display.

– Press buttons TP and TA -1- simultaneously until “1000” ap‐ pears on the digital display. Release buttons.

– With the help of station buttons 1 to 4 enter code number applied on radio card. Press button 1 to enter the first digit of code number, button 2 to enter the second digit and so on.

4. Descriptions of work:

55

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Then press buttons TP and TA -1- simultaneously again and hold down until “SAFE” appears on the frequency display. Re‐ lease buttons. Soon afterwards a frequency will automatically appear.

If the fixed code number has been entered correctly in the radio unit, the LED located next to the unit name must flash when the ignition key is removed. When the diode flashes the radio is ready-for-use and the anti-theft coding is activated.

On radio units “beta and gamma” activate the fixed code as fol‐ lows: – Switch radio unit on.

– “SAFE” appears on digital display.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i With the help of station buttons 1 to 4 enter code onumber tee r h t or u first digit of applied on radio card. Press button 1 to enter the ac a s s code number, button 2 to enter the second digit and so on.

– After approx. 3 seconds “1000” appears on display.

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– Then press the search function -1- or manual setting -2- rocker switch for longer than 2 seconds. Release button.

If the correct code has been entered, the actual radio frequency will appear after a short “learning phase”. During this pause the stations with the best reception will be automatically stored to an internal memory list and can be called up. The LED on the lower left of the radio must flash when the ignition key is removed. When the diode flashes the radio is ready-for-use and the anti-theft cod‐ ing is activated.

Window wash/wipe system and head‐ light washer system: checking function and settings r fo ng

Checking Windscreen Clear with anti-freeze of windscreen wash/ wipe system, replenishing with fluid if necessary ⇒ page 56 Prote cted by

Note

When during a functional test it is determined that the wiper blades judder or make noises, check wiper blade setting angle ⇒ page 61 .

4.10.1

Checking Windscreen Clear with antifreeze of windscreen wash/wipe sys‐ tem, replenishing with fluid if necessary

Checking anti-freeze concentration: Special tools and workshop equipment required

56 4. Descriptions of work:

AG.

Headlight washer system: Check spray jet settings, adjust if nec‐ essary ⇒ page 60

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c o p yri gh t .

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Windscreen wash/wipe system: Check spray jet settings, adjust if necessary ⇒ page 58

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4.10

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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–

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Refractometer - T10007-

. Volkswagen AG gen AG d

s

pe rm itte d

– Check concentration of anti-freeze additive using refractome‐ ter - T10007- (refer to operating instructions).

The scale -2- is designed for commercially available windscreen cleanser as well as a mixture of commercially available wind‐ screen cleanser and genuine Volkswagen Windscreen Clear with anti-freeze - G 052 164- .

Mixing ratio

In summer -16°C -35°C -40°C

1 part 1 part 1 part 2 parts

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AG.

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Windscreen Clear G 052 164 ht rig py Co t.

Frost protection to

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rrectness o f i t to the co n f orm spec atio h re n wit

The scale -1- of the refractometer - T10007- is calibrated for Gen‐ uine Volkswagen Windscreen Clear with anti-freeze - G 052 164- .

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oes swa at light-dark border. ktests not Read precise value for the following Vol by Using a pipette, place a drop ofedwater on the glass to improve the guara nte ris readability of the bright/dark eo hoboundary. The light-dark border can ut “WATERLINE”. ra be clearly recognised ons athe c

Water 4 parts 2 parts 1 part 1 part

Prote cted by c o p yri gh t.

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Replenishing with fluid The fluid reservoir of the window washer system must be filled completely.

Starting immediately, use only Genuine Volkswagen Windscreen Clear with anti-freeze - G 052 164- all-year-round when replen‐ ishing window wash/wipe system.

4. Descriptions of work:

57

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note ♦ For all vehicles having fan-type spray jets, the reservoir must

be filled with Genuine Volkswagen Windscreen Clear with an‐ ti-freeze - G 052 164- , as this fluid has a low viscosity at temperatures below freezing. Otherwise the complicated spray jet system can become blocked by the crystallised washer fluid, which affects the spray pattern of the spray jet.

Genuine Volkswagen Windscreen Clear with anti-freeze - G 052 164- ensures that the fan type spray jets remain fully func‐ tional at low temperatures.

♦ Genuine Volkswagen Windscreen Clear with anti-freeze - G

052 164- protects the spray jets, fluid reservoir and connecting wagen AG. Volkswagen AG doe s no olks hoses from freezing. t gu yV b ed

ara nte e

ris ♦ Use Genuine Volkswagen Windscreen Clear with anti-freeze tho un le

pe rm itte d

♦ Frost protection in the washer system must be guaranteed to

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

approx. -25°C (approx. -35°C in countries with an arctic cli‐ mate).

4.10.2

or ac ility ab y li an pt ce

uThe pow‐ - G 052 164- in the warmer periods of the year also. sa erful cleanser removes wax and oil residue from sthe glass.

Windscreen wash/wipe system: check‐ ing spray jet settings, adjusting if neces‐ sary

Windscreen without preset washer jets

Special tools and workshop equipment required

Prote cted by

♦ If spray jet is irregular or cannot be adjusted to centre of wiped

area, renew spray jet (repair measure).

♦ Never use a needle or similar object, as otherwise water pas‐

sages in spray jets will be damaged!

58 4. Descriptions of work:

AG.

to direction of spray with compressed air or water.

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♦ The spray jets may be cleaned in both directions, also opposite

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Note

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♦ Window washer jet adjusting tool - 3125 A-

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 AG. Volkswagen

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–

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–

AG do n es n wage ot g olks V y setting, if necessary adjust spray ua jets using Check spray jet b ran ed s i tee r windowhowasher jet adjustment tool - 3125 A- . t or u ac a Adjust ss the outer right spray jet to the following dimension:

pe rm itte d

a - 280 mm b - 300 mm

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c - 430 mm d - 560 mm – Adjust the inner left spray jet to the following dimension: e - 400 mm f - 330 mm – Adjust the outer left spray jet to the following dimension: g - 330 mm Tolerance for all spray jets: ± 20 mm Windscreen with preset washer jets

in t his d o cu m en

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h - 560 mm

rrectness o f i t to the co n f orm spec atio h re n wit

– Adjust the inner right spray jet to the following dimension:

The spray jets are preset. However, small differences in height may be corrected. ht rig py Co t.

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AG.

Prote cted by

c o p yri gh t .

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Note

The spray jets may be cleaned in both directions, also opposite to direction of spray with compressed air or water.

If both spray fields are not at same height, adjust spray direction upwards as follows:

– Turn eccentric on spray jet in -direction of arrow- using a screwdriver.

Rear window

Special tools and workshop equipment required

4. Descriptions of work:

59

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Window washer jet adjusting tool - 3125 A-

Note ♦ If spray jet is irregular or cannot be adjusted to centre of wiped

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d Never use a needle or similar object, as otherwise water nte isepas‐ r o eo h sages in spray jets will be damaged! t u ra a c s s

area, renew spray jet (repair measure).

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– Check jet setting.

pe rm itte d

♦

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es, in part or in w l purpos hole ercia , is n m ot com

Nozzle setting for rear window: spray jet aimed at centre of wiper field – Adjust jet with window washer jet adjusting tool - 3125 A- if necessary.

4.10.3

Headlight washer system: checking spray jet settings, adjusting if necessary

Special tools and workshop equipment required

r te o iva r rp fo ng

60 4. Descriptions of work:

Prote cted by

If stream of water is uneven or cannot be adjusted to specified dimensions, renew washer jet (repair measure).

AG.

Note

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c o p yri gh t.

C op yi

– Check jet settings, if necessary adjust with setting device 3019 A- .

in t his d o cu m en

Carry out following procedure:

ht rig py Co t.

♦ Adjusting tool - 3019 A-

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Jet adjustment dimensions for the right-hand headlight (left-hand mirror image).

– Adjust the outer right spray jet to the following dimension: a - 130 mm b - 60 mm – Adjust the inner right spray jet to the following dimension: c - 65 mm d - 125 mm

4.11

Windscreen wiper blades: checking . Volkswagen AG park lkposition, blades judder: gen AG if wiper does swa not o V g y ua b checking setting angle ran ed

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th wiper blades: check park position, adjust if necessary or Windscreen ac au s ⇒ pages 61

4.11.1

Windscreen wiper blades: checking park position, adjusting if necessary

Special tools and workshop equipment required

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AG.

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♦ Puller - T10130-

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♦ Torque wrench - V.A.G 1331-

rrectness o f i t to the co n f orm spec atio h re n wit

Wiper blades: checking setting angle, adjust if necessary ⇒ page 63

in t his d o cu m en

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pe rm itte d

Rear window wiper blades: check park position, adjust if neces‐ sary ⇒ page 62

Vehicles ►09.99 – Check park position.

4. Descriptions of work:

61

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 olksw

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agen AG AG. V does agen ksw not l o gu – Check if wiper blades are in park positiond bon y V markings in the ara e nte windscreen. is r o eo h ut ra a c a - Markings for left-hand drive vehicles s s

pe rm itte d

b - Markings for right-hand drive vehicles – Adjust park position by moving wiper arm if necessary.

Note

rrectness o f i t to the co n f orm spec atio h re n wit

Vehicles 10.99►

es, in part or in w l purpos hole ercia , is n m ot com

Wiper arm torque setting: 20 Nm

On RHD vehicles, the wiper blades are a mirror image of those on LHD vehicles.

– Deactivate APP function.

– Allow wiper to move to park position and then switch ignition off. r te o iva r rp fo ng

The distance -A- between wiper blade and upper side of plenum chamber cover must be 30 mm.

– Tighten threaded connections to prescribed torque settings »Vehicle electrics« ⇒ Vehicle electrics; Rep. gr. 92 ; Assem‐ bly overview - windscreen wiper system »Assembly overview - windscreen wiper system« Front passenger side: The distance -B- between wiper blade and upper side of plenum chamber cover must be 30 mm.

– Adjust windscreen wiper park position by moving the wiper arm if necessary.

Remove wiper arms »Vehicle electrics« ⇒ Vehicle electrics; Rep. gr. 92 ; Removing and installing windscreen wiper system »Re‐ moving and installing windscreen wiper system« – Tighten threaded connections to prescribed torque settings »Vehicle electrics« ⇒ Vehicle electrics; Rep. gr. 92 ; Assem‐ bly overview - windscreen wiper system »Assembly overview - windscreen wiper system«

4.11.2

Rear window wiper blades: checking park position, adjusting if necessary

Caddy – Check park position.

62 4. Descriptions of work:

AG.

Remove wiper arms »Vehicle electrics« ⇒ Vehicle electrics; Rep. gr. 92 ; Removing and installing windscreen wiper system »Re‐ moving and installing windscreen wiper system«

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– Adjust windscreen wiper park position by moving the wiper arm if necessary.

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Driver side:

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– Now adjust the windscreen wiper park position.

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

The distance -a- between wiper blade and lower edge of window must be 15 mm (measured from glass lower edge).

Polo Estate – Check park position.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

– Adjust park position by moving wiper arm if necessary. Speci‐ fied torque for wiper arm: 15 Nm

The distance -a- between wiper blade and lower edge of window must be 20 to 30 mm (measured from glass lower edge).

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4.11.3

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– Adjust park position by moving wiper arm if necessary. Speci‐ fied torque for wiper arm: 15 Nm

Wiper blades: checking setting angle, adjusting if necessary

Note

Check setting angle only if wiper blades judder or make noises.

Special tools and workshop equipment required ♦ Wiper setting device - 3358 B-

Carry out following procedure: – Set wiper arms to rest position.

– Remove wiper blade.

4. Descriptions of work:

63

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Insert wiper arm -2- into wiper arm setting device - 3358 Band secure with locking screw -3-.

– Check setting angle.

Contact angle (specifications) for LHD vehicles RHD vehicles -7° +7° -6° +6° Plastic wiper arm. Adjustment is not possible. ±2° ±2°

Driver side Front passenger side Rear wiper, Polo estate Tolerance

Adjust setting angle to specification, if required, as follows:

. Volkswagen AG gen AG d

wa device and adjust oes n – Fit 24 mm open jaw spanner -1- on Vsetting ot g olks y ua b wiper arm -2- to specification -arrows-. ra ed

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– Check setting against table. Repeat adjustment and check sequence until specifications are achieved.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Remove setting device and fit wiper blade.

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th – Release wiper arm -2- fromausetting device and then resecure with locking screw -3-. ss

– Check if wiper system operates without juddering.

4.12

Wheel securing bolts: tightening to specified torque

Special tools and workshop equipment required

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64 4. Descriptions of work:

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and if necessary, if anti-theft wheel bolts are installed:

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♦ Torque wrench - V.A.G 1332/- (40-200 Nm)

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Adapter set for tamper-proof wheel bolts - T10101Remove cover cap The puller hooks to remove the cover caps are located with the vehicle tool kit.

Wheel bolts The adapter to loosen and tighten the anti-theft wheel bolts is found in the vehicle tool kit or use the adapter set for wheel bolts - T10101- .

Note

Ensure that wheel bolts are tightened diagonally and alternately to the following torque setting: Specified torque: 120 Nm WARNING G. Volkswagen AG d Whenever wheels are mounted, wheel bolts or nuts must be nA oes wage s k not l tightened a second time. o gu yV b ed

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Note

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ris approx. 50 km.

Wheel bolts or nuts must be retightened after ho

rrectness of i t to the co nform spec at i h re o n wit in t his

At “Delivery inspection” do not hang a label on the interior rear view mirror, because the wheels have already been tightened to prescribed torque at the factory. The wheels must only be retight‐ ened at “Delivery inspection” to the prescribed torque.

– Whenever wheels are mounted, hang the label on interior rear view mirror in a visible position.

– Place puller hooks and adapter with vehicle tool kit after com‐ pleting work.

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Installing full sized wheel trim

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4. Descriptions of work:

65

AG.

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 n AG. Volkswagen A

4.13

rrectness of i t to the co nform spec a t i h re o n in wit thi s

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e does wagtyre – Install full sized wheel trim so that the filler valve is Gguided not olks V gu y through the cut-out provided -arrow-. b ar d

Tyres: checking condition, wear pattern, inflation pressure, tread depth

Note

♦ The following work descriptions also apply to the spare wheel, ♦ For safety reasons, only tyres of same type and tread pattern

should be fitted on a vehicle!

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Checking wear pattern ⇒ page 67

Tyre tread depth (including spare wheel): Check and enter ⇒ page 67 AG.

Tyre pressures (including spare wheel): Check, correct if neces‐ sary ⇒ page 67

4.13.1

Checking condition

Tests at delivery inspection – Check tyre areas for damage as follows: ♦ »Tyre tread« ♦ »Tyre side wall« – Remove foreign bodies from tyres such as nails and glass splinters if necessary.

Note

If damage is determined, always check to see if a new tyre should be fitted.

Checks during inspection service – Check tyre areas for damage as follows: ♦ »Tyre tread« ♦ »Tyre side wall« – Remove foreign bodies from tyres such as nails and glass splinters if necessary.

– Check tyres additionally for: ♦ »Cupping«

66 4. Descriptions of work:

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Check condition ⇒ page 66

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if a spare wheel with standard tyres is fitted.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ »One-sided tread wear« ♦ »Porous side walls« ♦ »Cuts« ♦ »Punctures« Note

The customer must be informed of any faults found.

4.13.2

Wear pattern: checking

The wear pattern on the front tyres will indicate, for example, if toe and camber settings should be checked: ♦ Feathering on tread indicates incorrect toe setting. ♦ One-sided tread wear is mainly attributed to incorrect camber.

When wear of this nature is detected, determine cause by check‐ ing alignment (repair measure).

4.13.3

Tyre tread depth (including spare wheel): checking and entering

– Check tyre tread depth.

Minimum tread depth: 1.6 mm Note ♦ This figure may vary according to legislation in individual coun‐

tries.

n AG. Volkswagen AG do es n ot g V ua worn down level with the 1.6 mm high tread wear by indicators d ran e s -arrows- positioned at intervals around theotyre. tee ri h or ut ac a If the tread depth is approaching the minimum allowed depth, ss

age whave ♦ The minimum tread depth is reached when the tyres olks

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Tyre pressures (including spare wheel): checking, correcting if necessary

rrectness of i t to the co nform spec at i h re o n wit in t his

4.13.4

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

inform the customer.

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♦ Tyre inflator - VAS 5216-

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Special tools and workshop equipment required

4. Descriptions of work:

67

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note ♦ “Checking tyre pressure” also applies to the spare wheel, if a

spare wheel with standard tyres is fitted.

♦ The pressures in the table apply to cold tyres. Do not reduce

increased pressures of warm tyres.

♦ Winter tyres and summer tyres may be used with the same

tyre sizes.

♦ The tyre pressure for winter tyres must be 0.2 bar higher than

the tyre pressure for standard tyres, but should not exceed 3.5 bar.

♦ Important information about brands of tyre recommended by

us can be found in “Volkswagen Commercial Vehicles Serv‐ iceNet/Accessories/Tyres/Wheels and Tyres/Wheels and Tyres Guide for Commercial Vehicles/Wheels and Tyres Cata‐ logue”.

♦ Tyre pressures for summer tyres for the relevant model can

also be found on a sticker attached to the inside of fuel tank flap.

♦ Values for pressure are given in “bar”. ♦ Adjust the tyre pressure to suit the vehicle load. When doing

this, commercial vehicles predominantly drive with a tyre pres‐ sure at full load.

♦ On vehicles with steel wheels and wheel trim check tyre pres‐

sure valve extensions for damage and soiling, otherwise leaks could occur. If necessary, renew extensions.

AG. Volkswagen AG d agen oes

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Vehicles with petrol engine Half load Front

Rear

Front

Rear

2.0 2.2

2.4 2.4

2.1 2.3

3.4 3.4

40 kW/44 kW with tyres 175/65 R 14 185/60 R 14 55 kW with tyres 175/65 R 14 185/60 R 14 Spare wheel:

2.2 2.2

2.4 2.3 2.4 2.3 Keep to the highest pressure required for the vehicle.

Half load

AG.

68 4. Descriptions of work:

Rear

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Front

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Vehicles with diesel engine

42 kW (not postal vehi‐ cles) with tyres

Full load

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Tyre pressures in bar

Front

3.4 3.4

Full load Rear

wa,gPolo Caddy Kasten/Kombi 1996 . Volks➤ en AG Classic 1996 ➤ , Polo Variant 1998 ➤ AG does agen ksw not Maintenance - Edition 03.2018 l o V g

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2.4 2.4

2.3 2.3

2.2 2.2

2.4 2.4

2.3 2.3

2.4 2.3 2.4 2.3 Keep to the highest pressure required for the vehicle.

r fo ng

2.2 2.2

Vehicles with petrol engine

Prote cted by

40 kW/44 kW with tyres 185/60 R 14 2.0 185/55 R 15 2.1 55 kW with tyres 185/60 R 14 2.2 185/55 R 15 2.1 66 kW with tyres 185/55 R 15 2.1 74 kW with tyres 185/55 R 15 2.2 Spare wheel (all engine types) Temp. spare standard wheel

Rear

3.4 3.4

3.4 3.4

3.4 3.4

Full load

Front

Rear

2.0 1.9

2.2 2.2

2.6 2.5

2.2 1.9

2.4 2.2

2.6 2.5

1.9

2.2

2.5

2.1

2.4

2.6

AG.

Front

Half load

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Tyre pressures in bar

2.2 2.2

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Polo Classic

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175/65 R 14 185/60 R 14 47 kW (not postal vehi‐ cles) with tyres 175/65 R 14 185/60 R 14 66 kW (not postal vehi‐ cles) with tyres 175/65 R 14 185/60 R 14 Spare wheel:

ua ran tee

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y db ise r o Vehicles with diesel engineauth s s

4.2 Keep to the highest pressure required for the vehicle.

Vehicles with diesel engine Half load 42 kW/44 kW with tyres 185/60 R 14 47 kW with tyres 185/60 R 14 185/55 R 15

Full load

Front

Rear

Front

Rear

2.1

2.0

2.3

2.6

2.1 2.1

2.0 1.9

2.3 2.2

2.6 2.5 4. Descriptions of work:

69

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Vehicles with diesel engine 50 kW with tyres 185/55 R 15 2.1 66 kW with tyres 185/60 R 14 2.3 185/55 R15 2.3 81 kW with tyres 185/60 R 14 2.3 185/55 R 15 2.4 Spare wheel (all engine types) Temp. spare standard wheel

1.9

2.2

2.5

2.2 2.1

2.4 2.4

2.6 2.6

2.2 2.2

2.4 2.5

2.6 2.7

4.2 Keep to the highest pressure required for the vehicle.

Polo Estate Tyre pressures in bar Vehicles with petrol engine Half load

Full load

Half load

2.1 2.1

AG.

70 4. Descriptions of work:

2.1

Rear

Rear

2.6 2.6

2.6 2.6

2.6

2.7 2.7

Full load

Front

Rear

2.1

2.2

2.6

2.0 2.0

2.2 2.2

2.6 2.6

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Front

42 kW/44 kW with tyres 185/60 R 14 47 kW with tyres 185/60 R 14 185/55 R 15

ht rig py Co t.

r fo ng

Vehicles with diesel engine

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Front Rear Front k s l w o a V 40 kW/44 kW g . e n AG d n AG oes wage with tyres not olks V gu y b ara d e 185/60 R 14 2.1 2.0 2.2 nte is r o eo h t 185/55 R 15 au 2.1 2.0 2.2 ra c ss 55 kW with tyres 185/60 R 14 2.1 2.0 2.2 185/55 R 15 2.1 2.0 2.2 66 kW with tyres 185/55 R 15 2.1 2.0 2.3 74 kW with tyres 185/60 R 14 2.2 2.2 2.3 185/55 R 15 2.2 2.3 2.2 Spare wheel (all engine types) Temp. spare 4.2 standard wheel Keep to the highest pressure required for the vehicle.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

2.4 2.4

2.7 2.7

2.2 2.2

2.4 2.4

2.7 2.7

4.2 Keep to the highest pressure required for the vehicle.

Engine oil level: checking r fo ng

After shutting off engine, wait at least 3 minutes so that the oil can flow back into the sump.

AG.

Note

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– Pull out dipstick, wipe with a clean cloth and push dipstick in again to limit stop.

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Please note the following:

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2.2 2.2

rrectness of i t to the co nform spec at i h re o n wit in t his

4.14

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a 2.0 2.2 2.6 c s s

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50 kW with tyres 185/55 R 15 2.1 66 kW with tyres 185/60 R 14 2.3 185/55 R 15 2.3 81 kW with tyres 185/60 R 14 2.3 185/55 R 15 2.3 Spare wheel (all engine types) Temp. spare standard wheel

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Vehicles with diesel engine

Please observe disposal instructions!

– Pull dipstick out again and read oil level.

Area a Area b Area c

Oil must be replenished. After replenishing it is sufficient when the oil level is somewhere in area -b-.

Oil does not have to be replenished.

Do not top up oil.

Note

A danger exists of damaging the catalytic converter when oil level is above area -c-.

4. Descriptions of work:

71

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – When oil level is below min. marking, replenish with oil to max. marking. Oil specifications ⇒ page 6

4.15

Engine oil: Draining or extracting and re‐ plenishing; renewing oil filter

Special tools and workshop equipment required ♦ Oil extractor - V.A.G 1307 A-

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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72 4. Descriptions of work:

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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or

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Used oil collection and extraction unit - V.A.G 1358 A♦ Torque wrench - V.A.G 1331Note ♦ If the engine oil is drained and not extracted with an oil ex‐

tractor, replace drain plug seal. This prevents leaks.

♦ Please observe disposal instructions! ♦ Oil capacities see »Engine mechanics« ⇒ Engine mechanics;

Rep. gr. 17 ; Removing and installing parts of lubrication sys‐ tem »Removing and installing parts of lubrication system«

TDI engines: After changing engine oil and oil filter, check follow‐ ing after first engine start: Volkswa

gen AG en AG. as long doeoil – The engine must only run at idling as the wagspeed s no olks in dash panel. Do not rev t gu V pressure warning lamp lights up up! y b ara d If the engine is revved up nte ir se the turbocharger can be damaged eo or fail completely. utho r un le

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es, in part or in w l purpos hole ercia , is n m ot com

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

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a ss

– The full oil pressure is not attained until the warning lamp has gone out, only then can the engine be revved up.

Remember that the following torque details must not be excee‐ ded. Excessive torque can cause leaks in the area of the oil drain plug or even damage.

Oil drain plug torque setting: 30 Nm Because of the positive oil properties, use only the following ap‐ proved engine oils: ♦ Oil specification for petrol and diesel engines ⇒ page 6 – After replenishing with oil, wait at least 3 minutes and then check oil level. r te o iva r rp fo g n

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c o p yri gh t .

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Please observe disposal instructions!

ht rig py Co t.

Note

do c um en

– Pull out dipstick, wipe with a clean cloth and push dipstick in again to limit stop.

AG.

Prote cted by

– Pull out dipstick and read off oil level:

Area a

Oil must be replenished. After replenishing it is sufficient when the oil level is somewhere in area -b-.

4. Descriptions of work:

73

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Area b Area c

Oil does not have to be replenished.

Do not top up oil.

Note

A danger exists of damaging the catalytic converter when oil level is above area -c-.

4.15.1

Oil filter: renewing

Special tools and workshop equipment required

pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com r te o iva r rp fo ng

♦ Oil filter strap wrench

Engine codes ADZ, AEY, AFN, AFT, AHB, AHU, AKW, ALE, 1F and 1Y

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AG.

74 4. Descriptions of work:

Prote cted by c o p yri gh t.

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Carry out following procedure:

in t his d o cu m en

or

rrectness o f i t to the co n f orm spec atio h re n wit

♦ Oil filter tool (commercially available)

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♦ Torque wrench - V.A.G 1331-

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♦ Oil filter tool - 3417-

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Loosen oil filter -arrow- from below with oil filter tool and re‐ move oil filter.

Note

Please observe disposal instructions!

– Clean engine sealing surface.

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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– Screw in filter and tighten hand-tight.

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– Oil rubber seal lightly on new filter. Thus the oil filter can ad‐ here better when tightening, which assures best possible seal‐ ing.

Engine codes AEE, AEX, AKV, ALM, ANX and APQ Carry out following procedure:

Please observe disposal instructions!

– Oil rubber seal lightly on new filter. Thus the oil filter can ad‐ here better when tightening, which assures best possible seal‐ ing.

AG.

Carry out following procedure:

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Engine codes AEH, AKL, APF and AUR

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– Screw in filter and tighten hand-tight.

in t his d o cu m en

– Clean engine sealing surface.

ht rig py Co t.

Note

r te o iva r rp fo ng

– Loosen oil filter -arrow- from below with strap wrench and re‐ move oil filter.

– Loosen oil filter -arrow- from below with strap wrench and re‐ move oil filter.

Note

Please observe disposal instructions!

– Clean engine sealing surface.

– Oil rubber seal lightly on new filter. Thus the oil filter can ad‐ here better when tightening, which assures best possible seal‐ ing.

– Screw in filter and tighten hand-tight.

Engine codes AGP, AGR, ALH, AQM, ASK, ASV and AYQ Carry out following procedure:

4. Descriptions of work:

75

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Release sealing cap -1- with oil filter key - 3417- .

– Renew O rings -2- and -3- as well as oil filter element -4-.

Note

Please observe disposal instructions!

– Tighten sealing cap -1- with oil filter key - 3417- .

Cover cap torque setting: 25 Nm Engine codes AKK, ANW, APE, AQQ, AUA and AUD Carry out following procedure:

– Loosen oil filter -arrow- from below with a 30 mm open jaw spanner and remove oil filter.

Note

Please observe disposal instructions!

– Clean engine sealing surface.

– Oil rubber seal lightly on new filter. Thus the oil filter can ad‐ here better when tightening, which assures best possible seal‐ ing.

– Screw in filter and tighten hand-tight.

4.16

AG. V agen Engine and components in engine com‐ ksw l o yV partment: inspecting for leaks andisedam‐ db r age (from above and below) autho un le es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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Inspect as follows:

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– Check engine and components in engine compartment for leaks and damage. ♦ Fuel system ♦ Cooling and heating system ♦ And brake system

rrectness of i t to the co nform spec at i h re o n wit in t his

– Check lines, hoses and connections of

For leaks, abrasions, porosity and brittleness.

Note

♦ Arrange for defects to be rectified as repair measures. ♦ If fluid loss is greater than can be expected through normal

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76 4. Descriptions of work:

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use, determine source and rectify (repair measure).

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.17

V-belt: checking condition and tension‐ ing

Special tools and workshop equipment required

♦ Ring spanner insert - V.A.G 1410/2-

4.17.1

Checking V-belt condition

r fo ng

– Check V-belt condition for:

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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♦ Torque wrench - V.A.G 1410-

♦ Sub-surface cracks (cracks, core ruptures, cross sectional breaks) Prote cted by c o p yri gh t.

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♦ Base break-up

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♦ Layer separation (top layer, cord strands) ♦ Frayed cord strands

♦ Flank wear (material wear, frayed flanks, flank brittleness glassy flanks-, surface cracks) ♦ Traces of oil and grease Note

If faults are found, it is absolutely necessary to renew the V-belt.

This can avoid breakdowns and malfunctions. The replacement of a V-belt is a repair measure.

4.17.2

Checking V-belt tension, tensioning V belt if necessary

Carry out following procedure: – Check V-belt tension by strong thumb pressure (deflection ap‐ prox. 5 mm) and adjust if necessary.

4. Descriptions of work:

77

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 AG. Volkswagen AG d agen oes

ksw – Loosen securing bolts -1- and -2-, clamping bolt -3- and olse‐ yV b curing nut -4- for tensioning arm at least 1 turn. sed

ri ho

– Tighten vane pump securing bolt -1- to 45 Nm. – Tighten vane pump securing bolt -2- and tensioning arm se‐ curing nut -4- to 25 Nm.

4.18

Poly V-belt: checking condition and ten‐ sioning belt

Carry out following procedure:

– Crank engine at vibration damper/belt pulley -arrow- using a socket.

– Raise vehicle and check poly V-belt -1- from below for:

♦ Flank wear (material wear, frayed flanks, flank brittleness glassy flanks-, surface cracks) ♦ Traces of oil and grease Note

If faults are found, it is essential for the poly V-belt to be renewed.

This can avoid breakdowns and malfunctions. The replacement of a poly V-belt is a repair measure.

4.18.1

Tensioning belt (engines without auto‐ matic tensioning roller)

Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331-

78 4. Descriptions of work:

AG.

♦ Frayed cord strands

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♦ Base break-up

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♦ Layer separation (top layer, cord strands)

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♦ Sub-surface cracks (cracks, core ruptures, cross sectional breaks)

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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ut belt) by turn‐ – Tension V-belt to 4 Nm (used belt) or 7 Nm (new sa s ing tensioning nut using torque wrench -A- and tighten ten‐ sioning nut clamping bolt -3- to 25 Nm.

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 es n ot g ua ran tee or ac

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Carry out following procedure: – Unbolt alternator securing bolts -1- and -2- at least one turn.

Vehicles with vane pump V-belt – Remove V-belt for power assisted steering vane pump:»Run‐ ning gear« ⇒ Running gear; Rep. gr. 48 ; Vane pump, reservoir, hydraulic lines »Vane pump, reservoir, hydraulic lines«

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Continued for all vehicles

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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♦ Tensioning arm - 3297- agen AG. Volkswagen AG do

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– Insert tensioning lever - 3297- , secure with pin -arrow- and swing alternator downwards (use e.g. torque wrench - 3297as drive for tensioning lever - V.A.G 1331- ).

AG.

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– Press alternator with tensioning lever - 3297- at least 3 times downwards onto stop, to ensure ease of movement.

– Rotate engine several times (approx. 10 engine revolutions) after fitting poly V-belt and with alternator loose, to do this op‐ erate starter briefly.

Note

When tightening adhere to prescribed sequence, do not lean on alternator and do not touch the poly V-belt.

4. Descriptions of work:

79

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Tighten securing bolt -2- to 25 Nm.

n AG. Volkswagen AG do es n wage s k l ot g o – Tighten securing bolt -1- to 25 Nm. yV ua b d ran e tee ris Vehicles with vane pump V-belt o h t or u ac a – Install V-belt for power assisted steeringssvane pump: »Run‐

rrectness of i t to the co nform spec at i h re o n wit in t his

4.19

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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ning gear« ⇒ Running gear; Rep. gr. 48 ; Vane pump, reservoir, hydraulic lines »Vane pump, reservoir, hydraulic lines«

Boots: inspecting

Carry out following procedure:

♦ Torque wrench - V.A.G 1331-

4.20.1

4 and 5-speed manual gearbox 020

Carry out following procedure: – Turn steering wheel left onto stop.

80 4. Descriptions of work:

AG.

Special tools and workshop equipment required

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Manual gearbox/final drive: checking oil level

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4.20

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– Check outer joint bellows -arrow- and inner joint bellows (not shown in illustration) for leaks and damage.

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–

n AG. Volkswagen AG do es n1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ wageCaddy Kasten/Kombi s k l ot g o yV ua b Maintenance - Edition 03.2018 d ran ir se tee o h t o ra au oil filler plug -arrow-.

Remove c ss

– If necessary top up gearbox oil “Specification G 50 SAE 75W90 (synthetic oil)” to lower edge of filler plug drilling.

– Fit oil filler plug -arrow- and tighten to 25 Nm.

4.20.2

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Checking oil level: The oil level must be to lower edge of filler plug drilling.

5-speed manual gearbox 085 up to build date 22.10.95

5-speed manual gearbox 085 from build date 23.10.95 ⇒ page 81

Carry out following procedure: agen lksw Vo by

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– Turn steering wheel left onto stop.

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The build date is stamped onto the gearbox, (Example: DCT25105 means gearbox with code letter DCT manufactured on 25.10.95).

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– Remove oil filler plug -arrow-.

– Checking oil level: The oil level must be to lower edge of filler plug drilling.

– If necessary top up gearbox oil “Specification G 50 SAE 75W90 (synthetic oil)” to lower edge of filler plug drilling.

– Fit oil filler plug -arrow- and tighten to 25 Nm.

4.20.3

5-speed manual gearbox 085 from build date 23.10.95

– Remove oil filler plug -arrow-.

– Checking oil level: The oil level must be to lower edge of filler plug drilling.

– If necessary top up gearbox oil “Specification G 50 SAE 75W90 (synthetic oil)” to lower edge of filler plug drilling.

– Fit oil filler plug -arrow- and tighten to 25 Nm.

4. Descriptions of work:

81

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.20.4

5-speed manual gearbox 02A

Carry out following procedure: – Remove charge air cooler »Engine mechanics« ⇒ Engine mechanics; Rep. gr. 21 ; Charge air system with turbocharger »Charge air system with turbocharger« – Remove oil filler plug -arrow-.

– Checking oil level: The oil level must be to lower edge of filler plug drilling.

. Volkswagen AG gen AG does not gu ara nte ris o eo h t u Fit oil filler plug -arrow- and tighten to 25 Nm. ra a c ss

a ksw – If necessary top up gearbox oil “Specification G 50 SAE Vol y b 75W90 (synthetic oil)” to lower edge of filler plug drilling. d e

–

rrectness o f i t to the co n f orm spec atio h re n wit

4.21

Automatic gearbox: checking final drive oil level

Special tools and workshop equipment required

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Carry out following procedure:

– Pull off connector -1- and remove speedometer drive -2-, wipe off with a cloth and reinstall drive.

Note

Please observe disposal instructions!

– Remove drive and check oil level.

82 4. Descriptions of work:

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♦ Extraction unit - V.A.G 1358 A-

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– Install charge air cooler »Engine mechanics« ⇒ Engine me‐ chanics; Rep. gr. 21 ; Charge air system with turbocharger »Charge air system with turbocharger«

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 The oil level must lie between the min. and max. markings.

Note

Oil quantity between min. and max. markings is 0.1 l.

– If oil level is too low top up with following oil: Gear oil SAE 75 W90 (synthetic oil). Gear oil is available under following part numbers: ♦ Container size 0.5 l -G 052 145 A1♦ Container size 1.0 l -G 052 145 A2– If oil level is too high, extract oil with extraction system V.A.G 1358 A- .

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rrectness o f i t to the co n f orm spec atio h re n wit

4.22

Brake system: inspecting for leaks and damage

Check following components for leaks and damage: ♦ Brake master cylinder r te o iva r rp fo ng

♦ Brake servo (for anti-lock brake system: hydraulic unit) ♦ Brake pressure regulator and – Ensure that brake hoses are not twisted.

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– Additionally ensure that brake hoses do not touch any vehicle components when steering is at full lock.

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AG.

– Check brake hoses are not porous or brittle.

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♦ Brake caliper

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–

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– Check brake hoses and lines for chafing.

– Check brake connections and fastenings for correct seating, leaks and corrosion.

WARNING

Faults found must always be rectified (repair measure).

4.23

Front and rear brake pads/linings: checking thickness

Special tools and workshop equipment required

4. Descriptions of work:

83

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Pliers - 3314-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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pe rm itte d

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♦ Torque wrench - V.A.G 1332-

and if necessary, if anti-theft wheel bolts are installed: ♦ Adapter set for tamper-proof wheel bolts - T10101♦ Electric hand torch and mirror Carry out following procedure: Removing full sized wheel trims

The adapter to loosen and tighten the anti-theft wheel bolts is found in the vehicle tool kit or use the adapter set for wheel bolts - T10101- .

– If necessary, pull wheel bolt covers off with pliers - 3314- or pull full sized wheel trim off.

– Mark position of wheel relative to brake disc.

– Unbolt wheel bolts and remove wheel.

84 4. Descriptions of work:

AG.

– For better evaluation of remaining pad thickness, remove the wheel on front passenger side (greater wear than on driver side).

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Front brake pads

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4.23.1

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Wheel bolts

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The puller hooks to remove the wheel trims are located in the vehicle tool kit.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Measure thickness of inner and outer pads. a - Brake pad thickness without backplate Wear dimension: 2 mm The brake pads have reached their wear limit at a pad thickness of 2 mm (without backplate) and must be renewed (repair meas‐ ure). Inform customer!

Note

When replacing brake pads, always check brake discs as well for wear! Checking and if necessary replacing the brake discs is a repair measure.

– Check brake disc for wear »Brake systems« ⇒ Brake systems; Rep. gr. 46 ; Repairing front brakes »Repairing front brakes« – Install wheel in marked position.

– Tighten wheel bolts diagonally and alternately to following specified torque: Specified torque: 120 Nm – Place puller hooks and adapter with vehicle tool kit after com‐ pleting work.

– Reinstall wheel bolt covers if necessary.

Installing full sized wheel trim

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rrectness o f i t to the co n f orm spec atio h re n wit

4.23.2

Rear drum brake pads

– Check thickness of brake pads through the hole -arrow B- and inspection hole in backplate -arrow A- (with a torch).

Wear limit: 2.5 mm (pad thickness only)

Check pads for brake fluid or grease contamination.

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– Remove full sized wheel trim if necessary.

AG.

Rear brake pads

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4.23.3

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Note

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At a pad thickness of 2.5 mm the brake pads have reached their wear limit and must be renewed (repair measure). Inform cus‐ tomer!

in t his d o cu m en

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– Install full sized wheel trim so that the tyre filler valve is guided Volkswagen AG does through the cut-out provided -arrow-. swagen AG.

4. Descriptions of work:

85

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– Inspect outer pad to determine thickness.

– Inspect inner pad to determine thickness. a - Inner and outer pad thickness without backplate Wear dimension: 2 mm

The brake pads have reached their wear limit at a pad thickness of 2 mm (without backplate) and must be renewed (repair meas‐ ure). Inform customer!

Note

When replacing brake pads, always check brake discs as well for wear! Checking and if necessary replacing the brake discs is a repair measure.

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Underbody protection: visual check for damage AG.

4.24

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– Check brake disc for wear »Brake systems« ⇒ Brake systems; Rep. gr. 46 ; Repairing rear brakes »Repairing rear brakes« – Install full sized wheel trim.

During inspection, also check floor pan, wheel housings and sills.

Note

Faults found must always be rectified (repair measure). This in‐ hibits corrosion and rusting through.

4.25

Track rod ends: checking clearance, firm seating and boots

Carry out following procedure: – With vehicle raised (wheels hanging free), check play by mov‐ ing track rods -arrow- and wheels. Clearance: zero clearance – Check attachment.

– Check if boots are not damaged and are seated correctly.

86 4. Descriptions of work:

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

– Illuminate area behind hole in wheel using an electric hand torch.

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 nte➤ , Polo Variant 1998 ➤ is r o eo h Maintenance - Edition 03.2018 ut ra a c s s

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.26

Swivel joints: inspecting

– Check swivel joint boots -arrow- for leaks and damage.

Note

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

Cooling system: checking coolant level and frost protection

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4.27

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

♦ Coolant additive G 12 Plus according to TL VW 774 F prevents

frost and corrosion damage, scaling and also raises boiling point of coolant. For these reasons, the cooling system must be filled all-year-round with a frost and corrosion protection additive.

♦ Thanks to its high boiling point, the coolant improves engine

reliability under heavy loads, particularly in countries with trop‐ ical climates.

♦ The coolant concentration must not be reduced by adding wa‐

ter even in warmer seasons and in warmer countries. The antifreeze portion must be at least 40%.

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Coolant level: checking, replenishing coolant if necessary

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4.27.1

– Check coolant level on expansion tank with engine cold. ht rig py Co t.

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♦ Delivery inspection: coolant level at max. marking.

♦ Inspection service: coolant level between min. and max. mark‐ ing. agen lksw Vo by

AG.

– If coolant is too low, add required amount according to mixture ratio.

Note

If fluid loss is greater than can be expected through normal use, determine source and rectify (repair measure).

Mixing ratio Frost protection to

Coolant additive G 12 Plus/ TL VW 774 F

Water

-25°C -35°C -40°C

approx. 40% approx. 50% approx. 60%

approx. 60% approx. 50% approx. 40%

4. Descriptions of work:

87

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.27.2

Frost protection: checking and replen‐ ishing coolant additive if necessary

Special tools and workshop equipment required ♦ Refractometer - T10007-

Note

Read precise value for the following tests at light-dark border.

Using a pipette, place a drop of water on the glass to improve the readability of the bright/dark boundary. The light-dark border can be clearly recognised on the “WATERLINE”.

– Check concentration of coolant additive using refractometer T10007- (refer to operating instructions). . Volkswagen AG

n AG The scale -1- of the refractometer - T10007- is calibrated for cool‐ wage olks V ant additives -G 12-, -G 12 Plus- and -G 11-. by d ise

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Note

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r The scale -2- is calibrated for coolant additive -G 13-. ho ut

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rrectness o f i t to the co n f orm spec atio h re n wit

vehicles type “L 80”.

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♦ At present the coolant additive -G 13- can be used only on ♦ Frost protection is required down to about -25°C (in countries

with arctic climates: down to about -35°C).

♦ If for climatic reasons a greater frost protection is required, the

amount of coolant additive can be increased, but only up to 60% (frost protection to about -40°C), as otherwise frost pro‐ tection is reduced again and cooling effectiveness is also reduced.

88 4. Descriptions of work:

AG.

-10

3.0 3.5 2.5 3.5 2.0 3.0

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-5

-25 -35 -25 -35 -25 -35

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0

Quantity to drain (in litres)

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Actual value

Frost protection to °C Specified value

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Frost protection table

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– If frost protection is insufficient, drain off required quantity shown in frost protection table and add coolant additive -G12-.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

Actual value

Frost protection to °C Specified value

-15

Quantity to drain (in litres)

-25 -35 -25 -35 -35 -35 -40

-20 -25 -30 -35

1.5 2.5 1.0 2.5 2.0 1.0 0.5

Note

Please observe disposal instructions!

– After road test check coolant additive concentration.

4.28

Spark plugs: renewing

Special tools and workshop equipment required ♦ Spark plug socket - 3122 B-

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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♦ Assembly tool - T10029-

4. Descriptions of work:

89

agen lksw Vo by

AG.

Prote cted by c o p yri gh t.

C op yi

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Torque wrench - V.A.G 1331-

4.28.1

Engine codes ADZ, AFT and 1F

Carry out following procedure: – Pull off spark plug connector and unscrew spark plugs with spark plug socket and extension - 3122 B- .

– Screw in new spark plugs using spark plug socket and exten‐ sion - 3122 B- .

Note ♦ For spark plug designation and torque setting, see »Engine

mixture preparation« ⇒ Engine mixture preparation; Rep. gr.

28 ; Checking glow plug system »Checking glow plug system«

♦ Please observe disposal instructions!

– Fit spark plug connectors.

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Carry out following procedure:

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Engine codes AEE, AEX, AKV, ALM, ANX and APQ es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

4.28.2

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

– Pull intake air preheating hose -arrow- off exhaust manifold.

rrectness of i t to the co nform spec at i h re o n wit in t his

Note

♦ The air filter securing bolts must be loosened or tightened only

by hand. When loosening or tightening the securing bolts it is only permitted to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm

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90 4. Descriptions of work:

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♦ Specified torque: max. 3 Nm

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Unscrew bolts -arrows- and remove air filter completely.

– Pull off spark plug connector and unscrew spark plugs with spark plug socket and extension - 3122 B- .

– Screw in new spark plugs using spark plug socket and exten‐ sion - 3122 B- .

Note ♦ For spark plug designation andetorque »Engine kswagen Asee n AG. Volsetting, G

doesRep. gr. wag mixture preparation; mixture preparation« ⇒ Engine not olks gu yV 28 ; Checking glow plug system »Checking glow plug system« b ara d e

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tho ♦ Please observeaudisposal instructions! pe rm itte d

– Fit spark plug connectors.

Engine codes AEH, AKL, APF and AUR

Carry out following procedure: – Lever off cover caps -arrows- in engine cover -A- with a screw‐ driver.

do c um en

r te o iva r rp fo g n

4.28.3

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Insert filter housing and tighten cross head bolts -arrows-.

4. Descriptions of work:

91

ht rig py Co t.

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AG.

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C op yi

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o e o 1998 ➤ h 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant Caddy Kasten/Kombi ut ra a c s Maintenance - Edition 03.2018 s pe rm itte d

– Remove securing nuts -arrows-.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Take engine cover -A- off upwards.

– Lever off cover caps for securing nuts in second engine cover with a screwdriver and remove securing nuts -arrows-.

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AG.

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C op yi

– Unscrew spark plugs using spark plug socket and extension 3122 B- -arrow-.

Note ♦ For spark plug designation and torque setting, see »Engine

mixture preparation« ⇒ Engine mixture preparation; Rep. gr.

28 ; Checking glow plug system »Checking glow plug system«

♦ Please observe disposal instructions!

– Screw in new spark plugs using spark plug socket and exten‐ sion - 3122 B- .

– Fit spark plug connectors using assembly tool - T10029- .

– Check that ignition cables and spark plug connectors are fitted securely.

92 4. Descriptions of work:

ht rig py Co t.

– Pull off spark plug connector -arrows- with assembly tool T10029- . The outer -arrows- (left and right) point to the hidden spark plug connectors.

do c um en

r te o iva r rp fo g n

– Take engine cover panel off upwards.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Insert engine cover, tighten nuts -arrows- and clip in cover caps for securing nuts.

– Install engine cover and secure with hexagon nuts -arrows-.

Engine codes AKK, ANW and AUD

Carry out following procedure: – Unclip caps -1- and remove bolts (below caps).

– Remove ignition cable -2- from air filter housing.

– If necessary, loosen hose clamp -3- using pliers for spring-type clips - V.A.G 1921- and pull hose off.

– Pull crankcase breather hose -arrow- off air filter housing.

ht rig py Co t.

r fo ng

– Pull off exhaust gas recirculation hose on left side of air filter housing and remove filter housing.

rrectness of i t to the co nform spec at i h re o n wit in t his

4.28.4

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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– Clip-in cover caps -arrows- for securing nuts.

4. Descriptions of work:

93

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AG.

Prote cted by c o py rig ht .

C op yi

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Pull off spark plug connector and unscrew spark plugs with spark plug socket and extension - 3122 B- .

– Screw in new spark plugs using spark plug socket and exten‐ sion - 3122 B- .

Note ♦ For spark plug designation and torque setting, see »Engine

mixture preparation« ⇒ Engine mixture preparation; Rep. gr.

28 ; Checking glow plug system »Checking glow plug system«

♦ Please observe disposal instructions!

– Fit spark plug connectors.

– Insert filter housing.

– Tighten securing bolts and fit caps -1-.

– Press ignition cables -2- into air filter housing.

– Fit hose and secure with hose clip -3-.

– Connect crankcase breather hose -arrow- to air filter housing.

– Connect exhaust gas recirculation hose to left side of air filter housing.

Engine codes APE, AQQ and AUA

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Carry out following procedure:

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4.28.5

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

– Take ignition cables -2- out of cover -3- and pull cover upwards slightly.

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AG.

Prote cted by

c o p yri gh t .

C op yi

94 4. Descriptions of work:

ht rig py Co t.

r fo ng

– Pull off spark plug connectors and place ignition cables with cover to side.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

– Remove oil filler cap -1-.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Remove hexagon socket head bolts -arrows- and take off en‐ gine cover.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Unscrew spark plugs using spark plug socket - 3122 B- .

– Screw in new spark plugs with spark plug wrench - 3122 B- .

Note ♦ For spark plug designation and torque setting, see »Engine

mixture preparation« ⇒ Engine mixture preparation; Rep. gr.

28 ; Checking glow plug system »Checking glow plug system«

♦ Please observe disposal instructions!

– Install spark plug cover.

– Install oil filler cap -1-.

– Fit spark plug connectors.

– Press ignition cables -2- into channels in spark plug cover.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

4.29

es, in part or in w l purpos hole ercia , is n m ot com

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– Install engine cover and secure with hexagon socket head bolts -arrows-.

Dust and pollen filter: renewing filter el‐ ement

Special tools and workshop equipment required

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c o p yri gh t.

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AG.

Carry out following procedure:

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The filter is located on right in the plenum chamber under a cover.

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♦ Torque wrench - V.A.G 1331-

4. Descriptions of work:

95

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.29.1

Removing

Vehicles ►09.99 Note

Before removing the wiper arm, ensure that the wiper motor is in park position. Only in this way the wiper arm park position can be adjusted correctly when installing.

– Pull off rubber seal -1- of plenum chamber cover upwards.

– Remove cross head bolt -2-.

– Lever off cover cap -3- using a screwdriver.

– Loosen hexagon nut below cover cap -3-, do not unscrew completely.

– Loosen wiper arm by moving lightly.

– Unscrew hexagon nut completely and remove wiper arm.

– Loosen plastic bolts -4- and remove bolts with clips.

– Carefully remove plenum chamber cover on right upwards. swagen AG.

– From the right-hand side of plenum chamber cover pull rubber seal -1- off upwards to vehicle centre.

– Unclip plenum chamber cover -2- and carefully pull out up‐ wards.

Continued for all vehicles

– Unclip cover cap in front of lugs -A- and remove (if fitted).

AG.

96 4. Descriptions of work:

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Please observe disposal instructions!

Prote cted by c o py rig ht .

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Note

ht rig py Co t.

– Separate filter element from frame.

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– Press filter housing lugs -A- in -direction of arrow- and take filter element with frame out upwards.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ss

Volkswagen AG does not gu ara nte eo ra c ility ab y li an pt ce

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Vehicles 10.99►

olk yV db e ris tho au

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Guide frame -A- on left and right into the first lamination of the new filter element -arrows B-.

– Guide frame lugs -C- into filter housing recesses -D- and press frame with filter element downwards.

4.29.2

Installing

Install in the reverse order of removal observing the following on vehicles ►09.99: When installing the wiper arm the park position must be adjusted ⇒ page 61 .

Specified torque for wiper arm: 20 Nm

4.30

Camshaft drive belt: checking (petrol AG. Volkswagen AG d agen oes engine) ksw not l o V g y db ise r tho au

Toothed belt: checking condition

ua ran tee

♦ Cracks, cross sectional breaks

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– Check condition of toothed belt for:

rrectness o f i t to the co n f orm spec atio h re n wit

♦ Frayed cord strands

es, in part or in w l purpos hole ercia , is n m ot com

♦ Layer separation (toothed belt body, tensile cords) ♦ Toothed belt body breakup

or ac ility ab y li an pt ce

– Open clips for upper toothed belt guard andss remove cover.

♦ Surface cracks (synthetic coating) ♦ Traces of oil and grease Note

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When checking condition, especially watch for following damage:

AG.

-D- Cracks (in teeth base)

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-C- Fraying

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-B- Side contact

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-A- Cracks (coating)

in t his d o cu m en

If faults are found, always renew toothed belt. This can avoid breakdowns and malfunctions. The replacement of a toothed belt is a repair measure.

4. Descriptions of work:

97

n AG. Volkswagen AG do es n wage s k l ot g Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ ,yPolo Variant 1998 ➤ Vo ua b d ran Maintenance - Edition 03.2018 ir se tee o h t or u ac a ss

Toothed belt: checking for wear (SDI/ TDI engines ►2000) es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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ility ab y li an pt ce

4.31

Special tools and workshop equipment required

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ Vernier caliper (commercially available)

4.31.1

Engine codes AEY, AFN, AHB, AHU, AKW and ALE

Carry out following procedure: – Remove air cleaner completely.

– Unclip the clamps -1- from toothed belt guard.

Prote cted by

When a toothed belt has reached a width of 22 mm, the wear limit has been reached and it must be renewed (repair measure). In‐ form customer!

WARNING

The engine must never under any circumstances be turned over using the camshaft when checking and making adjust‐ ments. Not observing this can lead to severe engine damage.

4.31.2

Engine codes AGP, AGR, ALH, AQM, ASK and ASV

Carry out following procedure: – Remove engine cover panel.

– Open clips on upper toothed belt guard.

– Pull upper toothed belt guard to side or remove.

98 4. Descriptions of work:

AG.

Note

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c o p yri gh t .

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Wear dimension: 22 mm

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– Measure the width of the toothed belt with a vernier caliper.

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– Unscrew cross head bolt -2- and remove toothed belt guard.

AG. Volkswagen AG d agen o ksw Caddy Kasten/Kombies1996 not l o gu ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ yV b ara d e Maintenance - Edition 03.2018 nte is r o eo h ut ra a c ss

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ility ab y li an pt ce

– Measure the width of the toothed belt with a vernier caliper.

Note

When a toothed belt has reached a width of 22 mm, the wear limit has been reached and it must be renewed (repair measure). In‐ form customer!

WARNING

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AG.

Prote cted by c o py rig ht .

C op yi

4.32.1

Camshaft drive toothed belt: checking condition and tension (diesel engine with engine code ALH and automatic gearbox) ht rig py Co t.

4.32

in t his d o cu m en

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The engine must never under any circumstances be turned over using the camshaft when checking and making adjust‐ ments. Not observing this can lead to severe engine damage.

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

Wear dimension: 22 mm

Toothed belt: checking condition

– Open clips for upper toothed belt guard and remove cover.

– Check condition of toothed belt for: ♦ Cracks, cross sectional breaks ♦ Layer separation (toothed belt body, tensile cords) ♦ Toothed belt body breakup ♦ Frayed cord strands ♦ Surface cracks (synthetic coating) ♦ Traces of oil and grease Note

If faults are found, always renew toothed belt. This can avoid breakdowns and malfunctions. The replacement of a toothed belt is a repair measure.

When checking condition, especially watch for following damage: -A- Cracks (coating) -B- Side contact -C- Fraying -D- Cracks (in teeth base) Note

To check the toothed belt tension, the upper toothed belt cover must remain removed.

4. Descriptions of work:

99

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.32.2

Checking toothed belt tension

– Check eccentric on tensioning roller if indicator -1- and mark‐ ing lug -2- align.

When the indicator -1- and the marking tab -2- align, the check is finished.

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4.32.3

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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If the indicator and the marking tab do not align, the toothed belt must be tensioned.

Tensioning toothed belt

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331-

AG.

Prote cted by

100 4. Descriptions of work:

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c o p yri gh t.

C op yi

Carry out following procedure:

ht rig py Co t.

♦ Diesel injection pump locking pin - 3359-

in t his d o cu m en

r te o iva r rp fo ng

♦ Pliers for spring-type clips - V.A.G 1921-

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Open hose clips -arrows- with pliers for spring-type clips V.A.G 1921- and pull off hose -1-.

– Loosen tensioning roller securing bolt.

– Check tensioning roller for damage and wear.

Note

If damage is determined, the tensioning roller must always be re‐ newed (repair measure).

If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The eccentric must nev‐ er be turned back when it has been turned too far.

– Tighten lock nut on tensioning roller. Specified torque: 20 Nm – Turn crankshaft two rotations in engine direction of rotation until the crankshaft is positioned at TDC No. 1 cylinder -arrow-.

WARNING

ht rig py Co t.

r fo ng

The engine must never under any circumstances be turned over using the camshaft when checking and making adjust‐ ments. Not observing this can lead to severe engine damage.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ss

ran tee or ac

e ris ho t au

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Note

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– Tension toothed belt. Do this by turning eccentric clockwise AG. Volkswagen AG d agen o s using a commercially available ksw hexagon key, until theemarking not l o V gu tab and indicator align in of the marking tab raised portion. yarea b a d

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– Lock injection pump sprocket with pin for diesel injection pump - 3359- . agen lksw Vo by

– Again check if the crankshaft is at TDC for No. 1 cylinder.

AG.

– Remove pin for diesel injection pump - 3359- from injection pump sprocket.

4. Descriptions of work:

101

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Fit hose -1- and secure with hose clips -arrows-.

– Start engine and run at idling speed for approx. 1 minute.

– Switch off engine.

– Check eccentric on tensioning roller again that indicator -1and marking tab -2- align in area of marking tab raised portion.

If the indicator and marking tab do not align the tensioning sequence must be repeated.

4.33

Toothed belt: checking condition and tension (diesel engine with engine code 1Y)

4.33.1

Toothed belt: checking condition

– Open clips for upper toothed belt guard and remove cover.

– Check condition of toothed belt for: ♦ Cracks, cross sectional breaks ♦ Layer separation (toothed belt body, tensile cords) ♦ Toothed belt body breakup ♦ Frayed cord strands

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AG.

Note

Prote cted by c o py rig ht .

C op yi

♦ Traces of oil and grease

If faults are found, always renew toothed belt. This can avoid breakdowns and malfunctions. The replacement of a toothed belt is a repair measure.

102 4. Descriptions of work:

ht rig py Co t.

r fo ng

♦ Surface cracks (synthetic coating)

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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– Install upper toothed belt guard.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 When checking condition, especially watch for following damage: -A- Cracks (coating) -B- Side contact -C- Fraying -D- Cracks (in teeth base) Note

To check the toothed belt tension, the upper toothed belt cover must remain removed.

4.33.2

Checking toothed belt tension

Before checking the toothed belt tension, the semi-automatic ten‐ sioning device must be checked for correct function as follows: – Press toothed belt forcibly with thumb. Notch and raised mark . Volkswagen AG gen AG does -arrows- should move. a w s olk yV

not gu ara nte eo ra c

db – Check tensioning roller for damage and wear. ise

r ho ut a ss

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

Note

If damage is determined on tensioning roller, the toothed belt ten‐ sioning roller must always be renewed (repair measure).

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

– Release tension on toothed belt. The tensioning roller must return to its initial position. (Notch and raised mark must align).

If the notch and raised mark -arrows- align, the check is finished.

If the notch and raised mark do not align, the toothed belt must be tensioned.

4.33.3

Tensioning toothed belt

ht rig py Co t.

r fo ng

Special tools and workshop equipment required

4. Descriptions of work:

103

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

ility ab y li an pt ce

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♦ Pin wrench - V159-

Prote cted by

104 4. Descriptions of work:

AG.

– Loosen tensioning roller.

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c o p yri gh t .

C op yi

Carry out following procedure:

ht rig py Co t.

♦ Torque wrench - V.A.G 1331-

do c um en

r fo ng

♦ Diesel injection pump locking pin - 3359-

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Tension toothed belt. Using pin wrench (e.g. Matra V159) on eccentric turn clockwise until the notch and the raised mark -arrows- align.

Note

If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The eccentric must nev‐ er be turned back when it has been turned too far.

– Tighten lock nut on tensioning roller. Specified torque: 20 Nm – Turn crankshaft two turns further in engine direction of rotation until the crankshaft is at TDC for No. 1 cylinder.

WARNING

rrectness of i t to the co nform spec at i h re o n wit in t his

– Lock injection pump sprocket with pin for diesel injection pump - 3359- .

– Again check if the crankshaft is at TDC for No. 1 cylinder.

– Remove pin for diesel injection pump - 3359- from injection pump sprocket.

– Repeat functional test sequence of tensioning device.

If now the notch and raised mark do not align, repeat adjusting procedure.

– Install upper toothed belt guard.

r fo ng

Toothed belt: renewing (diesel engine with engine codes AGP, AGR, ALH, AQM, ASK, ASV and AYQ)

ht rig py Co t.

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4.34

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V byany circumstances be turned guar The engine must never under d an e is tee or over using the camshaftthwhen checking and making adjust‐ or u can lead to severe engine damage. ac a ments. Not observing this ss

Prote cted by c o p yri gh t.

C op yi

– Carry out procedure »Engine mechanics« ⇒ Engine mechan‐ ics; Rep. gr. 15 ; Removing and installing cylinder head »Removing and installing cylinder head« AG.

4.35

Toothed belt: renewing (diesel engine with engine codes AEY, AFN, AHB, AHU, AKW and ALE)

– Carry out procedure »Engine mechanics« ⇒ Engine mechan‐ ics; Rep. gr. 13 ; Dismantling and assembling engine »Dis‐ mantling and assembling engine«

4. Descriptions of work:

105

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.36

Air filter: cleaning housing and renewing filter element

4.36.1

Engine codes ADZ, AEY, AFN, AFT, AHB, AHU, AKW, 1F and 1Y

Carry out following procedure: Removing – Release spring retainers -arrows-.

– Remove filter housing upwards.

Installing

– Clean filter housing and install new filter element.

– Insert filter housing and secure spring retainers -arrows-.

Note

Removing Note ♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm ♦ Specified torque: max. 3 Nm

106 4. Descriptions of work:

Prote cted by

Carry out following procedure:

AG.

Engine codes AEE, AEX, ALM, ANX, AKV and APQ

agen lksw Vo by

c o p yri gh t.

C op yi

4.36.2

ht rig py Co t.

r fo ng

When installing the air filter housing ensure that sealing surfaces are properly seated.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Please observe disposal instructions!

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Note

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– Take out used filter element.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Remove securing bolts -arrows-.

– Raise filter housing upper part and remove upwards.

– Take out used filter element -arrow-.

Note

Please observe disposal instructions!

Installing Note ♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm ♦ Specified torque: max. 3 Nm – Clean filter housing and install new filter element.

ility ab y li an pt ce

rrectness of i t to the co nform spec a t i h re o n in wit thi s

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AG.

4. Descriptions of work:

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Prote cted by c o py rig ht .

C op yi

Carry out following procedure:

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Engine codes AEH, AGP, AGR, AKL, ALE, ALH, APF, AQM, ASK, ASV, AUR and AYQ

ht rig py Co t.

4.36.3

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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–

AG. Volkswagen AG d agen oes ksw not l o gu yV Insert filter housing upper part and tighten bolts -arrows-. b ara d e nte is r o eo h ut ra a c s s

107

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Removing – Remove securing bolts -arrows-.

– Raise filter housing upper part and remove upwards.

– Take out used filter element -arrow-.

Note

Please observe disposal instructions!

Installing

pe rm itte d

4.36.4

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Insert filter housing upper part and tighten bolts -arrows-.

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–

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara Clean filter housing and d install new filter element. e nte is r o eo h ut ra a c s s

Engine codes AKK, ANW and AUD

♦ Pliers for spring-type clips - V.A.G 1921-

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AG.

Prote cted by c o py rig ht .

C op yi

108 4. Descriptions of work:

ht rig py Co t.

Carry out following procedure:

do c um en

r te o iva r rp fo g n

Special tools and workshop equipment required

– Unclip caps -1- and remove bolts (below caps).

– Remove ignition cable -2- from air filter housing.

– If necessary, loosen hose clamp -3- using pliers for spring-type clips - V.A.G 1921- and pull hose off.

– Pull crankcase breather hose -arrow- off air filter housing.

– Pull off exhaust gas recirculation hose on left side of air filter housing and remove filter housing.

♦ The bolts must be loosened or tightened only by hand. When c o p yri gh t .

C op yi

loosening or tightening the securing bolts it is only permitted to use a power screwdriver if: AG.

Prote cted by

♦ Specified torque: max. 3 Nm

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♦ Speed of power screwdriver max. 200 rpm

ht rig py Co t.

Note

r fo ng

– Unscrew cross head bolts -1- and remove filter housing lower part.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

ility ab y li an pt ce

Removing

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ➤ , Polo Variant 1998 ➤ Caddy rKasten/Kombi 1996 ➤ , Polo Classic 1996 ise tee o h t or Maintenance - Edition 03.2018 u ac a ss

– Take out used filter elements -arrows-.

Note

Please observe disposal instructions!

Installing – Clean filter housing and insert new filter elements.

– Insert filter housing lower part and tighten cross head bolts -1-.

Note ♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm ♦ Specified torque: max. 3 Nm – Insert filter housing.

4. Descriptions of work:

109

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Tighten securing bolts and fit caps -1-.

– Press ignition cables -2- into air filter housing.

– Fit hose and secure with hose clip -3-.

– Connect crankcase breather hose -arrow- to air filter housing.

– Connect exhaust gas recirculation hose to left side of air filter housing.

4.36.5

Engine codes APE, AQQ and AUA

Carry out following procedure: Removing – Remove hexagon socket head bolts -arrows- and take off en‐ gine cover.

– Pull crankcase breather hose off filter housing upper part.

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–

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♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm ♦ Specified torque: max. 3 Nm

– Lift filter housing upper part and remove upwards.

Note

Please observe disposal instructions!

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– Clean filter housing and install new filter element. agen lksw Vo by

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110 4. Descriptions of work:

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– Take out used filter element -arrow-.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Screw in cross head bolts -arrows-.

– Fit crankcase breather hose onto filter housing upper part.

Fuel filter: renewing (diesel engine) Note

♦ Ensure that no diesel fuel contacts coolant hoses. Clean ho‐

ses immediately if soiled.

♦ Please observe disposal instructions!

– Remove air filter housing if necessary.

– Pull fuel hoses off hose connections -1- and -2-.

AG.

– Remove control valve with fuel lines connected.

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– Pull off retaining clip -5-.

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4.37

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– Install engine cover and secure with hexagonAsocket head G. Volkswagen AG d agen oes bolts -arrows-. n lksw

– Loosen bolt on filter mounting and pull filter out upwards.

Installing new filter – Fit new O-ring to seal regulating valve.

Note

Fuel through-flow direction is marked on the connections by ar‐ rows (do not interchange connections).

– Fill new filter with clean Diesel. This allows the engine to start quicker.

– Slide filter downwards through filter mounting and tighten.

– Install control valve with fuel lines connected.

4. Descriptions of work:

111

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Fit retaining clip -5-.

Note

Flow direction is marked by arrows (do not interchange connec‐ tions).

– Push fuel hoses over hose connections -1- and-2- and secure hoses with hose clips.

– Install air cleaner housing if necessary.

– Start engine and check fuel system for leaks (visual check).

– Operate throttle several times and when engine is at idling speed fuel must flow bubble-free through the transparent ho‐ ses.

Note

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Fuel filter: draining water (diesel engine)

♦ Ensure that no diesel fuel contacts coolant hoses. Clean ho‐

ses immediately if soiled.

♦ Please observe disposal instructions!

Carry out following procedure:

– Pull off retaining clip -5- and remove control valve with fuel lines connected.

– Fit hose onto water drain screw connection, open screw and drain approx. 0.1 l of fluid.

– Tighten water drain screw and remove hose.

– Fit new O-ring to seal regulating valve.

– Install control valve and fit retaining clip.

– Operate throttle several times. Then fuel must flow bubble-free through the transparent line when engine is at idling speed.

Automatic gearbox: checking ATF level

♦ With fault reader - V.A.G 1551- ⇒ page 112 or using ♦ Vehicle diagnosis, testing and information system - VAS 5051B- or subsequent units ⇒ page 115 Check ATF level as follows:

4.39.1

Checking oil temperature of automatic gearbox using -V.A.G 1551-

Special tools and workshop equipment required

112 4. Descriptions of work:

AG.

To check the oil level of the automatic gearbox, measure oil tem‐ perature. The oil temperature can be measured in two different ways:

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4.39

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– Start engine and check fuel system for leaks (visual check).

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4.38

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

– Connect fault reader ⇒ page 20 Conditions for testing •

Gearbox not emergency running, ATF temperature not above approx. 30°C

•

Vehicle standing on level ground

•

Selector lever in “P” position

•

Parking brake applied

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Carry out following procedure:

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♦ ATF filling unit - V.A.G 1924-

4. Descriptions of work:

113

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Secure reservoir of ATF filling system - V.A.G 1924- to vehicle.

– Start engine and run it at idling speed.

On -V.A.G 1551- : Indicated on display: V.A.G - SELF DIAGNOSIS HELP 1 - Rapid data transfer

or V.A.G - SELF DIAGNOSIS HELP 2 - Flash code output

Appears alternately – Press button 1 to select “Rapid data transfer” mode.

Indicated on display: Rapid data transfer HELP Enter address word XX

– Press keys 0 and 2 . “02” enters the address word “gearbox electronics”.

Indicated on display: Rapid data transfer Q 02 Gearbox electronics

– Confirm entry with Q key.

– Raise vehicle.

– Place container under gearbox.

Indicated on display: Rapid data transfer HELP Select function XX

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Indicated on display:

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– Confirm entry with Q key.

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Read measured value block Enter display group number XXX

– Press keys 0 , 0 and 5 . (005 selects “Display group number 005”).

Indicated on display:

Read measured value block Q Enter display group number 005

The first display zone shows the ATF temperature.

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114 4. Descriptions of work:

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– Bring ATF to test temperature.

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Read measured value block 5 -> 30°C 0011011 0 900 rpm

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Indicated on display:

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– Confirm entry with Q key.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Check oil level ⇒ page 117 .

4.39.2

Checking oil temperature of automatic gearbox using vehicle diagnosis, testing and information system - VAS 5051B- or subsequent units

Special tools and workshop equipment required ♦ ATF filling unit - V.A.G 1924-

– Connect fault reader ⇒ page 20 Conditions for testing . Volkswagen AG Gearbox not emergency running, ATF temperature not above n AG does wage s k not l o approx. 30°C g yV

•

Vehicle standing on level ground

•

Selector lever in “P” position

•

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•

Carry out following procedure:

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– Secure reservoir of ATF filling system - V.A.G 1924- to vehicle.

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– Start engine and run it at idling speed.

4. Descriptions of work:

115

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Indicated on display: Selecting operating mode – Press button for operatingn Amode wagen AG self-diagnosis olksVehicle e G. V does on display -arrow-.olkswag no t gu ara nte eo ra c

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Indicated on display: Selecting vehicle system – Press 02 - Gearbox electronic on display -arrow-.

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Indicated on display:

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Observe actual operating instructions for fault reader, which are shown on display after selecting functions Administration and Operating manual .

The control unit identification and coding are displayed -arrow-.

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– Place container under gearbox.

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Indicated on display: – Select 08 - Read measured value block on display .-arrow-.

116 4. Descriptions of work:

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– Raising vehicle

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Indicated on display:

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– Press -arrow- 0 ; 0 and 5 on display number block (with 005 the “display group number 005” is selected).

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Indicated on display:

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– Confirm entry with Q button on display number block.

The display zone -1- shows the ATF temperature.

– Bring ATF to test temperature. Specification: 35 to 45°C r te o iva r rp fo ng

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Checking oil level

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4.39.3

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– Check oil level ⇒ page 117 .

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Continue with test only when temperature has been achieved.

Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331-

Test temperature 35°C to 45°C – Unbolt ATF control plug -arrow 1- from oil sump.

4. Descriptions of work:

117

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 The ATF present in the overflow pipe -arrow 2- runs out.

If ATF drips out of drilling ATF need not be topped up.

– If the ATF level is checked the seal -arrow- of the plug to check ATF must always be renewed.

– Tighten plug -arrow 1- with new seal to 15 Nm. This completes the ATF check.

– End output on fault reader and separate the diagnostic con‐ nection.

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If only the ATF present in the overflow pipe runs out of drilling: Top up ATF

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Note

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– Lever off plug securing cap -arrow- with a screwdriver. This destroys cap detent so always replace cap.

A cap with a spring retainer is fitted on some gearboxes. This cap may be reused.

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118 4. Descriptions of work:

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– Remove plug from filler pipe.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Fill with ATF using -V.A.G 1924- , until ATF runs out of level hole -arrow-.

Only top up with VW ATF: Container size 0.5 l -G 052 162 A1Container size 1.0 l -G 052 162 A2Note

An insufficient ATF filling as well as excessive filling affects the function of the gearbox.

– Tighten plug with new seal -arrow 1- to 15 Nm. – Fit sealing plug onto filler pipe until locking device engages, or – Fit sealing plug on filler pipe and secure with a new cap -arrow 2-.

– Engage cap.

Note ♦ Always renew cap without clip. The cap secures the plug. olkswagen AG en AG. V

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4.40

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Carry out following procedure:

4.40.1

Oil in cold condition:

– Do not start engine but bring front wheels to straight-ahead position.

– Unscrew cap -1- with dipstick from oil reservoir.

– Wipe off dipstick using a clean cloth.

– Screw filler cap on hand tight and unscrew again.

Note

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The cap must be fully screwed on in order to obtain an accurate fluid level reading.

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Power assisted steering: checking fluid level

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–

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4. Descriptions of work:

119

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Check fluid level: The fluid level must be in area of MIN. mark‐ ing (up to 2 mm above or below marking).

Note ♦ If fluid level is above specified range, fluid must be extracted. ♦ If fluid level is below above-mentioned area, hydraulic system

must be checked for leaks (repair measure). It is not sufficient just to top up with fluid. If the hydraulic system is not leaking, top up with oil -G 002 000- .

– Screw cap on hand tight.

4.40.2

Fluid at operating temperature (above approx. 50°C)

– Do not start engine but bring front wheels to straight-ahead position.

– Unscrew cap -1- with dipstick from oil reservoir.

– Wipe off dipstick using a clean cloth.

– Screw filler cap on hand tight and unscrew again.

Note

The cap must be fully screwed on in order to obtain an accurate fluid level reading.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ If fluid level is below MIN. marking, then hydraulic system must

be checked for leaks (repair measure). It is not sufficient just to top up with fluid. If the hydraulic system is not leaking, top up with oil -G 002 000- .

– Screw cap on hand tight.

4.41

Changing brake fluid

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120 4. Descriptions of work:

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Special tools and workshop equipment required

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♦ If fluid level is above MAX. marking, fluid must be extracted.

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–

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Brake pedal depressor - V.A.G 1869/2-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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♦ Brake filling and bleeding equipment - VAS 5234-

♦ Brake filling and bleeding equipment - V.A.G 1869or

♦ Brake filling and bleeding unit - V.A.G 1869- with set V.A.G 1869/4Permissible brake fluid specification

♦ Brake fluid conforming to VW standard, VW 501 14 (new brake fluid).

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♦ Never allow brake fluid to come into contact with fluids that contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐ eral oils damage the seals and boots in the brake system.

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WARNING

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♦ Brake fluid conforming to US standard FMVSS 116 DOT 4 (previous brake fluid)

♦ Brake fluid is poisonous. In addition, due to its corrosive nature, it must not come into contact with paint. ♦ Brake fluid is hygroscopic, which means it absorbs mois‐ ture from the ambient air and should therefore always be stored in air-tight containers. ♦ Rinse off spilled brake fluid using plenty of water. ♦ Observe relevant disposal regulations.

Carry out following procedure: Observe operating instruction for -VAS 5234- or -V.A.G 1869- !

– Unbolt cap from brake fluid reservoir.

4. Descriptions of work:

121

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Extract as much brake fluid as possible using suction hose from -VAS 5234- -1- or from -V.A.G 1869- or using a suction bottle if strainer is built in.

WARNING

Do not reuse extracted (used) brake fluid.

– Fit brake pedal actuator - V.A.G 1869/2- between driver seat and brake pedal and pretension.

– Connect adapter -1- on brake fluid reservoir.

– Connect filling hose from -VAS 5234- or -V.A.G 1869- to adapter.

Note

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d On vehicles with 5-speed manual gearbox 02A the brake fluid of e nte is r o eo the hydraulic clutch mechanism must also be changed.

Vehicles h ut ra a with a 5-speed manual gearbox s085 and 4- and 5-speed manual c s pe rm itte d

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gearbox 020 have no hydraulic clutch mechanism.

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Vehicles with 5-speed manual gearbox 02A

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– Pull off cover cap -arrow-, connect collector bottle bleed hose to clutch slave cylinder, open bleed screw and allow approx.

0.1 l to flow out. Close bleed screw and fit cover cap -arrow-.

– Operate clutch pedal several times.

Continued for all vehicles

– Push collector bottle bleed hose -1- onto rear bleeder screw 7) , open bleeder screw and let appropriate quantity of brake fluid (see following table) run out. Close bleed screw.

AG.

122 4. Descriptions of work:

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Repeat procedure on other side of vehicle at rear.

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7) Start at rear right of left-hand drive vehicles and at rear left of right-hand drive vehicles.

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– Remove caps from bleeder screws.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Volkswa

gen AG AG. – Push collector bottle bleeder hose -1doscrew agenonto front bleeder es n ksw l 8) ot g o Vlet appropriate quantity of brake , open bleeder screw and y ua b d ran e fluid (see table) run out.risClose bleed screw. te un le

Sequence: Wheel brake cylinders, brake calipers

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Repeat procedure on other side of vehicle at front.

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tho 8) Start at front right of left-hand au drive vehicles and at front left of right-hand drive s s vehicles.

Brake fluid quantity which must flow out of wheel brake cylinders or brake calipers:

Rear right

400 to 500 cm3

Rear left

400 to 500 cm3 400 to 500 cm3

Front left

400 to 500 cm3

Total quantity: approx. 2 litre

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– Fit cover caps on bleeder screws.

– Move fill lever of -VAS 5234- or -V.A.G 1869- to position -B(see operating instructions).

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– Take filler hose off adapter.

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Front right

– Unscrew adapter from brake fluid reservoir.

– Screw in cap of brake fluid reservoir.

– Remove brake pedal depressor.

– Check pedal pressure and brake pedal free play. Free play: max. 1/3 of pedal travel.

4.42

Brake fluid level (dependent upon brake pad/lining wear): checking

Permissible brake fluid specification ♦ Brake fluid conforming to US standard FMVSS 116 DOT 4 (previous brake fluid) ♦ Brake fluid conforming to VW standard, VW 501 14 (new brake fluid).

4. Descriptions of work:

123

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 WARNING

♦ Never allow brake fluid to come into contact with fluids that contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐ eral oils damage the seals and boots in the brake system. ♦ Brake fluid is poisonous. In addition, due to its corrosive nature, it must not come into contact with paint. ♦ Brake fluid is hygroscopic, which means it absorbs mois‐ AG. Volkswagen AG d ture from the ambient air and should therefore always be agen oes ksw not l stored in air-tight containers. o g yV

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Please note the following: Delivery inspection

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♦ Observe relevant disposal regulations.

At delivery inspection the fluid level must be at MAX. marking.

Note

To prevent that brake fluid flows out of reservoir, the MAX marking must not be exceeded.

Inspection service

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– When fluid level is at MIN. marking or just above, fluid should not be topped up if linings are almost at wear limit.

Battery: checking battery terminal clamps for secure seating

Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331- (5-50 Nm)

124 4. Descriptions of work:

AG.

4.43

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– If fluid level is below MIN. marking, the brake system should be checked before fluid is added. (repair measure).

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– If linings/pads are new or well within wear limit, then fluid level must be between MIN. and MAX. markings.

in t his d o cu m en

– The fluid level must always be judged in conjunction with lin‐ ing/pad wear. When vehicle is in use, fluid level tends to drop slightly due to lining/pad wear and automatic adjustment.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note

A securely seated battery clamp ensures trouble free function and long service life of the battery.

Carry out following procedure:

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– Press lugs -arrows- together and open cover out forwards.

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If the battery clamp is not seated securely on the positive ter‐ minal, first disconnect battery clamp from battery negative terminal to prevent possible accidents.

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WARNING

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– Check if battery clamps -4- and -5- are seated securely on battery terminals by moving battery positive cable -2- and bat‐ tery negative cable -3- back and forth.

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– Open heat protective jacket -arrow- (if part of original equip‐ ment).

If the battery terminal clamp on positive terminal is not seated securely – Disconnect battery terminal clamp -5- on battery negative ter‐ minal first.

– Tighten battery clamp on battery positive terminal to 5 Nm. – Reconnect battery clamp -5- to battery negative terminal and tighten to 5 Nm. If the battery clamp on negative terminal is not seated securely – Tighten battery clamp -5- on battery negative terminal to 5 Nm.

4. Descriptions of work:

125

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

4.44

Battery: checking

Procedure: »Electrical system« ⇒ Electrical system; Rep. gr. 27 ; Checking battery »Checking battery«

4.45

Idling speed: checking

Diesel engine with engine code 1Y Special tools and workshop equipment required ♦ Ignition tester - V.A.G 1767 -

or ♦ Ignition tester - V.A.G 1367 -

– Connect ignition tester - V.A.G 1767- or ignition tester V.A.G 1367 - .

– Start engine and run it at idling speed.

Headlight adjustment: checking

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126 4. Descriptions of work:

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Special tools and workshop equipment required

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4.46

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– Check idling speed, if necessary adjust by turning the idling speed adjustment screw -1-.

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Carry out following procedure:

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara Note d e nte is r o eo h ut ra a Test and adjustment conditions and specifications ⇒ Data sheets c s s

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

or ♦ Headlight adjustment unit - VAS 5046-

rrectness of i t to the co nform spec at i h re o n wit in t his

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♦ Headlight adjustment unit - VAS 5047-

The following test and adjustment instructions are applicable in all countries. However, national guidelines and regulations of the respective country are to be followed.

Test and adjustment conditions •

Tyre pressures OK.

•

Lenses must not be damaged or dirty

•

Reflectors and bulbs OK.

•

Vehicle must be loaded.

Loading: with one person or 75 kg on the driver seat and the ve‐ hicle otherwise unloaded (unladen weight).

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The unladen weight is the weight of vehicle ready for operation with a full fuel tank (at least 90%) including weight of all equipment usually carried (e.g. spare wheel, tools, jack, fire extinguisher etc.).

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If the fuel tank is not at least 90% full, then load as follows: agen lksw Vo by

– Read off fuel level in fuel tank on fuel gauge -arrow-. Deter‐ mine additional weight from following table and place weight in luggage compartment.

AG.

Fuel gauge table

Fuel gauge reading

Additional weight in kg

1/4 1/2 3/4 Full

20 15 5 0

Example: When the fuel tank is half full an additional weight of 15 kg must be placed in the luggage compartment.

4. Descriptions of work:

127

Note

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The additional weight is best produced using fuel canisters filled with water (a 5 litre fuel canister filled with water weighs approx.

5 kg).

The vehicle must be rolled forward or backward several metres or front and rear springs must be bounced fully several times so that springs settle.

•

Vehicle and headlight adjuster must be aligned.

•

Inclination must be set.

Note

♦ The headlights must be set according to the inclination in “%”

Fog light inclination: 20 cm ♦ On vehicles with headlight range control the thumb wheel on the dash panel must be in basic setting (-).

4.46.1

Checking headlight adjustment (without 15° setting line)

Headlights Please check the following: – Whether, with the dipped beam switched on, the horizontal light-dark border contacts the dividing line -1- of the test area and – Whether the breaking point -2- between the horizontal part of the bright/dark boundary on the left and the rising part on the right lies on the vertical line of the central point -3-. The bright core of the light beam must be to the right of the vertical line.

128 4. Descriptions of work:

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beam, adjust main beam additionally. When adjusting main beam ensure that the adjustment unit is set to 0%.

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♦ If the vehicle is equipped with separate dipped and main

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-arrow C- stamped on the headlight. Percentage indicated on sticker is based on a projection distance of 10 metres. For ex‐ ample: inclination of 1.2% converts to approx. 12 cm.

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Vehicle and headlight adjuster must be on a level surface ⇒ Headlight adjuster operating instructions

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•

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note ♦ To simplify finding the breaking point -2-, cover and uncover

left (from driver perspective) half of the headlight a few times.

Then check dipped beam again.

♦ After correct adjustment of dipped beams, the centre point of

the main beam must lie on the centre mark -3-.

♦ To avoid incorrect settings, ignore the 15° setting line.

Fog lights – Check whether the upper bright/dark boundary touches the setting line and runs horizontally over the entire width of the test screen.

Other additional lights

Note

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Adjusting headlights

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4.46.2

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When the dipped beam is set the main beams are set at the same time.

Left headlight

Both adjustment screws on right-hand headlight are a mirror im‐ age.

-A- Lateral adjustment -B- Height adjustment

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Please check also that the reflectors in both headlights move evenly when operating the headlight range control.

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Note

4. Descriptions of work:

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– Adjust headlights, through holes -A- and -B-, using a suitable cross-head screwdriver.

129

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– To reduce the beam range turn adjustment screw -arrow- to the right. There is no provision for lateral adjustment. es, in part or in w l purpos hole ercia , is n m ot com

Other additional lights Additionally retrofitted lights of other systems must be checked and set according to valid guidelines.

4.47

Carry out road test

Which of the following can be checked depends on vehicle equip‐ ment and local conditions (urban/country).

– Engine: output, misfiring, idling speed, acceleration Prote cted by c o py rig ht .

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– Gear selection: ease of operation, stick position – Automatic gearbox: selector lever position, shift lock/ignition key removal lock, shift behaviour, dash panel insert display.

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– Clutch: pulling away, pedal pressure, odours agen lksw Vo by

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– Foot brake and handbrake: function, free travel and effective‐ ness, pulling to one side, juddering, squeal – ABS function: Pulsing must be felt at the brake pedal during ABS-regulated braking.

– Steering: function, steering free clearance, steering wheel centred when vehicle is travelling straight ahead – Tilting roof: function – Radio/radio navigation system: function, reception, GALA, in‐ terference noise – Multi-function indicator (MFI): functions – Air conditioning system: function – Vehicle: pulling to one side when travelling straight-ahead (level road) – Imbalance: wheels, drive shafts, propshaft – Wheel bearings: noises – Engine: hot starting behaviour

130 4. Descriptions of work:

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Check the following during a road test:

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Location of adjustment screw on right-hand headlight is a mirror image.

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

5

Exhaust emissions test Note

♦ Please observe the country specific legal regulations. ♦ The exhaust emissions test described below has been created

according to the legal regulations valid in Germany.

♦ In Germany the following is legally prescribed: ♦

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01.01.2001 must be equipped with EOBD. es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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♦ Procedures for vehicles with petrol engine without OBD

⇒ page 131 ⇒ page 142

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With fault reader - V.A.G. 1551With complete emissions testing station - VAS 6300-

♦ Procedures for vehicles with petrol engine and OBD ⇒ page 151 ♦ Procedures for vehicles with diesel engine without OBD ⇒ page 153

5.1

Exhaust emissions test for vehicles with petrol engine without OBD with -Fehler‐ auslesegerät V.A.G. 1551-

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5.1.1

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⇒ page 131 ⇒ page 135 ⇒ page 139

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ADZ, AEX, AKV, ANX, APQ and 1F AEE, AFT and ALM AEH, AKK, AKL, ANW, APE, APF, AQQ, AUA, AUD and AUR

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Procedure according to engine codes

Engine codes ADZ, AEX, AKV, ANX, APQ and 1F

Special tools and workshop equipment required ♦ Fault reader - V.A.G 1551-

5. Exhaust emissions test

131

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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132 5. Exhaust emissions test

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or

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♦ Ignition tester - V.A.G 1767 -

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♦ Adapter cable - V.A.G 1551/3 A-

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Ignition tester - V.A.G 1367 ♦ Trigger clamp - V.A.G 1367/8♦ 4-component exhaust emission tester - V.A.G 1787or ♦ 4-component exhaust emission tester - V.A.G 1788♦ ⇒ Data sheets for exhaust emissions test Procedure Note ♦ All test conditions and data required for emissions test ⇒ Data

sheets for exhaust emissions test

♦ Faults identified (engine electronics) when fault memory is

read must be rectified and the fault memory then cleared.

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

Carrying out visual check of components influencing emissions ⇒ Data sheets for exhaust emissions test – Performing visual check for: ♦ Installation ♦ Completeness ♦ Leakage un le pe rm itte d

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♦ Damage

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Note

Faults found are to be rectified.

Connecting test units – Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral.

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Connect -V.A.G 1551- with ignition switched off ⇒ page 20

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5. Exhaust emissions test

133

AG.

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Connect ignition tester - V.A.G 1367- or ignition tester V.A.G 1367/8- using trigger clamp - V.A.G 1767- with ignition switched off.

– Connect CO-tester - V.A.G 1363 A- or: 4-component exhaust emission tester - V.A.G 1787- or: 4-component exhaust emis‐ sion tester - V.A.G 1788 ( D )- to sampling pipe.

Carry out following procedure: – Start engine and run it at idling speed.

– Check idling speed and CO content (not adjustable).

If actual figures deviate from specifications: Carry out repair measures!

On -V.A.G 1551- : Indicated on display: V.A.G - SELF DIAGNOSIS HELP 1 - Rapid data transfer

or

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V.A.G - SELF DIAGNOSIS HELP 2 - Flash code output

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– Press button 1 to select “Rapid data transfer” mode.

Indicated on display: es, in part or in w l purpos hole ercia , is n m ot com

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Rapid data transfer HELP Enter address word XX

– Press buttons 0 and 1 for address word “Engine electronics” and confirm entry with Q button.

– Press → button.

Indicated on display: Rapid data transfer HELP Select function XX

– Press buttons 0 and 4 for function “Initiate basic setting” and confirm entry with Q button.

Basic setting HELP Enter display group number XXX

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– Check ignition timing, if necessary adjust by turning distributor.

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134 5. Exhaust emissions test

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– Press buttons 0 ; 0 and 1 for “Display group number 001” and confirm entry with Q button.

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Indicated on display:

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note ♦ The ignition timing is displayed directly on ignition tester with

TDC sender.

♦ With strobe lamp the strobe must be directed at ignition timing

mark -arrow-.

On -V.A.G 1551- : – Press → button.

Indicated on display: Rapid data transfer HELP Select function XX

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does ag – Press buttons 0 oand and ksw 6 for function “End data notransfer” t gu V l y b ara button. confirm entry with Q d e

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Note

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

5.1.2

Engine codes AEE, AFT and ALM

Special tools and workshop equipment required

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♦ Fault reader - V.A.G 1551-

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♦ Operate assemblies e.g. power assisted steering, automatic

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♦ Adapter cable - V.A.G 1551/3 A-

5. Exhaust emissions test

135

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Ignition tester - V.A.G 1767 -

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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136 5. Exhaust emissions test

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or

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ Ignition tester - V.A.G 1367 ♦ Trigger clamp - V.A.G 1367/8♦ 4-component exhaust emission tester - V.A.G 1787or ♦ 4-component exhaust emission tester - V.A.G 1788♦ ⇒ Data sheets for exhaust emissions test Procedure

code AEE, a spacer (6 mm thick) must be fitted onto the in‐ ductive sender, otherwise it will be damaged.

♦ All test conditions and data required for emissions test ⇒ Data

sheets for exhaust emissions test

♦ The CO content is regulated to specification by the lambda

regulation. Faults in the lambda regulation are detected in selfdiagnosis and stored in fault memory.

♦ Faults identified (engine electronics) when fault memory is

read must be rectified and the fault memory then cleared.

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

Carrying out visual check of components influencing emissions – Performing visual check for:

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♦ Leakage

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♦ Completeness

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♦ Installation

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⇒ Data sheets for exhaust emissions test

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Before attaching the inductive sender on vehicles with engine

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Note

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♦ Damage Note

Faults found are to be rectified.

Connecting test units – Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral.

Connect -V.A.G 1551- with ignition switched off ⇒ page 20

5. Exhaust emissions test

137

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Connect ignition tester - V.A.G 1367- or ignition tester V.A.G 1367/8- using trigger clamp - V.A.G 1767- with ignition switched off.

Note

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is engine Before attaching the inductive sender on vehicles with r o eo h code AEE, a spacer (6 mm thick) must be fitted onto ut the inductive ra a c s s sender, otherwise it will be damaged.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Carry out following procedure:

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– Connect CO-tester - V.A.G 1363 A- or: 4-component exhaust emission tester - V.A.G 1787- or: 4-component exhaust emis‐ sion tester - V.A.G 1788 ( D )- to sampling pipe.

– Start engine and run it at idling speed.

– Check idling speed and CO content (not adjustable).

or

Appears alternately

– Press button 1 to select “Rapid data transfer” mode.

Rapid data transfer HELP Enter address word XX

– Press buttons 0 and 1 for address word “Engine electronics” and confirm entry with Q button.

– Press → button.

Indicated on display: Rapid data transfer HELP Select function XX

– Press buttons 0 and 8 for function “Read measured value block” and confirm entry with Q button.

Indicated on display: Read measured value block HELP Enter display group number XXX

– Press buttons 0 ; 0 and 1 for “Display group number 001” and confirm entry with Q button.

Indicated on display: (1…4 = Display zones) Read measured value block 1 -> 1 2 3 4

Only continue with test when in 4th display zone -8-digit number block- 00000000 is displayed.

138 5. Exhaust emissions test

AG.

Indicated on display:

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V.A.G - SELF DIAGNOSIS HELP 2 - Flash code output

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V.A.G - SELF DIAGNOSIS HELP 1 - Rapid data transfer

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Indicated on display:

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On -V.A.G 1551- :

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If actual figures deviate from specifications: Carry out repair measures!

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note

If at one or more positions a 1 is displayed in display zone 4, the test conditions have not been fulfilled.

– Allow engine to idle for at least 1 minute.

– Check ignition timing.

– If necessary adjust ignition timing by turning distributor.

On -V.A.G 1551- : – Press → button.

Indicated on display: Rapid data transfer HELP Select function XX

– Press buttons 0 and 6 for function “End data transfer” and confirm entry with Q button.

If actual figures deviate from specifications: Carry out repair measures!

Note ♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

. Volkswagen AG gen AG does not gu ara nte eo ra c

wa ANW, Engine codes AEH, AKK,y VAKL, olks db APE, APF, AQQ, AUA, ise AUD and AUR or

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

♦ Fault reader - V.A.G 1551-

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5.1.3

5. Exhaust emissions test

139

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Prote cted by

♦ ⇒ Data sheets for exhaust emissions test Procedure Note ♦ All test conditions and data required for emissions test ⇒ Data

sheets for exhaust emissions test

♦ Idling speed and CO content not adjustable. ♦ The CO content is regulated to specification by the lambda

regulation. Faults in the lambda regulation are detected in selfdiagnosis and stored in fault memory.

♦ Faults identified (engine electronics) when fault memory is

read must be rectified and the fault memory then cleared.

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

Carrying out visual check of components influencing emissions ⇒ Data sheets for exhaust emissions test – Performing visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage

140 5. Exhaust emissions test

AG.

♦ 4-component exhaust emission tester - V.A.G 1788-

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or

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♦ 4-component exhaust emission tester - V.A.G 1787-

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♦ Adapter cable - V.A.G 1551/3 A-

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note

Faults found are to be rectified.

Connecting test units – Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral.

Connect -V.A.G 1551- with ignition switched off ⇒ page 20 . Volkswagen AG gen AG d a lksw

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ss

– Start engine and run it at idling speed.

On -V.A.G 1551- : Indicated on display: or Appears alternately

V.A.G - SELF DIAGNOSIS HELP 1 - Rapid data transfer V.A.G - SELF DIAGNOSIS HELP 2 - Flash code output

– Press button 1 to select “Rapid data transfer” mode.

Indicated on display:

Rapid data transfer HELP Enter address word XX

Rapid data transfer HELP Select function XX

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Indicated on display:

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– Press buttons 0 and 8 for function “Read measured value block” and confirm entry with Q button.

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Indicated on display:

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– Press buttons 0 and 1 for address word “Engine electronics” and confirm entry with Q button.

– Press → button.

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Read measured value block HELP Enter display group number XXX

– Press buttons 0 ; 0 and 1 for “Display group number 001” and confirm entry with Q button.

Indicated on display: (1…4 = Display zones)

Read measured value block 1 -> 1 2 3 4

Do not continue with check until 80°C appears in display zone 2.

– Check idling speed in display zone 1.

– Allow engine to idle for at least 1 minute.

– Read CO content on exhaust gas tester.

– Press → button.

Indicated on display:

Rapid data transfer HELP Select function XX

– Press buttons 0 and 6 for function “End data transfer” and confirm entry with Q button.

5. Exhaust emissions test

141

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Note

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

5.2

Exhaust emissions test for vehicles with petrol engine without OBD with emis‐ sions testing station - VAS 6300r te o iva r rp fo ng

Special tools and workshop equipment required ♦ Exhaust emissions station - VAS 6300-

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♦ ⇒ Data sheets for exhaust emissions test Note ♦ It is only possible to carry out an exhaust emissions test when

all units of the exhaust emissions station - VAS 6300- are con‐ nected properly and combined with each other according to the operating instructions.

♦ All work to be performed is displayed by the exhaust emissions

station - VAS 6300- .

Conditions for testing •

All test conditions and data required for emissions test ⇒ Data sheets for exhaust emissions test

•

For bar code reading the EET data sheet must be printed out.

•

Automatic gearbox: selector lever in position “P” or “N”.

•

Manual gearbox: gear lever in neutral

•

Parking brake applied

– Perform exhaust emissions test according to instructions on display.

142 5. Exhaust emissions test

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♦ OBD adapter cable - VAS 5052/16-

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measures!

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n AG. Volkswagen AG do es n wage s k l ot gVariant 1998 ➤ o , Polo Classic 1996 ➤ , Polo Caddy Kasten/Kombi 1996 ➤ yV ua b ran ed Maintenance - Editionris03.2018 tee o h t or u ac a ss specifications: Carry out repair If actual figures deviate from

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Initial screen

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d r Caddy Kasten/Kombi 1998 ➤ ir se 1996 ➤ , Polo Classic 1996 ➤ , PoloanVariant tee o h t or Maintenance Edition 03.2018 u ac a ss

rrectness o f i t to the co n f orm spec atio h re n wit

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– Select button -arrow- Exhaust emissions test .

An overview is displayed to select the respective EET type.

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– Select EET petrol -arrow-.

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The display for warm-up phase appears.

5. Exhaust emissions test

143

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– Continue exhaust emissions test according to instructions on display.

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– If the EET specification selection is displayed, select respec‐ tive “EET specification selection” -arrow-. ♦ When exhaust emissions test is performed for the first time, either select “Standard values”, ♦ Or “Last vehicle” when an exhaust emissions test is to be car‐ ried out again.

– Select Continue on display, see -item 1-.

Vehicle data input

The vehicle data input menu is displayed.

Note

registration document is now called the vehicle registration certificate part 1.

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144 5. Exhaust emissions test

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log book is now called the vehicle registration certificate part 2.

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♦ For new models the document previously known as the vehicle

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♦ For new models the document previously known as the vehicle

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 ♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ♦ -2- Vehicle type: “e.g. Golf” ♦ -3- Key number for 1: “e.g. 11” ♦

♦ -5- Key number for 2.2 (code for D2): “e.g. 358” (vehicle reg‐ istration certificate part 1) ♦ -6- Engine code “e.g. AQY” ♦ -7- Registration number: “e.g. WOB-HH 1234” ♦ -8- Vehicle identification number: “e.g.

WVWZZZ1JZYW123456” – Enter mileage at -item 9- “e.g. 32000”.

Note

♦ Further functions can be called up using GoTo button.

Specified data input for EET

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Note

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♦ The test can be terminated using GoTo button.

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♦ -5- Key number for 3: “e.g. 358” (vehicle registration docu‐ ment)

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0603” (vehicle reg‐ c s s

♦ If specifications are not available as bar code, they are to be AG.

entered manually.

♦ All test conditions and data required for emissions test ⇒ Data

sheets for exhaust emissions test

Manual specified data input for EET: – Perform manual data input according to instructions on dis‐ play.

5. Exhaust emissions test

145

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Enter displayed values on EET data sheet in column “Test values for exhaust emissions test” on display as follows: 1-

Test speed (idling speed)

2-

Warm-up phase for catalytic converter

3-

Engine temperature

4-

Increased idling speed

5-

CO content at increased idling speed

Lambda probe value

– When all data have been entered properly, press button ► -arrow- to continue.

Specified data input for EET as bar code: – If specified data for EET are available as bar code, read bar code of EET data sheet with bar code reader.

All data required are shown on display.

– If visual check is OK, press OK button -arrowNote

When not OK button is pressed a check will be carried out The visual check is displayed with the request to connect the di‐ agnostic connector.

– Follow instructions on display: – Switch off ignition.

– Connect adapter for older vehicles - VAS 5051/2- or engine speed adapter - VAS 5087/- to the vehicle.

– Switch ignition on.

146 5. Exhaust emissions test

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– Perform visual check.

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– Follow instructions on display:

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Inspection

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– Press ► button -arrow- to proceed.

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9-

Select type of control circuit test -item 1-. After selecting the basic procedure, note the different methods to activate dis‐ turbance variable ⇒ page 149 .

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6-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara Lambda at increased idling speed d e nte is r o eo h ut Idling speed ra a c s s

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Follow instructions on display, see -arrow C- and -arrow A-.- – Start engine.

– Insert emission probe into exhaust tail pipe.

Note

The exhaust emissions test is only continued when the test probe AG. Volkswagen AG d is in the exhaust tail pipe. agen o

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It is automatically switched to warm-up phase of catalytic con‐ verter.

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– Follow instructions on display:

Measurement starts when the engine speed has reached the re‐ quired level.

– Maintain engine speed in required engine speed range.

Warm-up phase

It is automatically switched to display for measuring engine tem‐ perature.

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This is only indicated on display if engine temperature has not reached 80℃.

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– Follow instructions on display:

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The remaining time to carry out the warm-up phase -arrow A- is displayed.

– Bring engine to required temperature.

5. Exhaust emissions test

147

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Measurement at increased idling speed: It is automatically switched to display for measuring increased idling speed.

– Follow instructions on display: Measurement starts when the engine speed has reached the re‐ quired level.

Note . Volkswagen AG gen AG does not gu y ara emissions test has failed. db e nte is r o eo h Measured values are reset using ← button,autand the test can ra c s s

a ♦ Measurement can be skipped using ► button, i.e. the exhaust ksw Vol

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be repeated.

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– Maintain engine speed in required engine speed range.

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The remaining time to perform measurement is displayed -arrow A-.- Measuring idling speed and CO content It is automatically switched to display for measuring the idling speed and CO content.

Measurement starts when the engine speed has reached the re‐ quired level.

The remaining time to perform measurement is displayed -arrow A-.- Lambda control circuit test

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Now remarks concerning the exhaust emissions test can be en‐ tered -arrow A-. They will then be included in the test log.

– When the exhaust emissions test is classed as passed, select EET sticker issued and the date from drop-down menu -arrow B-.

– Then confirm with Yes , see -arrow C-.

– Then press ► button -arrow D-.

148 5. Exhaust emissions test

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The test result is displayed.

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When the exhaust emissions test is performed, the log is shown on display.

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Evaluation

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For basic procedure a disturbance variable must be activated ⇒ page 149 .

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 After confirming, the two “TEST CERTIFICATES” are printed out automatically.

– Follow instructions on display: – Take emission probe out of exhaust tail pipe.

– Then press ► button -arrow B-.

The exhaust emissions test is completed, a new exhaust emis‐ sions test can be performed.

5.2.1

Methods to activate disturbance varia‐ n AG. Volkswagen AG do ble at lambda control circuit test es n wage o olks

Procedure according to engine codes

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⇒ page 149 ⇒ page 150 ⇒ page 150 ⇒ page 151 ⇒ page 151

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Engine codes ADZ and 1F

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ADZ and 1F AEE, AEX, AKK, AKV, ALM, ANW, ANX and APQ AEH, APF and AKL AFT APE AQQ

– Activate disturbance variable within 60 seconds as follows: – Pull vacuum hose off injection part towards intake air preheat‐ ing temperature selector -arrow-

The control unit must recognise deactivation of the disturbance variable and eliminate through regulation within 60 seconds.

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– Activate disturbance variable within 60 seconds as follows:

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Engine codes AEE, AEX, AKK, AKV, ALM, ANW, ANX and APQ

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The control circuit test is also completed when the disturbance variable has been recognised only in one direction.

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– Reconnect vacuum hose.

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The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

5. Exhaust emissions test

149

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Pull 4-pin connector -1- off coolant temperature sender -2-.

The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

Note

The throttle valve must not be operated during the test, otherwise the disconnected connector will be recognised as fault by the selfdiagnosis and stored in the fault memory.

– Reconnect 4-pin connector.

Note

When connecting the connector always ensure that it is fitted properly and engages noticeably.

The control unit must recognise deactivation of the disturbance variable and eliminate through regulation within 60 seconds.

The control circuit test is also completed when the disturbance variable has been recognised only in one direction.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se Activate disturbance variable within 60 seconds as follows: tee o h t or u ac a ss

Engine codes AEH, APF and AKL –

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– Pull connector -1- off coolant temperature sender -2-.

– Deactivate the disturbance variable immediately as follows: – Fit coolant temperature sender connector.

Note

When connecting the connector always ensure that it is fitted properly and engages noticeably.

The control unit must recognise deactivation of the disturbance variable and eliminate through regulation within 60 seconds.

The control circuit test is also completed when the disturbance variable has been recognised only in one direction.

Engine code AFT

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150 5. Exhaust emissions test

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– Activate disturbance variable within 60 seconds as follows:

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The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Pull vacuum hose -arrow- off fuel pressure regulator and seal.

Wait 20 seconds.

– The control circuit test is initiated.

– Open vacuum hose.

The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

– Reconnect vacuum hose on fuel pressure regulator The control unit must recognise deactivation of the disturbance variable and eliminate through regulation within 60 seconds.

The control circuit test is also completed when the disturbance variable has been recognised only in one direction.

Engine code APE – Activate disturbance variable within 60 seconds as follows: – Pull 4-pin connector off coolant temperature sender - G62with coolant temperature sender - G2- -arrow-.

The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

– Deactivate the disturbance variable as follows: Volkswa AG. agen

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Engine code AQQ

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– Activate disturbance variable within 60 seconds as follows: – Pull 4-pin connector off coolant temperature sender - G62with coolant temperature sender - G2- -arrow-.

The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

– Deactivate the disturbance variable as follows: – Reconnect connector on coolant temperature sender - G62- .

The control unit must recognise deactivation of the disturbance variable and eliminate through regulation within 60 seconds.

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Exhaust emissions test for vehicles with petrol engine and OBD AG.

♦ Exhaust gas testing station L - VAS 7320 A-

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Special tools and workshop equipment required

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The control circuit test is also completed when the disturbance variable has been recognised only in one direction.

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5. Exhaust emissions test

151

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note ♦ The following description refers to vehicles fitted with “On‐

board diagnosis” OBD.

♦ The OBD monitors all components and part systems influenc‐

ing the exhaust emissions quality.

♦ It is possible to carry out an exhaust emissions test only when

all units of the emissions testing station are connected prop‐ erly and joined to each other according to the operating in‐ structions.

♦ All work to be performed is displayed by the emissions testing

station .

Conditions for testing •

All test conditions and data required for exhaust emissions test are found on EET data sheet for the respective engine.

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12V battery fully charged (if battery charge is too low, raise idling speed if necessary).

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•

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– Perform exhaust emissions test according to instructions on display.

Vehicle data input

– Enter the following data: ♦ Registration number ♦ Key numbers

♦ Vehicle identification number ♦ Fuel type ♦ Mileage

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♦ Emission key number “Field 14.1 (code for field 14)”

♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for field D.2)” Specified data input for EET There are different ways to enter the specified data: ♦ 1. By manual input ♦ 2. By bar code input from EET data sheet ♦ 3. Through ELSA web service

152 5. Exhaust emissions test

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♦ Vehicle identification number “field E”

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♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”

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♦ Registration number: “e.g. WOB-HH 1234”

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The following vehicle data can be found in the vehicle registration certificate part 1:

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Note ♦ To use the ELSA web service, the exhaust gas testing station

L which is used for the exhaust emissions test must be inte‐ grated in the workshop network.

♦ The ELSA web service automatically transmits the data for the

specific vehicle via the network to the respective mask.

Manual specified data input for EET: Note

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All test conditions and data required for exhaust emissions test can be found in the ⇒ Data sheets for exhaust emissions test for respective engine.

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– Perform manual data input according to instructions on dis‐ play.

– Enter displayed values on EET data sheet in column “Test values for exhaust emissions test” on display as follows: Warm-up phase for catalytic converter

3-

Engine temperature

4-

Increased idling speed

5-

CO content at increased idling speed

6-

Lambda at increased idling speed

7-

Idling speed

8-

Select regulating probe type; either “Step-type probe” or “Broad-band probe”.

9-

Lambda probe value

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2-

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– If specified data for EET are available as bar code, read bar code of EET data sheet with bar code reader.

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Specified data input for EET as bar code:

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Test speed (idling speed)

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1-

All data required are shown on display.

Inspection – Inspect all exhaust emissions relevant components.

– Check if exhaust system is fitted and complete and check for leaks and damage.

Procedure – Follow instructions from exhaust gas testing station .

5.4

Exhaust emissions test for diesel en‐ gines without OBD

Exhaust emissions test with diesel tester V.A.G. 1743 ⇒ page 154 Exhaust emissions test with emissions testing station VAS 6300 ⇒ page 160

5. Exhaust emissions test

153

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5.4.1

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ e nte is r o eo h Maintenance - Edition 03.2018 ut ra a c s s

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Special tools and workshop equipment required

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♦ ⇒ Data sheets for exhaust emissions test

♦ All test conditions and data required for emissions test ⇒ Data

sheets for exhaust emissions test

♦ If possible, the test should be completed outdoors following a

road test. If this is not possible for various reasons (weather, excessive noise in residential areas), then the test can be car‐ ried out in a workshop.

♦ To reduce noise levels, the bonnet should be closed on first

catch during tests.

Carrying out visual check of components influencing emissions ⇒ Data sheets for exhaust emissions test – Performing visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

154 5. Exhaust emissions test

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Note

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Test sequence

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♦ Data reader - V.A.G 1798-

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♦ Diesel tester - V.A.G 1743-

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♦ Test equipment trolley - V.A.G 1700-

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Connecting test units

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does wag – Connect diesel tester - V.A.G not olks 1743- according to operating gu yV instructions. b ara ed

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– Start engine and run it at idling speed.

Carry out exhaust emissions test according to instructions on die‐ sel tester display.

If this message appears on the display: Please insert vehicle identity card!!

Manual input with -> button

– Enter vehicle identification data from vehicle identification document using keyboard as follows (press Return button after each entry).

Vehicle data input:

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Note

♦ For new models the document previously known as the vehicle

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registration document is now called the vehicle registration certificate part 1.

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– Press F2 button for “EET diesel” on data reader.

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Test sequence

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tho process, function, setting up and opera‐ Description, measuring au s tion see ⇒ V.A.G 1743 operating instructions s

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♦ For new models the document previously known as the vehicle

log book is now called the vehicle registration certificate part 2.

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♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ♦ -2- Vehicle type: “e.g. Golf” ♦ -3- Key number for 1: “e.g. 11” ♦ -4- Key number for 2: “e.g. 0603” (vehicle registration docu‐ ment) ♦ -4- Key number for 2.1 (code for 2): “e.g. 0603” (vehicle reg‐ istration certificate part 1) ♦ -5- Key number for 3: “e.g. 358” (vehicle registration docu‐ ment) ♦ -5- Key number for 2.2 (code for D2): “e.g. 358” (vehicle reg‐ istration certificate part 1) ♦ -6- Engine code “e.g. AQY” ♦ -7- Registration number: “e.g. WOB-HH 1234” ♦ -8- Vehicle identification number: “e.g.

WVWZZZ1JZYW123456” – Enter odometer reading “e.g. 32000”.

– Confirm entry of vehicle identification data with Q button.

Check input with -> button Continue with Q button

If this message appears on the display: Read bar code Manual input with -> button

5. Exhaust emissions test

155

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Enter specifications with bar code reader of data reader, to do this slide bar code reader over respective bar code of data sheets for exhaust emissions test. or – Carry out entry by hand following instructions on data reader display using → button.

– If this message appears on the display: Check input with -> button Continue with Q button

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– Enter result of visual check.

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If this message appears on the display: F1 Temperature measurement with sensor F2 Enter temp. measurement manually

– Press F1 button for “Temperature measurement with sensor”.

– If engine oil temperature has reached 80°C, pull out measuring sensor and push dipstick in until stop.

– Continue test sequence by pressing the Q button.

If this message appears on the display: Idling speed -> Speed ACT. xxxx rpm SPEC. xxxx rpm

Idling speed not in specified range for engine codes AEY, AFN, AHB, AHU, AGP, AGR, AKW, ALE, ALH, AQM, ASK and AYQ

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The idling speed and maximum speed can be checked but not adjusted.

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– If the values are not within specified range, a repair must be made.

Idling speed not in specified range for engine code 1Y

156 5. Exhaust emissions test

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Note

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– Press → button.

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Continuation for all engine codes

– Continue test sequence by pressing the Q button.

If this message appears on the display:

Rev limit 5 sec Speed ACT. xxxx rpm SPEC. xxxx...xxxx rpm

– Depress accelerator pedal fully and hold for specified time.

WARNING

If the rev limit is exceeded, lift off accelerator pedal immediately and adjust rev limit to specification or perform repair measures.

AG.

– Check actual figures, to do this switch further the actual display using → button.

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– Release accelerator pedal.

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Rev limit -> Speed ACT. xxxx rpm SPEC. xxxx...xxxx rpm

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If this message appears on the display:

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– To adjust idling speed, turn adjustment screw -1-.

Rev limit not in specified range for engine codes AEY, AFN, AHB, AHU, AGP, AGR, AKW, ALE, ALH, AQM, ASK and AYQ Note

Governed speed can be checked but not adjusted.

– If the values are not within specified range, a repair must be made.

Governed speed not in specified range for engine code 1Y

5. Exhaust emissions test

157

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Adjust lock nut of adjustment screw -2-.

– Lock adjustment screw.

Continuation for all engine codes – Continue test sequence by pressing the Q button.

If this message appears on the display: Idling speed 1st measurement 15 sec Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm

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Depress accelerator quickly

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y db If this message appears on the display:orise th au s Data transfer to diesel tester s

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Indicated on display:

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– Depress accelerator pedal fully and hold.

Data transfer to diesel tester Neutral accel. running

– Continue to depress and hold accelerator pedal.

If this message appears on the display: Idling speed 2nd measurement 15 sec Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm

– Release accelerator pedal.

The data reader accepts the actual figures within 15 seconds.

Data transfer to diesel tester Depress accelerator quickly

If this message appears on the display: Idling speed 3rd measurement 15 sec Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm

– Release accelerator pedal.

The data reader accepts the actual figures within 15 seconds.

If this message appears on the display: Data transfer to diesel tester Depress accelerator quickly

– Depress accelerator pedal fully and hold.

Indicated on display: Data transfer to diesel tester Neutral accel. running

– Continue to depress and hold accelerator pedal.

158 5. Exhaust emissions test

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– Continue to depress and hold accelerator pedal.

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Data transfer to diesel tester Neutral accel. running

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Indicated on display:

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– Depress accelerator pedal fully and hold.

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If this message appears on the display:

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 If this message appears on the display: Idling speed 4th measurement 15 sec Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm

– Release accelerator pedal.

The data reader accepts the actual figures within 15 seconds.

If this message appears on the display: Data transfer to diesel tester Depress accelerator quickly

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. Volkswagen AG gen AG does swa k not l o – Depress accelerator pedal fully and hold. y V gu ara db e nte s i r Indicated on display: o eo h ut ra a c s s Data transfer to diesel tester

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Neutral accel. running

– Continue to depress and hold accelerator pedal.

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If this message appears on the display: Highest opacity figure -> ACT. x.xx rpm SPEC. x...x.xx rpm

– Release accelerator pedal.

– Press → button.

If this message appears on the display: Average opacity figure -> ACT. x.xx rpm SPEC. x...x.xx rpm

– Press → button.

Opacity band width -> ACT. x.xx rpm SPEC. x...x.xx rpm

AG.

Test OK Continue with Q button Repeat test with F1 button

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If this message appears on the display:

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– Press → button.

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If this message appears on the display:

– Press Q button.

If the following is indicated on display: Press F1 button and repeat test or carry out repair measures.

Test not OK Continue with Q button Repeat test with F1 button

If this message appears on the display: Enter remarks with -> button Continue with Q button

– Enter remarks if necessary after pressing the → button.

– Press Q button.

If this message appears on the display: Select tester / manual input F3 F1 XXXXX F2 XXXXX

– Select tester or enter name using F1 to F3 buttons.

– Press Q button, wait for log print-out.

5. Exhaust emissions test

159

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– End exhaust emissions test by pressing F2 button.

5.4.2

Exhaust emissions test with emissions testing station VAS 6300 Caution

•

Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐ CAUTIONS” in the operating instructions for VAS 6300.

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♦ Exhaust emissions station - VAS 6300AG.

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♦ OBD adapter cable - VAS 5052/16Note ♦ It is only possible to carry out an exhaust emissions test when

all units of the exhaust emissions station - VAS 6300- are con‐ nected properly and combined with each other according to the operating instructions.

♦ All work to be performed is displayed by the exhaust emissions

station - VAS 6300- .

Test prerequisites: •

All test conditions and data required for exhaust emissions test are found on EET data sheet for the respective engine.

•

For bar code reading of specified data for EET, the EET data sheet must be printed out.

•

Automatic gearbox: selector lever in position “P” or “N”.

•

Manual gearbox: gear lever in neutral

•

Parking brake applied

– Perform exhaust emissions test according to instructions on display.

160 5. Exhaust emissions test

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The following description refers to vehicles not fitted with “On‐ board diagnosis”, OBD.

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– Press → button.

– Select button “Exhaust emissions test” -arrow-.

An overview is displayed to select the respective EET type.

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– Select “EET diesel” -arrow-.

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Initial screen:

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The display for warm-up phase appears.

5. Exhaust emissions test

161

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Continue exhaust emissions test according to instructions on display.

– If the EET specification selection is displayed, select respec‐ tive “EET specification selection” -arrow-. ♦ When exhaust emissions test is performed for the first time, either select “Standard values”, ♦ Or “Last vehicle” when an exhaust emissions test is to be car‐ ried out again.

– Select “Continue” -item 1- on display.

Vehicle data input: The vehicle data input menu is displayed.

Note ♦ For new models the document previously known as the vehicle

registration document is now called the vehicle registration certificate part 1.

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♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ♦ -2- Vehicle type: “e.g. Golf”

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♦ -3- Key number for 1: “e.g. 11”

♦ -4- Key number for 2: “e.g. 0603” (vehicle registration docu‐ ment) ♦ -4- Key number for 2.1 (code for 2): “e.g. 0603” (vehicle reg‐ istration certificate part 1) ♦ -5- Key number for 3: “e.g. 358” (vehicle registration docu‐ ment) ♦ -5- Key number for 2.2 (code for D2): “e.g. 358” (vehicle reg‐ istration certificate part 1) ♦ -6- Engine code “e.g. AQY”

♦ -7- Registration number: “e.g. WOB-HH 1234”

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♦ The test can be terminated using GoTo button.

162 5. Exhaust emissions test

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♦ Further functions can be called up using GoTo button.

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Note

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– Enter odometer reading at -item 9- “e.g. 32000”.

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♦ -8- Vehicle identification number: “e.g.

WVWZZZ1JZYW123456”

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i Specified data input for EET: tee r o h t or u ac a There are different ways to enter the specified data: ss

– Select “diesel below 3.5t” or “diesel above 3.5t” -arrow-.

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♦ 1. By manual input

Note

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♦ 3) Through ELSA web service

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♦ 2) By bar code input from EET data sheet

♦ To use the ELSA web service, the VAS 5052 which is used for

the exhaust emissions test, must be integrated in the work‐ shop network.

♦ For the ELSA web service the vehicle specified data are au‐

Note

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– Perform manual data input according to instructions on dis‐ play.

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All test conditions and data required for exhaust emissions test ⇒ Data sheets for exhaust emissions test for respective engine.

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Manual specified data input for EET:

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tomatically transmitted via the network to the respective mask.

– Enter displayed values on EET data sheet in column “Test values for exhaust emissions test” on display as follows: 1-

Speed for conditioning

2-

Number of throttle bursts for conditioning

3-

Engine oil temperature (min. value)

4-

Select engine oil temperature measurement procedure

5-

Idling speed

6-

Governed speed

7-

Rev limit measuring period (1 second)

8-

Opacity figure (average)

9-

Select probe type (No. of probe)

10 - Select measuring mode 11 - Measured period portion – When all data has been entered properly, press → button -arrow-.

Specified data input for EET as bar code: – If specified data for EET are available as bar code, read bar code of EET data sheet with bar code reader.

5. Exhaust emissions test

163

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y db ise r All required data is shown on display -1-. tho au s s

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– Press → button -arrow- to continue.

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Visual inspection: – Follow instructions on display: – Perform visual check.

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Ignition is switched off.

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Connecting diagnostic connector:

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Pressing "not OK" button causes a check to be carried out.

The visual check is displayed with the request to connect the di‐ agnostic connector -arrow A-

– Follow instructions on display -arrow A- and -arrow B-.

– Connect diagnosis cable connector to diagnostic connection.

Conditioning: – Start engine.

In the conditioning phase the engine and, if necessary, the emis‐ sion control systems are brought to operating temperature by throttle bursts and are prepared for the exhaust emissions test.

164 5. Exhaust emissions test

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– If visual check is OK, press “OK” button -arrow-.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Follow instructions on display: – Maintain engine speed in required engine speed range.

If no conditioning is necessary, press → button -arrow- for the next measurement.

Measuring engine temperature:

It is automatically switched to display for measuring engine tem‐ perature.

– Follow instructions on display: Note

♦

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♦

AG. Volkswagen AG d agen oes ksw not l o V gu This is only indicated on display if engine temperature has not y b ara d nte reached 80℃. ise r o eo h t u ra a tail pipe. c Do not insert emission probe into exhaust s s

inputs can be selected to measure the engine temperature.

The measured value must then be entered by hand. At end of exhaust emissions test the measured value is marked by # in the evaluating mask and in the log print-out.

♦ The button “Alternative input” is only active, if previously a dif‐

ferent method has been selected at specified data input for EET for “Engine oil measurement”.

Caution

Measuring the engine temperature is normally carried out via the oil temperature probe. The engine temperature must not be determined with engine running, otherwise the engine and probe could be damaged!

It is automatically switched to display for measuring the idling speed.

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Measuring idling speed:

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– Bring engine to required temperature.

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♦ Using button “Alternative input” -arrow- other measured value

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5. Exhaust emissions test

165

AG.

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Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Follow instructions on display: Measurement starts when the engine speed has reached the re‐ quired level.

Note ♦ Do not insert emission probe into exhaust tail pipe. ♦ The measurement can be skipped by pressing the → button,

i.e. the exhaust emissions test has failed.

♦ Measured values are reset using ← button, and the test can

be repeated.

– Maintain engine speed in required engine speed range.

The remaining time to perform measurement is displayed -arrow-. . Volkswagen AG gen AG d

wa olks yV b ed ris ho t au It is automatically switched to display for measuring rev limit. ss

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Measuring rev limit:

– Operate throttle until the measurement is carried out. To do this, immediately depress accelerator pedal.

The remaining time to perform measurement is displayed -arrow-.

Note

♦ Do not insert emission probe into exhaust tail pipe. ♦ The measurement can be skipped by pressing the → button,

i.e. the exhaust emissions test has failed.

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An air quality check is carried out before starting the free accel‐ eration. When doing this, no emission probe must be in the exhaust tail pipe. Otherwise measuring errors or faulty signals could occur during further measurements.

It is automatically switched to display for “Free acceleration”.

During “Free acceleration” the engine is revved up to rev limit without load as quickly as possible.

The “Free acceleration” test consists of at least four throttle bursts.

Free acceleration - phase 1:

166 5. Exhaust emissions test

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Free acceleration:

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– When the air quality check is carried out, insert emission probe into exhaust tail pipe

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Air quality check:

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Measurement starts when the engine speed has reached the re‐ quired level.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 – Follow instructions on display -arrow A- and -arrow C-.

– Maintain idling speed in engine speed range indicated -arrow D-.

The remaining time to perform measurement is displayed -arrow B-.

Note ♦ The emissions probe must be in the exhaust tail pipe. ♦ If the speed deviates from engine speed range indicated, the

measurement starts again.

♦ The measurement can be skipped by pressing the → button,

i.e. the exhaust emissions test has failed.

Free acceleration - phase 2: –

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the prompt for idling is shown on display. un le

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e Follow instructions on display -arrow B-. nte is r o eo h utwhen prompted and hold until ra a Depress accelerator pedal fully c s s pe rm itte d

Free acceleration - phase 3:

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– Remove foot from accelerator pedal as soon as the prompt for idling is shown on display -arrow B- and run engine at idling speed.

The test results and information on the latest “Free acceleration” are shown on display -arrow A-. If the measured values are not OK, here you can obtain information why the “Free acceleration” has failed.

Note

♦ If the field is coloured white the measured value is within tol‐

erance.

♦ If the field is coloured yellow the measured value is outside

tolerance, but can be assessed by the operator.

AG.

Now the next throttle burst follows, starting with phase 1 of “free acceleration”.

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– Follow instructions on display -arrow B-.

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Further throttle bursts:

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erance.

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♦ If the field is coloured red the measured value is outside tol‐

“Free accelerations” can be carried out until: ♦ three “free accelerations” have been completed in succession and the range of acceleration is OK. ♦ all values are OK, with the exception of range of acceleration, and the test is continued by pressing the → button -arrow C-.

(In this case, the operator assesses if the value is OK). ♦ the values are not OK and the measurement is terminated/ skipped by pressing the → button -arrow C-.

If the measured values are OK after three throttle bursts in suc‐ cession, i.e. all fields are coloured white, the exhaust emissions test is completed.

5. Exhaust emissions test

167

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d e nte When the exhaust emissions test has been performed, the logois ris eo h t shown on display. u ra a c s s

Evaluation:

Now remarks concerning the exhaust emissions test can be en‐ tered -arrow A-. They will then be included in the test log.

– When the exhaust emissions test is classed as passed, select “EET sticker issued” and the date from drop-down menu -arrow B-.

– Then confirm with “Yes” -arrow C-.

The exhaust emissions test log is shown on display and can be printed out as often as required in the menu “Print preview” using “Print” button -arrow A-.

– Press button “Close” -arrow B- to close the menu “Print pre‐ view ”.

– Follow instructions on display:

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168 5. Exhaust emissions test

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The exhaust emissions test is completed, a new exhaust emis‐ sions test can be performed.

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– Then press → button -arrow B-.

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– Take emission probe out of exhaust tail pipe.

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The test result is displayed.

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018

6

Glossary

These explanations only apply to “Maintenance Manual”. They are not necessarily generally valid!

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

CN DIN Part no.

EN

(Automatic transmission fluid); gear oil for automatic gearboxes Filling level of ATF in gearbox (Carbon monoxide); is produced when fuels containing carbon are not combusted completely (Cetane number); measurement unit for ignition quality of diesel fuel Deutsches Institut für Normung e.V (German Institute for Standardization) Abbreviation for part number European standard

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ATF ATF level CO

AG. Volkswagen AG d agen oes ksw no l o gu yaVregulating system in the braket system, b (Anti-lock brake system); the ABSeis that ara d s i tee steera‐ r prevents locking when braking.hoThis helps to maintain directional stability nand t or bility. ac au ss un le

ABS

Explanation

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Term

Explanation

EOBD FAME FSI TFSI MIL OBD

European On-Board Diagnosis Fatty acid methyl ester Fuel stratified injection Turbo fuel stratified injection (Malfunction indicator light); American designation for exhaust emissions warning lamp K83 Onboard diagnosis, the OBD monitors all components influencing the exhaust emissions quality.

American onboard diagnosis Unit injector for diesel engines Abbreviation for production control number. Identifies among other things optional equipment and country-specific deviations (Particulate matter); soot particulate value for diesel engine emissions Vehicles are “not” factory-fitted with components for LongLife service. For maintenance, the intervals based on time and distance (non-flexible intervals) apply. agen lksw Vo by

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PM QG0

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OBD-II Unit injector PR No.

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Term

Term

Explanation

QG1

Vehicles are factory-fitted with active LongLife service. This means, vehicles have a flexible service interval display and are fitted with the following components: ♦ Flexible service interval display in dash panel insert ♦ Engine oil level sensor ♦ Brake lining wear indicator

QG2

The LongLife service is not factory-activated. This means that vehicles have a non-flexible serv‐ ice interval display (time and distance dependent service intervals) and are fitted with the following components: ♦ Non-flexible service interval display in dash panel insert ♦ Engine oil level sensor ♦ Brake lining wear indicator

Readiness 8-digit binary code which indicates if all exhaust relevant diagnoses have been performed by the code engine management.

RON (Research octane number); measurement unit of the knock resistance of petrol 6. Glossary

169

Caddy Kasten/Kombi 1996 ➤ , Polo Classic 1996 ➤ , Polo Variant 1998 ➤ Maintenance - Edition 03.2018 Term

Explanation

SAE

(Society of Automotive Engineers); society which creates proposals/guidelines for implementing legal requirements (e.g. standards).

Naturally aspirated diesel engine Naturally aspirated diesel engine - direct injection Turbo diesel engine - direct injection Distributor injection pump Ultra low emission vehicle

SD SDI TDI DP ULEV

Explanation

ESI Common rail

AG. Volkswagen AG d Extended service interval agen oes ksw not l o gu y V line (rail), which supplies all cylinders Refers to a common high-pressure injection of the b ara d e nte s i r relevant cylinder bank with fuel. ho e t or ac au The LongLife service enables extremely long inspection or oil change intervals, de‐ ss pending on individual driving style and conditions under which the vehicle is used. For the LongLife service a special engine oil is required.

Also called finger probe (LPH lambda probe heating), (FLP flat lambda probe) or planar lambda probe. The voltage of the output signal of the lambda probe jumps rapidly. The lambda probe value is determined by a change in voltage. The probe is used as after catalytic converter probe.

Also called (ULP probe) universal lambda probe. The voltage of the output of the lambda probe nearly increases linear. The lambda probe value is determined by a change in voltage. This enables to measure the lambda probe value via a larger measuring range (broad band). The probe is used as before catalytic converter probe.

Tyre pressure monitoring, tyre monitor display un le

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170 6. Glossary

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TPMS, TPLI

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Broad-band probe

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Step-type probe

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LongLife service

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Term