DOWNLOAD PDF Volkswagen Polo 1995 Maintenace Manual

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

Maintenance

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Polo 1995 ➤

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Service Department. Technical Information

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Edition 03.2018

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Service

Service Maintenance

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

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6. Glossary

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3. General information

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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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2018 Volkswagen AG, Wolfsburg

00450215020

Polo 1995 ➤ Maintenance - Edition 03.2018

Contents

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1 6 6 8 9 11 17 17 18 20 22 22 23 23 23 24 25 26 26 26 27 28 32 32 34 37 38 38 39 40 40 40 42 44 46 49 49 57 58 58 59

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4.29 4.30 4.31 4.32 4.33 4.34 4.35

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4.26 4.27 4.28

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

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

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

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

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

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

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

Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

Descriptions of work: . . . . . . . . . . . . . . . . . . . . . . A. G. ..V.o.lk.sw. a.g.e.n .A. . . . . . . . . . . . . . . . . . . . .

G gen Swivel joints: inspecting . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . .do. e.s.no. t. . . . . . . . . . . . . . . g y d b topping up if necessary . . . . . . .u.ar.a . . . . . . . . . . .

Automatic gearbox: checking ATF level, nte ise r Battery: checking . . . . . . . . . . . u.th.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o. r . . . . . . . . a a ss clamps for secure seating . . . . . . . . . . . . . . . c. . . . . . .

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

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

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

Brake system: changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake fluid level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric windows: initialising (activation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle system test: carrying out test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Folding fabric sunroof: cleaning and lubricating guide rails . . . . . . . . . . . . . . . . . . . . . . . .

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

Checking first aid box expiry date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Poly V-belt: checking condition, tensioning if necessary . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filter: draining water (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Idling speed: checking and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine cover panel -top-: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine cover panel, -bottom- (noise insulation): removing and installing . . . . . . . . . . . . . .

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrying out road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Radio and radio-navigation system: sticking serial number and code number onto unit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio/radio-navigation system: activating anti-theft coding . . . . . . . . . . . . . . . . . . . . . . . .

Manual gearbox/final drive: checking oil level, topping-up oil if necessary . . . . . . . . . . . .

Headlight adjustment: checking, adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Wiper blades: checking park position and setting angle . . . . . . . . . . . . . . . . . . . . . . . . . .

Power assisted steering: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ility ab y li an pt ce

1 2 2.1 2.2 2.3 2.4 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 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25

Contents

64 64 65 67 67 68 69 76 77 82 84

i

Polo 1995 ➤ Maintenance - Edition 03.2018 Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 101 Dust and pollen filter: renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Door arrester: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Clock: setting to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Underbody protection: visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Toothed belt: checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Camshaft drive toothed belt and tensioning roller: renewing, PD diesel engine . . . . . . . . 106 Toothed belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Toothed belt: checking condition and tensioning, tensioning toothed belt if necessary . . . . 107 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Camshaft drive toothed belt: checking (4-cylinder petrol engine) . . . . . . . . . . . . . . . . . . . . 112 Driver and front passenger airbags: visual check of airbag units . . . . . . . . . . . . . . . . . . . . 113 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Exhaust emissions test for petrol engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Exhaust emissions test for petrol engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Exhaust emissions test for diesel engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

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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4.36 4.37 4.38 4.39 4.40 4.41 4.42 4.43 4.44 4.45 4.46 4.47 4.48 5 5.1 5.2 5.3 6

Polo 1995 ➤ Maintenance - Edition 03.2018

1

Engine list

(VIGG001139; Edition 03.2018) ♦ Petrol engines ⇒ page 1 ♦ Diesel engines ⇒ page 5 Petrol engines Engines Displacement Codes

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Manufactured

from to No. of cylinders/valves per cyl‐ inder Power kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Injection/ignition RON unleaded, at least Market Onboard diagnosis

Petrol engine 1.3 ADX

Petrol engine 1.6 AEA

Petrol engine 1.6 AEE

09.94 07.95 4/2

09.94 07.95 4/2

08.95 08.95 4/2

40/5200 100/2800…3400 76.5 70.5 10.0 Mono-Motronic

55/5200 128/2800…3400 76.5 86.9 9.8 Mono-Motronic

55/4800 135/2800…3600 75.0 86.9 9.8 1AV

95 1)

95 1)

95 1)

RoW ---

RoW ---

RoW ---

. Volkswagen AG 1) Under exceptional circumstances petrol unleaded, at least 91 RON, but with gen AG does swa k not l o reduced output. gu yV b ara d e nte is r o eo h ut ra a c s s

Petrol engine 1.0 AEV

Petrol engine 1.4 AEX

09.94 2000 4/2

09.94 07.96 4/2

08.95 2000 4/2

37/5000

33/5200

44/4700 2)

Nm at rpm

86/3000…3600

76/2800…3200

Bore ∅ mm Stroke mm Compression ratio Injection/ignition RON unleaded, at least Market Onboard diagnosis

67.1 70.6 10.5 Motronic 9.0

75.0 59.0 10.0 Mono-Motronic1.2.3R

116/2800…32002) 76.5 75.6 10.2 Motronic MP9.0

95 1)

95 1)

95 1)

RoW ---

RoW ---

RoW ---

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1) Under exceptional circumstances petrol unleaded, at least 91 RON, but with reduced output.

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Engines Displacement Codes

1. Engine list

1

AG.

Polo 1995 ➤ Maintenance - Edition 03.2018 2) Austria: reduced output, performance: 40 kW and specified torque: 116 Nm at 3000 rpm

05.96 2000 4/4

Petrol engine 1.4 AHW

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

55/5000 126/3500 76.5 75.6 10.5 Magneti Marelli 4 AV

98 2)

95 1)

95 1)

RoW ---

RoW ---

RoW ---

ss

1) Under exceptional circumstances petrol unleaded, at least 91 RON, but with reduced output.

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from 03.98 to 2000 No. of cylinders/valves per cyl‐ 4/4 inder Power kW at rpm 88/6200 Torque Nm at rpm 150/4500 Bore ∅ mm 76.5 Stroke mm 86.9 Compression ratio 10.5 Injection/ignition Magneti Marelli 4 AV RON unleaded, at 98 2) least Market RoW Onboard diagnosis ---

Petrol engine 1.4 AKK

Manufactured

10.99 2002

10.99 2002

4/2 RRF 3)

4/2 RRF 3)

44/4700 116/3000 76.5 75.6 10.4 Motronic ME 7.5.10

40/4700 116/3000 76.5 75.6 10.4 Motronic ME 7.5.10

95 1) 4)

95 1)

RoW ---

Austria ---

1) Under exceptional circumstances petrol unleaded, at least 91 RON, but with reduced output.

2 1. Engine list

Petrol engine 1.4 AKP

AG.

Petrol engine 1,6 AJV

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Engines Displacement Codes

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3) Abbreviation for roller rocker finger

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2) Under exceptional circumstances super unleaded, at least 95 RON, but with reduced output.

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74/6000 128/4400 76.5 75.6 10.5 1AV

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from to No. of cylinders/valves per cyl‐ inder Power kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Injection/ignition RON unleaded, at least Market Onboard diagnosis

Petrol engine 1.4 AFK

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Petrol engine 1,4 AFH

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Polo 1995 ➤ Maintenance - Edition 03.2018 2) Under exceptional circumstances super unleaded, at least 95 RON, but with reduced output.

3) Abbreviation for roller rocker finger 4) leaded fuel permitted

Engines Displacement Codes

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Petrol engine 1,4 AKV

Petrol engine 1.0 ALD

Petrol engine 1.0 ALL

10.99 2002 4/2 RRF 2)

09.97 2000 4/2

37/5000 86/3000…3600 67.1 70.6 10.7 Motronic ME 7.5.10

37/5000 86/3000…3600 67.1 70.6 10.5 MPI

95 1)

95 1)

RoW ---

RoW ---

Petrol engine 1.4 APE

Petrol engine 1.4 APQ

10.99 2001

4/4 RRF 2)

01.98 2000 4/2

55/5000 126/3800 76.5 75.6 10.5 Motronic ME 7.5.10

44/4700 116/2800…3200 76.5 75.6 10.2 Motronic MP 9.0

95 1)

95 1)

95 1)

RoW ---

RoW ---

RoW ---

Manufactured

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1) Under exceptional circumstances petrol unleaded, at least 91 RON, but with reduced output.

2) Abbreviation for roller rocker finger

→ l

01.98 2000 4/2 44/4700 116/2800…3200 76.5 75.6 10.2 Motronic MP 9.0

AG.

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Petrol engine 1,4 ANX

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from 05.97 to 2000 No. of cylinders/valves per cyl‐ 4/2 inder Power kW at rpm 44/4700 Torque Nm at rpm 116/2800…3200 Bore ∅ omm 76.5 . V lkswagen AG gen AG d a o e w s75.6 Stroke mm not olks gu yV ara d b ratio e Compression 10.2 nte is r o eo h ut ra Injection/ignition MPI a c s s 1) RON unleaded, at 95 least Market RoW Onboard diagnosis ---

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1) Under exceptional circumstances petrol unleaded, at least 91 RON, but with reduced output.

2) Abbreviation for roller rocker finger

1. Engine list

3

Polo 1995 ➤ Maintenance - Edition 03.2018

Engines Displacement Codes

→ l

Petrol engine 1,4 AQQ

Petrol engine 1.6 ARC

Petrol engine 1.4 AUA

10.99 2002 4/4

10.99 2002 4/4 RRF 3)

92/6200 150/4500 76.5 86.9 10.5 Simos 3PC

55/5000 126/3800 76.5 75.6 10.5 Magneti Marelli 4 AV

98 2)

95 1)

RoW ---

RoW ---

Manufactured

from 07.99 to 2001 No. of cylinders/valves per cyl‐ 4/4 RRF 3) inder Power kW at rpm 74/6000 Torque Nm at rpm 126/4400 Bore ∅ mm 76.5 Stroke mm 75.6 Compression ratio 10.5 Injection/ignition Magneti Marelli 4 AV RON unleaded, at 95 1) least agen AG Market n AG. VolkswRoW does wage s k not l o V gu Onboard diagnosis d by --ar un le

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2) Under exceptional circumstances super unleaded, at least 95 RON, but with reduced output.

Petrol engine 1,4 AUB

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from 10.99 to 2002 No. of cylinders/valves per cyl‐ 4/4 RSH 3) inder Power kW at rpm 74/6000 Torque Nm at rpm 128/4500 Bore ∅ mm 76.5 Stroke mm 75.6 Compression ratio 10.5 Injection/ignition Magneti Marelli 4 LV RON unleaded, 95 1) at least Market RoW Onboard diagnosis ---

10.99 2002 4/2 37/5000 86/3600 67.1 70.6 10.7 Motronic ME 07/05/2010

Petrol engine 1.6 AVY

10.99 2002 4/2

05.00 2002 4/4 RSH 3) 92/6200 150/4500 76.5 86.9 10.5 Simos 3

95 1)

95 1)

98 2)

RoW yes

RoW ---

RoW yes

AG.

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1) Under exceptional circumstances petrol unleaded, at least 91 RON, but with reduced output.

2) Under exceptional circumstances super unleaded, at least 95 RON, but with reduced output.

4 1. Engine list

Petrol engine 1.4 AUD

44/5000 116/3000 76.5 75.6 10.4 Motronic ME 7.5.10

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Petrol engine 1.0 AUC

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Engines Displacement Codes

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3) Abbreviation for roller rocker finger

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Polo 1995 ➤ Maintenance - Edition 03.2018 3) Abbreviation for roller rocker finger

Diesel engines → l

Diesel engine 1,9 AEF

Diesel engine 1.9 AGD

Diesel engine 1.7 AHG

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

Market Onboard diagnosis

from 11.95 2002 4/2

07.96 04.00 4/2

04.97 12.99 4/2

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Diesel engine 1.9 ASX

08.97 05.00 4/2

10.99 2002 3/2

05.00 2002 4/2

44/4200 115/2200…3000 79.5 86.4 19.5 SDI 49 RoW ---

55/4000 195/2200 79.5 95.5 19.5 TDI unit injector 49 RoW ---

47/4200 124/2000…2800 79.5 95.5 19.5 SDI 49 RoW --agen lksw Vo by

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Diesel engine 1.4 AMF

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Market Onboard diagnosis

Diesel engine 1,7 AKU

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Engines Displacement Codes

47/4400 47/4200 42/4200 k s l w o a V g . e G n 125/2000…3000 124/2200…2800 112/2200…2600 A AG do agen es n ksw ot g Vol 79.5 79.5 79.5 y ua b d ran e tee ris 95.5 95.5 86.4 o h t or u ac a 22.5 19.5 19.5 ss Nat. asp. diesel (NAD) SDI SDI 49 49 49 RoW RoW RoW -------

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Engines Displacement Codes

1. Engine list

5

Polo 1995 ➤ Maintenance - Edition 03.2018

2

Service work

This chapter provides information on the following subjects: Service tables ⇒ page 6 Delivery inspection ⇒ page 8 Oil change service ⇒ page 9 Inspection service ⇒ page 11

Service tables

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2.1

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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VW engine oil standards ⇒ page 6 Filter change intervals ⇒ page 6 es, in part or in w l purpos hole ercia , is n m ot com

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Toothed belt change intervals ⇒ page 7 Service intervals ⇒ page 7

2.1.1

VW engine oil standards Caution

POLO 6N VW ENGINE OIL STANDARDS

505 00/505 01 505 01 agen lksw Vo by

AG.

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2.1.2

501 01/502 00

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PETROL ENGINES 4-cylinder engines DIESEL ENGINES 4-cylinder engines without unit injector 3-cylinder unit injector engines without diesel particulate filter

do c um en

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Only engine oils approved by VW may be used. Up-to-date information ⇒ ServiceNet, Technical information, Inspection and maintenance, Approved oils

Filter change intervals Filter change intervals

ENGINE OIL FILTER SD, engine code: AEF All remaining vehicles

According to service interval display

AIR FILTER All engine types ► 1999 All engine types 2000 ► FUEL FILTER 1) All diesel engines

6 2. Service work

Every 15,000 km or 1 year

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

Diesel conforming to EN 590

Diesel not conforming to EN 590

Biodiesel -RME-

Polo 1995 ➤ Maintenance - Edition 03.2018 Filter change intervals Change Drain water Change Every Every Every swagen A 60,000 km agen30,000 30,000 km AG. Volkkm G do

1) When using diesel fuel with a high sulphur content, the fuel filter must be changed at 7,500 km. Countries where the diesel has a high sulphur content ⇒ page 23 .

Toothed belt change intervals Toothed belt change intervals

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AMF

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AGD, ASX Prote cted by

1.9 l SDI

AMF

Drain water Every 15,000 km

Change interval Every 60,000 km Every 90,000 km

Tensioning roller -----

Every 60,000 km Tensioning roller: every 60,000 km do c um en

1.4 l, TDI unit in‐ jector

Period Up to model year 2000 From model year 2001 Up to model year 2000 From model year 2001 Since introduc‐ tion AG.

Engine code AHG, AKU

Every 90,000 km Tensioning roller: every 90,000 km Every 90,000 km

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Diesel engines Engine type 1.7 l SDI

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2.1.3

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engine types

es n ot g ua ran tee or ac 2 years Every 30,000 km or

Change Every 30,000 km

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Drain water Every 15,000 km

---

Note

The test intervals for engine codes not listed here can be found in the maintenance table or chapter “Inspection service” ⇒ page 11

2.1.4

Service intervals

Petrol and diesel engines Models Polo Polo

Polo

From - to

Engine/Engine code/PR No./ Remarks

Intervals: Service

Since intro‐ Diesel, in countries where the Oil change service duction sulphur content in fuel is high every 7,500 km or 1 year 11.95►10.01 SD Oil change service engine code: AEF flexible from 7,500 km to max. 15,000 km Inspection service flexible to max. 1 year Inspection service every 30,000 km 10.94►10.01 Petrol and SDI / TDI Oil change service every 15,000 km or 1 year Inspection service every 12 months

2. Service work

7

Polo 1995 ➤ Maintenance - Edition 03.2018 Models

From - to

Engine/Engine code/PR No./ Remarks

Intervals: Service Inspection service every 30,000 km

2.2

Delivery inspection

Notes on performing inspection service

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a ksw ♦ The sequence of the individual service tasks has been tested Vol y and optimised. Therefore, it should be followed to avoideun‐ db ris necessary interruptions in the work. o h t au

Scope of work

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ss measures ♦ For stock vehicles and vehicles in storage perform according to ⇒ ElsaWin - “Maintenance tables” !

Page

– Electric windows: carry out initialisation (activation) – Clock: set to correct time

– Radio and radio-navigation system: activate anti-theft coding, store local radio stations to station buttons

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c o p yri gh t.

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– Check vehicle interior for cleanliness: front and rear seats, interior trim, carpets/mats, windows – Seat and carpet protective coverings: remove – Fit all equipment which has been packed inside vehicle (if fitted): Mats, wiper arms, spoilers, roof aerial, wheel trims/hub caps, valve extensions – Edge protection on doors (plastic film): remove – Check vehicle exterior for cleanliness: paintwork, decorative parts, windows, wiper blades – Wheel bolts: tighten to specified torque agen lksw Vo by

AG.

Prote cted by

– Tyre pressure of all 4 wheels and spare wheel: set to correct pressures (in the factory the tyres are inflated to 3.5 bar) – Vehicle from below; engine (components in engine compartment), brake system, axles, gearbox/ final drive, steering, joint protective bellows/boots, hoses, fluid reservoirs: visual check for leaks and damage (without removing engine compartment cover for noise insulation) – Vehicle underside (floor pan): inspect for damage – Battery: check battery terminals by hand for tightness – Window wipe/wash and headlight washer system: check function and jet settings; replenish fluid G 052 164 to maximum

8 2. Service work

do c um en

– Radio card (part of radio and radio-navigation system operating instructions): stick radio serial number and fixed code number sticker onto radio card

⇒ page 86 ⇒ page 38 ⇒ page 103 ⇒ page 67 ⇒ page 67

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

– Fuse(s) (in ashtray): insert – All switches, electrical consumers, gauges and other controls: check function – Service interval display: reset

⇒ page 65 ⇒ page 28 ⇒ page 58 ⇒ page 104 ⇒ page 27 ⇒ page 77

Polo 1995 ➤ Maintenance - Edition 03.2018 Scope of work

Page

– Engine oil level: check, top-up with engine oil if necessary; observe oil specifications! ⇒ page 6

– –

2.3

Oil change service

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

– – –

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–

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–

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–

⇒ page 58 Engine and components in engine compartment: inspect for leaks and damage (from above). ⇒ page 58 Coolant level: check it is at maximum ⇒ page 46 Power assisted steering: check fluid level ⇒ page 84 Brake fluid level: check level is at maximum ⇒ page 37 n AG. Volkswagen AG do e n wage s k l ot gbe o pillar (B-pillar); the sticker scan V “Your first service” sticker: attach sticker to driver side door ⇒ y ua d b Destroy the instruction after attaching ran found on an instruction attached at front of vehicle wallet. page ir se tee ho the sticker! or 18 ut ac a s s Vehicle data sticker: stick into service schedule ⇒ page 18 Service schedule: enter delivery inspection Owner's literature: check that literature is complete and prepare for delivery to customer.

Carry out road test ⇒ page 64

Oil change service every 15,000 km ⇒ page 9 Oil change service according to flexible service interval display (7,500…15,000 km) ⇒ page 10

c o p yri gh t .

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♦ In countries where diesel has a high sulphur content, change Prote cted by

♦ The sequence of the individual service tasks has been tested

AG.

♦ Affected countries with a high sulphur content ⇒ page 23

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oil every 7,500 km.

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Note

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Oil change service every 15,000 km

in t his d o cu m en

2.3.1

and optimised. Therefore, it should be followed to avoid un‐ necessary interruptions in the work.

♦ When faults requiring repair measures are found during an oil

change service, inform the customer.

♦ Ask customer if new wiper blades should be fitted and if he or

she wishes to have Windscreen Clear G 052 164 (cleanser and anti-freeze) in the washer system.

♦ Removing and installing engine compartment cover -bottom-

(noise insulation tray) ⇒ page 58

2. Service work

9

pe rm itte d

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Polo 1995 ➤ Maintenance - Edition 03.2018

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

– Toothed belt: Check for wear

⇒ page 104

-SDI / TDI engines ► 2000– Fuel filter: drain water ♦ Every 15,000 km for vehicles with diesel engine model year 1995, using diesel according to DIN EN 590 ♦ Every 15,000 km when using diesel not conforming to DIN EN 590 ♦ Every 15,000 km for vehicles with diesel engine from model year 1996, using biodiesel according to DIN EN 14214 r te o iva r rp fo ng

in t his d o cu m en

– Engine oil: drain or extract, renew oil filter ♦ If engine oil is drained rather than being extracted with the used oil collection and extraction unit, replace oil drain plug

Front disc brake pads: check thickness Engine oil: replenish Service interval display: reset Enter date for next service on sticker and attach sticker to driver side door pillar (B-pillar). agen lksw Vo by

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2.3.2

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– – – –

Page

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

Vehicles driving more than 15,000 km per year: Vehicles with petrol engines Vehicles with diesel engine codes AGD, AHG, AKU, AMF, ASX

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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

⇒ page 44

⇒ page 59

⇒ page 32 ⇒ page 59 ⇒ page 86 ⇒ page 18

Oil change service according to flexible service interval display (7,500…15,000 km)

Note ♦ In countries where diesel has a high sulphur content, change

oil every 7,500 km.

♦ Affected countries with a high sulphur content ⇒ page 23 ♦ 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.

♦ When faults requiring repair measures are found during an oil

change service, inform the customer.

♦ Ask customer if new wiper blades should be fitted and if he or

she wishes to have Windscreen Clear G 052 164 (cleanser and anti-freeze) in the washer system.

♦ Removing and installing engine compartment cover -bottom-

(noise insulation tray) ⇒ page 58

Vehicles from model year 1996 with diesel engine code AEF – Fuel filter: drain water ♦ For vehicles with diesel engine, model year 1995, using diesel according to DIN EN 590

Page ⇒ page 44

♦ For vehicles using diesel not conforming to DIN EN 590 ♦ For vehicles with diesel engine from model year 1996, using biodiesel according to DIN EN 14214 – Engine oil: drain or extract, renew oil filter ♦ If engine oil is drained rather than being extracted with the used oil collection and ex‐ traction unit, replace oil drain plug

10 2. Service work

⇒ page 59

Polo 1995 ➤ Maintenance - Edition 03.2018 Vehicles from model year 1996 with diesel engine code AEF – – – –

Page

Front disc brake pads: check thickness Engine oil: replenish Service interval display: reset Enter date for next service on sticker and attach sticker to driver side door pillar (B-pillar).

2.4

⇒ page 32 ⇒ page 59 ⇒ page 86 ⇒ page 18

Inspection service

Inspection service every 12 months ⇒ page 11 Inspection service every 30,000 km ⇒ page 13

2.4.1

Inspection service every 12 months

Note ♦ In countries where diesel has a high sulphur content, change

oil every 7,500 km.

♦ Affected countries with a high sulphur content ⇒ page 23 ♦ 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.

AG. Volkswagen o o y V work, which is the most com‐ t gua quence of inspection service db ran e monly performed service. tee ris ho t or u ac a If faults requiring repair measures are found during an inspec‐ ss

AG do agen ♦ The sequence of task descriptions es n lksw corresponds to the se‐

♦ Ask customer if new wiper blades should be fitted and if he or

she wishes to have Windscreen Clear G 052 164 (cleanser and anti-freeze) in the washer system.

♦ Check if storage life date of first aid box has been exceeded

and if warning triangle is fitted.

♦ Removing and installing engine compartment cover -bottom-

(noise insulation tray) ⇒ page 58

Scope 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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Electrics – Front lights - check function: side lights, dipped beam, main beam, fog lights, turn signals, hazard warning lights – Rear lights - check function: brake lights (including 3rd brake light), tail lights, re‐ versing lights, rear fog light, number plate light, luggage compartment light, turn signals, hazard warning lights – Interior and glove compartment lighting, cigarette lighter, warning lamps and horn: check function – Carry out vehicle system test Vehicle exterior – Door arrester and securing pins: grease – Windscreen wash/wipe system and headlight washer system: check function and jet settings – Wiper blades: check for damage; check park position; only if wiper blades “judder”: check setting angle Tyres

Page

⇒ page 38 ⇒ page 102 ⇒ page 77 ⇒ page 82

2. Service work

11

agen lksw Vo by

AG.

Prote cted by c o p yri gh t.

C op yi

Polo 1995 ➤ Maintenance - Edition 03.2018 Scope of work

Page

r fo ng

– Engine and components in engine compartment: inspect for leaks and damage (from below).

– 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 Engine compartment – Engine oil: replenish – Battery Check – Engine and components in engine compartment: visual check for leaks and damage (from above) – Window wash/wipe system: replenish with Windscreen Clear - G 052 164– Cooling system: check frost protection and coolant level – Air filter: clean housing and renew filter element •

Only applies to vehicles up to model year 1999

AG.

Every 2 years or every 60,000 km whichever occurs first

– Air filter: clean housing and renew filter element •

Every 4 years or every 60,000 km whichever occurs first

•

Only applies to vehicles from model year 2000

– Fuel filter: drain water •

Every 15,000 km for vehicles with diesel engine using biodiesel according to EN 14214

•

Every 15,000 km when using diesel not conforming to EN 590

•

For vehicles with diesel engine, model year 1995, using diesel according to EN 590

– Toothed belt: check for wear •

⇒ page 40 ⇒ page 32 ⇒ page 32

⇒ page 101 ⇒ page 26 ⇒ page 59 ⇒ page 26 ⇒ page 58 ⇒ page 77 ⇒ page 46 ⇒ page 49

⇒ page 49

⇒ page 44

⇒ page 104

SDI / TDI engines ► 2000

– Camshaft drive toothed belt: check •

⇒ page 58

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Prote cted by c o py rig ht .

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•

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

If engine oil is drained rather than being extracted with the used oil collection and extraction unit, replace oil drain plug

ht rig py Co t.

•

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 left tyre: check condition, wear pattern, inflation pressure; enter tread depth ⇒ page 28 _______ mm – Rear left tyre: check condition, wear pattern, inflation pressure; enter tread depth ⇒ page 28 _______ mm – Rear right tyre: check condition, wear pattern, inflation pressure; enter tread depth ⇒ page 28 _______ mm – Front right tyre: check condition, wear pattern, inflation pressure, Aenter tread depth ⇒ page 28 G. Volkswagen AG d agen oes _______ mm ksw not l o V gu by arapage 28 – Spare wheel: check condition, wear pattern, inflation enter tread depth ⇒ dpressure; nte ise r o _______ mm eo h ut ra a c s Underside of vehicle s – Engine oil: drain or extract; renew oil filter ⇒ page 59

Only valid for 4-cylinder petrol engine without prescribed change interval

12 2. Service work

⇒ page 112

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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Scope of work

•

Additional work as a separate charge!

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

Every 2 years

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

pe rm itte d

– Change brake fluid •

Polo 1995 ➤ Maintenance - Edition 03.2018

– Brake fluid level (dependent upon brake pad/lining wear): check – Carry out exhaust emissions test, additional work as a separate charge!

•

3 years after initial registration and then every 2 years 2)

– Idling speed: check and adjust if necessary •

⇒ page 37 ⇒ page 115

⇒ page 49

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Vehicles ►1996: every 12 months ht rig py Co t.

Vehicles 1997►: every 30,000 km

⇒ page 69

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Prote cted by c o py rig ht .

C op yi

•

⇒ page 34

Valid for diesel engines with code AEF, when no exhaust emissions test has been performed

Headlight adjustment / documentation / final checks – Headlight adjustment: check •

Page

– Service sticker: enter date of next service (including change of brake fluid) on sticker and secure sticker to driver side door pillar (B-pillar) – Carry out road test

⇒ page 18 ⇒ page 64

agen lksw Vo by

AG.

2) Applicable only for countries where there are no country specific mandatory exhaust emission regulations.

2.4.2

Inspection service every 30,000 km

Note ♦ In countries where diesel has a high sulphur content, change

oil every 7,500 km.

♦ Affected countries with a high sulphur content ⇒ page 23 ♦ 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.

♦ The sequence of task descriptions corresponds to the se‐

quence of inspection service work, which is the most com‐ monly performed service.

♦ If faults requiring repair measures are found during an inspec‐

tion service, inform the customer.

♦ Ask customer if new wiper blades should be fitted and if he or

she wishes to have Windscreen Clear G 052 164 (cleanser and anti-freeze) in the washer system.

♦ Check if storage life date of first aid box has been exceeded

and if warning triangle is fitted.

♦ Removing and installing engine compartment cover -bottom-

(noise insulation tray) ⇒ page 58

Scope of work

Page

Electrics – Front and tail lights, turn signals, hazard warning lights, luggage compartment lights: check function 2. Service work

13

Polo 1995 ➤ Maintenance - Edition 03.2018 Scope of work

Page

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

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ility ab y li an pt ce

– Interior and glove compartment lighting, cigarette lighter, warning lamps and horn: check function – Carry out vehicle system test – Service interval display: reset Vehicle exterior – Door arrester and securing pins: grease – Sunroof: check function, clean guide rails and lubricate with special grease - G 000 450 02– Folding fabric sunroof: lubricate guide rails – Windscreen wash/wipe system and headlight washer system: check function and jet settings – Wiper blades: check for damage; check park position; only if wiper blades “judder”: check setting angle Tyres – Front left tyre: check condition, wear pattern, inflation pressure; enter tread depth _______ mm – Rear left tyre: check condition, wear pattern, inflation pressure; enter tread depth n AG. Volkswagen AG do es n wage _______ mm s k l ot g o yV ua b d raenter – Rear right tyre: check condition, wear pattern, inflation pressure; tread depth nte ir se o eo _______ mm h t ra au ss condition, wear pattern, inflation pressure, enterctread depth – Front right tyre: check _______ mm – Spare wheel: check condition, wear pattern, inflation pressure; enter tread depth _______ mm Underside of vehicle – Engine oil: drain or extract; renew oil filter

⇒ page 102 ⇒ page 76 ⇒ page 76 ⇒ page 77 ⇒ page 82

⇒ page 28 ⇒ page 28 ⇒ page 28 ⇒ page 28 ⇒ page 28

⇒ page 59

If engine oil is drained rather than being extracted with the used oil collection and extraction unit, replace oil drain plug

– Engine and components in engine compartment: inspect for leaks and damage (from below) – Poly V-belt: check condition and tension belt •

⇒ page 38 ⇒ page 86

Engines without automatic tensioning roller

•

Engines with automatic tensioning roller

•

Every 60,000 km

in t his d o cu m en

r te o iva r rp fo ng

– Poly V-belt: check condition

– Gearbox, final drive and drive shaft boots: inspect for leaks and damage.

– Manual gearbox/final drive: check oil level – Brake system: inspect for leaks and damage – Front and rear brake pads/linings: check thickness – Underbody protection: visual check for damage – 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 Engine compartment – Engine oil: replenish – Engine and components in engine compartment: inspect for leaks and damage (from above) ht rig py Co t.

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14 2. Service work

⇒ page 58 ⇒ page 40

⇒ page 40

⇒ page 40 ⇒ page 68 ⇒ page 32 ⇒ page 32 ⇒ page 104 ⇒ page 101 ⇒ page 26 ⇒ page 59 ⇒ page 58

Polo 1995 ➤ Maintenance - Edition 03.2018 Scope of work

Page

– Window wash/wipe system: replenish fluid – Cooling system: check frost protection and coolant level – Spark plugs: renew •

⇒ page 77 ⇒ page 46 ⇒ page 108

Every 4 years or every 60,000 km whichever occurs first

– Dust and pollen filter: renew filter element – Toothed belt: check for wear •

⇒ page 101 ⇒ page 104

SDI / TDI engines ► 2000

– Toothed belt and toothed belt tensioning roller: renew

⇒ page 106

•

Every 60,000 km: vehicles with engine code AMF ►2000

•

Every 90,000 km: vehicles with engine code AMF AMF 2001►

•

Additional work as a separate charge!

– Toothed belt: renew

⇒ page 106

•

Every 60,000 km: vehicles with SDI engines - codes AHG and AKU ►2000

•

AG. Volkswagen G d Every 90,000 km: vehicles with AHG and AKU 2001► agen SDI engines -Acodes o

•

V gu and ASX by Every 90,000 km: vehicles with SDI engines - codes AGD ara ed

nte eo ra c

is or

thas a separate charge!

Additional work au ss

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• •

Every 30,000 km: vehicles with engine code AEF ►1999 Every 90,000 km: vehicles with engine code AEF 2000►

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

– Toothed belt: check condition and tension, tension toothed belt if necessary

Additional work without a separate charge!

– Camshaft drive toothed belt: check •

•

Every 2 years or every 60,000 km whichever occurs first Only applies to vehicles up to model year 1999

– Air filter: clean housing and renew filter element

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Only applies to vehicles from model year 2000 c o p yri gh t .

C op yi

– Fuel filter: renew

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•

Every 4 years or every 60,000 km whichever occurs first

•

For vehicles with diesel engine using biodiesel according to EN 14214

•

For vehicles with diesel engine using diesel not conforming to EN 590

•

For vehicles with diesel engine up to and including model year 1996, using diesel according to EN 590

agen lksw Vo by

AG.

Prote cted by

– Fuel filter: drain water •

⇒ page 49

⇒ page 49

do c um en

•

⇒ page 112

Only valid for 4-cylinder petrol engine without prescribed change interval

– Air filter: clean housing and renew filter element •

⇒ page 107

⇒ page 42

⇒ page 44

At 30,000, 90,000, 150,000 km etc.: vehicles with diesel engine from model year 1997, using diesel according to EN 590

2. Service work

15

Polo 1995 ➤ Maintenance - Edition 03.2018 Scope of work

Page

– Automatic gearbox: check ATF level •

⇒ page 26

Every 60,000 km

– Power assisted steering: check fluid level •

⇒ page 84

Every 60,000 km

– Change brake fluid

⇒ page 34

•

Every 2 years

•

Additional work as a separate charge!

– Brake fluid level: check – Battery: check – Exhaust emissions test: carry out test • •

.3)Volkswagen AG 3 years after initial registration and then every 2ayears gen AG do

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Additional work as a separate charge! d by V e ris tho u a ss

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Valid for diesel engines with code AEF, when no exhaust emissions test has been performed es, in part or in w l purpos hole ercia , is n m ot com

•

Vehicles ►1996: every 12 months

•

Vehicles 1997►: every 30,000 km

⇒ page 69

– Service sticker: enter date of next service (including change of brake fluid) on sticker and secure sticker to driver side door pillar (B-pillar) – Carry out road test

⇒ page 18 ⇒ page 64

do c um en

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3) Applicable only for countries where there are no country specific mandatory exhaust emission regulations.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

16 2. Service work

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

Headlight adjustment / documentation / final checks – Headlight adjustment: check

⇒ page 49

ility ab y li an pt ce

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– Idling speed: check •

⇒ page 37 ⇒ page 26 ⇒ page 115

Polo 1995 ➤ Maintenance - Edition 03.2018

3

General information

This chapter provides information on the following subjects: Lifting vehicle ⇒ page 17 Sticker ⇒ page 18 Connecting vehicle diagnostic tester ⇒ page 20 Vehicle identification number ⇒ page 22 Vehicle data sticker ⇒ page 22 Countries where diesel has a high sulphur content ⇒ page 23 Engine code and engine number ⇒ page 23 RME fuel (biodiesel) ⇒ page 23 Type plate ⇒ page 24

Lifting the vehicle

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

Please note the following:

3.1.1

Trolley jack:

To prevent damage always use a suitable rubber or wooden block.

AG.

Before driving on to a lifting platform ensure there is sufficient clearance between low lying vehicle components and lifting plat‐ form.

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Lifting platform:

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3.1.2

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On no account should vehicle be lifted at the engine sump, gear‐ box or on front or rear axle as this may cause serious damage.

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WARNING

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3.1

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3. General information

17

Polo 1995 ➤ Maintenance - Edition 03.2018

3.1.3

Lifting points for lifting platform and trol‐ ley jack:

Front: At reinforcement of floor pan.

WARNING

r fo ng

“Your first service” sticker (delivery inspection) ⇒ page 19

Vehicle data sticker

The vehicle data sticker -arrow- 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.

18 3. General information

Prote cted by

3.2.1

AG.

“Your next service” sticker ⇒ page 19

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Vehicle data sticker ⇒ page 18

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Sticker

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3.2

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Rear: At mounting bracket -arrow-.

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AG. Volkswagen AG d agen oes ksw not l o gu On no account must front of vehicle be raised on side member d by V ara nte vertical stiffener. ise r o eo h t u ra a c s s

Polo 1995 ➤ Maintenance - Edition 03.2018 The sticker contains the following data of the vehicle 1 - Production control number 2 - Vehicle identification number 3 - Model identification number 4 - Model explanation/engine output 5 - Engine and gearbox code letters 6 - Paint number/ interior equipment code 7 - Optional equipment identification number

3.2.2

“Your first service” sticker (delivery in‐ spection)

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

“Your next service” sticker

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– “Your next service” sticker: Enter a cross at the position for oil change service or inspection service (next service due) and enter date/odometer reading; if necessary, enter a cross at the position for supplementary information (e.g. renew toothed belt) and changing brake fluid and enter date/odometer read‐ ing.

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

3.2.3

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– Attach sticker on driver door pillar (B-pillar); the sticker is found on an instruction which is attached at front in the vehicle wallet.

Destroy the instruction after attaching the sticker!

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3. General information

19

AG.

Prote cted by

c o p yri gh t.

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Polo 1995 ➤ Maintenance - Edition 03.2018 – Attach sticker to driver door pillar (B-pillar).

3.3

Connecting vehicle diagnostic tester

Special tools and workshop equipment required

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

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20 3. General information

do c um en

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♦ Vehicle diagnostic tester - VAS 5051B-

Polo 1995 ➤ Maintenance - Edition 03.2018

ot g ua ran tee or ac

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WARNING

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♦ Diagnostic cable - VAS 5051/6A-

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♦ Vehicle diagnosis and service information system - VAS 5052. Volkswagen AG gen AG does or successor a w ks n

AG.

♦ Always secure testing and measuring equipment on the rear seat during a road test. ♦ Only a passenger may operate these devices while the vehicle is in motion.

– Insert connector of diagnostic cable - VAS 5051/6A- in diag‐ nostic connection.

Vehicles ► 1997 – Open stowage compartment on driver side and unhook.

– Connect vehicle diagnosis, testing and information system VAS 5051- or vehicle diagnosis and service information sys‐ tem - VAS 5052- using diagnostic cable - VAS 5051/6A- with ignition switched off.

3. General information

21

Polo 1995 ➤ Maintenance - Edition 03.2018 Vehicles 1998 ►

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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– Remove cover in front of fuse strip.

Vehicles 2000 ►

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– Connect vehicle diagnosis, testing and information system VAS 5051- or vehicle diagnosis and service information sys‐ tem - VAS 5052- using diagnostic cable - VAS 5051/6A- with ignition switched off.

– Pull ashtray insert out of centre console.

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

– Switch on ignition.

AG.

– Switch on tester.

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– Manual gearbox: gear lever in neutral.

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– Apply handbrake.

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– Connect vehicle diagnosis, testing and information system VAS 5051- or vehicle diagnosis and service information sys‐ tem - VAS 5052- using diagnostic cable - VAS 5051/6A- with ignition switched off.

Now follow information given on screen to start desired functions.

3.4

Vehicle identification number

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

3.4.1

Interpretation of vehicle identification number:

WVW

ZZZ

Manufactur‐ er's mark

6N

Filler Model char‐ acters

Z

Y4) 5)

Y

000 001

Filler charac‐ ters

Model year 2000

Pro‐ duc‐ tion loca‐ tion

Serial number

4) Model year 2000 5) Model year 2001

3.5

Vehicle data sticker

– ⇒ page 18

22 3. General information

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Countries where diesel has a high sul‐ phur content

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Macedonia Moldova Mozambique Myanmar New Caledonia Nigeria Oman Pakistan Panama Papua New Guinea Peru Russia (East & West) Saudi Arabia Zimbabwe Sri Lanka ht rig py Co t.

Jordan Yugoslavia6) Cambodia Kazakhstan Kenya Columbia Cuba Kuwait Lebanon Madagascar Malawi Malaysia Mali Morocco Mauritius

in t his d o cu m en

Egypt Armenia Bahrain Bangladesh Chile Dominican Republic El Salvador Ecuador Ghana Guatemala Honduras Indonesia Iraq Iran Jamaica

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For vehicles with TDI unit injector and VEP engines an oil change service must always be performed every 7,500 km in the following countries:

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3.6

AG. Volkswagen AG d agen oes ksw not l o V gu y b Polo 1995 ➤ ara d nte ise r o Maintenance Edition 03.2018 e h t or ac au s s

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

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6) Yugoslavia = Serbia, Montenegro, Vojvodina, Kosovo

3.7

Engine code and engine number

Engine code and engine number are located: ♦ ⇒ Technical data; Rep. gr. 00 ; Engine number . ♦ On vehicle data sticker, in rear of vehicle in the spare wheel recess or in the luggage compartment ⇒ page 18 . ♦ On vehicle data sticker in service schedule for the customer.

3.8

RME fuel (biodiesel)

RME fuel may only be used in vehicles which have been approved for this purpose by Volkswagen - either in the standard version or in vehicles which have had special equipment (PR No. 2G0) ⇒ page 18 .

Caution

♦ When RME fuel is used and your vehicle is not suitable for this, the fuel system can be damaged. ♦ When filling the tank with biodiesel, only use RME fuel conforming to DIN EN 14214 (FAME)! ♦ When biodiesel is used which does not conform to the re‐ quired standard, the fuel filter can become blocked.

For VW diesel engines the RME fuel must conform to DIN EN 14214 (FAME) from Week 05/2004. ♦ RME means “Rapeseed Methyl Ester”. ♦ DIN means “German Standards Authority e.V”.

3. General information

23

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ 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 ♦ At ambient temperatures below -10°C we recommend using winter diesel fuel.

Note ♦ When using biodiesel observe the changed intervals for drain‐

ing and changing the fuel filter.

♦ 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.

3.9

Type plate

The type plate is attached to front lock carrier -arrow-

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C op yi

24 3. General information

do c um en

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Vehicles for certain export countries have no type plate.

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to right bulkhead -arrow-.

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Descriptions of work:

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4

Polo 1995 ➤ Maintenance - Edition 03.2018

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

♦ Swivel joints: inspecting ⇒ page 26

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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

This chapter provides information on the following subjects:

♦ Driver and front passenger airbags: visual check of airbag units ⇒ page 113 ♦ Automatic gearbox: checking ATF level, topping-up ATF if necessary ⇒ page 26 ♦ Battery: checking ⇒ page 26

♦ Battery: checking battery terminal clamps for secure seating ⇒ page 27

♦ Check tyres: condition, wear pattern, inflation pressure, tread depth ⇒ page 28 ♦ Brake system: visual check for leaks and damage ⇒ page 32

♦ Front and rear brake pads: checking thickness ⇒ page 32 ♦ Brake fluid level: checking ⇒ page 37

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♦ Brake system: changing brake fluid ⇒ page 34 Prote cted by c o p yri gh t.

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♦ Electric windows: performing initialisation (activation) ⇒ page 38 agen lksw Vo by

♦ Vehicle system test: carrying out test ⇒ page 38 AG.

♦ Folding fabric sunroof: cleaning and lubricating guide rails ⇒ page 39 ♦ Protective bellows: inspecting ⇒ page 40 ♦ Checking first aid box expiry date ⇒ page 40 ♦ Poly V-belts: checking condition, tensioning if necessary ⇒ page 40 ♦ Fuel filter: renewing ⇒ page 42 ♦ Fuel filter: draining water (diesel engine) ⇒ page 44 ♦ Cooling system: checking frost protection and coolant level ⇒ page 46 ♦ Idling speed: checking, adjusting if necessary ⇒ page 49 ♦ Air filter: cleaning housing and renewing filter element ⇒ page 49 ♦ Engine cover -top-: removing and installing ⇒ page 57 ♦ Engine compartment cover - bottom - (noise insulation): re‐ moving and installing ⇒ page 58 ♦ Engine oil level: checking ⇒ page 58 ♦ Engine oil: draining or extracting and topping up; renewing oil filter ⇒ page 59 ♦ Engine and components in engine compartment: inspecting for leaks and damage (from above and below) ⇒ page 64 ♦ Carrying out road test ⇒ page 64 ♦ Wheel securing bolts: tightening to specified torque ⇒ page 65 ♦ Radio/radio-navigation system: activating anti-theft coding ⇒ page 67

4. Descriptions of work:

25

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ Manual gearbox/final drive: checking oil level, topping-up oil if necessary ⇒ page 68 ♦ Headlight adjustment: checking, adjusting headlight if neces‐ sary ⇒ page 69 ♦ Sunroof: checking function, cleaning and lubricating guide rails ⇒ page 76 ♦ Window wash/wipe system and headlight washer system: checking function ⇒ page 77 ♦ Wiper blades: checking park position and setting angle ⇒ page 82 ♦ Power assisted steering: checking fluid level ⇒ page 84 ♦ Service interval display: resetting ⇒ page 86 ♦ Track rod ends: checking clearance, security and boots ⇒ page 101 ♦ Dust and pollen filter: renewing filter element ⇒ page 101 ♦ Door arrester: lubricating ⇒ page 102 ♦ Clock: setting to correct time ⇒ page 103 ♦ Underbody protection: visual check visually for damage ⇒ page 104 ♦ Toothed belt: checking for wear ⇒ page 104 . Volkswage n AG wage

n AG d oe

olks ♦ Camshaft drive toothed belt: checking (4-cylinder petrol en‐s not gu yV b ara d gine) ⇒ page 112 n ise

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♦ Toothed belt: checking condition and tensioning, tensioning toothed belt if necessary ⇒ page 107 ♦ Spark plugs: renewing ⇒ page 108

4.1

Swivel joints: inspecting

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Automatic gearbox: checking ATF level, topping up if necessary

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4.2

Procedure: »Automatic gearbox« ⇒ Automatic gearbox; Rep. gr.

37 ; Checking ATF level and topping up »Checking ATF level and topping up«

4.3

Battery: checking

– Procedure: »Electrical system« ⇒ Electrical system; Rep. gr.

27 ; Battery »Battery«

26 4. Descriptions of work:

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– Check swivel joint boots -arrow- for leaks and damage.

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♦ Toothed belt: renewing ⇒ page 106

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t ♦ Camshaft drive toothed au belt and tensioning roller: renewing, ss PD diesel engine ⇒ page 106

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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♦ Torque wrench - V.A.G 1331-

Note

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A securely seated battery clamp ensures trouble free function and long service life of the battery.

AG.

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Carry out following procedure:

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Special tools and workshop equipment required

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Battery: checking battery terminal clamps for secure seating

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4.4

Polo 1995 ➤ Maintenance - Edition 03.2018

– Press lugs -arrows- together and open cover sidewards.

– Check whether battery clamps -3- and -4- are secure on bat‐ tery terminals by moving battery positive cable -1- and battery negative cable -2- back and forth.

WARNING

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.

If the battery clamp is not seated securely on positive terminal:

4. Descriptions of work:

27

Polo 1995 ➤ Maintenance - Edition 03.2018 – Disconnect battery terminal clamp -4- from battery negative terminal first.

– Tighten battery clamp -3- on battery positive terminal to 5 Nm. – Reconnect battery clamp -4- to battery negative terminal and tighten to 5 Nm. If the battery clamp on negative terminal is not seated securely: – Tighten battery clamp -4- on battery negative terminal to 5 Nm.

4.5

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

Checking condition of tyre ⇒ page 28 .

AG. Volkswagen AG d agen oes ksw not l o V gu y ara Tread depth (including spare wheel): check ⇒ page 29 . sed b nte i r o eo h t u ra General notes ⇒ page 29 a c s s

Checking wear pattern ⇒ page 29

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Tyre pressure: Check, correct inflation pressure if necessary ⇒ page 30 .

Special tools and workshop equipment required

Prote cted by

– Check tyre treads and side walls for damage and remove for‐ eign bodies such as, for example, nails or glass splinters.

Tests at inspection service – Check tyre treads and side walls for damage and remove for‐ eign bodies such as, for example, nails or glass splinters.

– Check tyres for cupping, one-sided wear, porous side walls, cuts and punctures.

28 4. Descriptions of work:

AG.

Tests at delivery inspection

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

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WARNING

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Tyres: checking condition

do c um en

4.5.1

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♦ Tyre inflator - VAS 5216-

Polo 1995 ➤ Maintenance - Edition 03.2018

4.5.2

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).

4.5.3

Tyre tread depth: 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.

♦ The minimum tread depth is reached when the tyres have

worn down level with the 1.6 mm high tread wear indicators -arrows- positioned at intervals around the tyre.

. Volkswagen AG gen AG does not gu ara nte eo ra c

a ♦ If the tread depth is approaching the minimum ksw allowed depth, Vol

inform the customer.

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General information

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4.5.4

by ed ris o th au ss

♦ For safety reasons, only tyres of same type and tread pat‐ tern should be fitted on a vehicle! ♦ On four-wheel drive vehicles, tyres of the same type and tread pattern must be used. Otherwise the centre differ‐ ential may be damaged.

Note

♦ “Checking tyre pressure” applies also to the spare wheel if a ♦ The tyre pressure table is valid for standard tyres for all tyre

sizes fitted at the factory.

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increased pressures of warm tyres.

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♦ Adjust the tyre pressure to suit the vehicle load.

AG.

sticker attached to the inside of fuel tank flap.

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♦ Tyre pressures for the relevant model can also be found on a

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

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spare wheel with standard tyres or a temporary spare wheel is fitted.

♦ The spare wheel should have the highest tyre pressure deter‐

mined for the vehicle.

♦ Commercial vehicles predominantly drive with a tyre pressure

at full load.

♦ The tyre pressures indicated are valid when towing a trailer up

to a speed of 130 km/h.

4. Descriptions of work:

29

Polo 1995 ➤ Maintenance - Edition 03.2018 M+S tyres Note ♦ Important information on winter tyres recommended by Volks‐

wagen can be found in ⇒ ElsaWin; Technical information; Guidelines Wheels, Tyres .

♦ For winter tyres the tyre pressure must be increased to 0.2 bar.

Explanation for speed indexes used in the table: ♦ Q. up to 160 km/h ♦ T: up to 190 km/h ♦ H: up to 210 km/h ♦ W: up to 270 km/h ♦ Y: up to 300 km/h

4.5.5

Tyre pressure: checking, correcting in‐ flation pressure if necessary

Inflation pressures (for all factory fitted tyre sizes): Tyre pressure table Half load

un le

2.4 2.1 2.1 2.1

2.9 2.4 2.4 2.4

2.0 2.1 1.9 1.9

2.0 2.1 1.9 1.9

2.3 2.2 2.2 2.2

2.8 2.5 2.5 2.5

2.2 2.1 2.1 2.1

2.2 2.1 2.1 2.2

2.5 2.3 2.3 2.3

3.0 2.6 2.6 2.6

1.9 2.0 2.0

2.2 2.4 2.4

2.5 2.8 2.8

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2.1 2.1 2.1

2.1

1.9

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2.1 2.1 2.1

2.3 2.3 2.3 2.3

AG.

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2.0 2.2 2.2

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2.1 1.9 1.9 1.9

2.6 2.6 2.6 2.6

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

30 4. Descriptions of work:

2.1 1.9 1.9 1.9

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Vehicles with petrol engine: 1.0l, 33/37 kW ► 09.99 with tyres 155/70 R 13 175/65 R 13 185/55 R 14 195/45 R 15 1.0l/37 kW 09.99 ► with tyres 155/70 R 13 175/65 R 13 185/55 R 14 195/45 R 15 1.3l/40kW 1.4l/40-/44-kW ► 09.99 with tyres 155/70 R 13 175/65 R 13 185/55 R 14 195/45 R 15 1.4l, 40/44 kW 10.99 ► with tyres 175/65 R 13 185/55 R 14 195/45 R 15 1.4l/1.6l, 55 kW ► 09.99 with tyres 175/65 R 13 185/55 R 14 195/45 R 15 1.4l/1.6l, 55 kW 10.99 ► with tyres 175/65 R 13

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Front

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Polo 1995 ➤ Maintenance - Edition 03.2018 Half load

Full load Rear

Front

Rear

185/55 R 14 2.3 2.1 195/45 R 15 2.3 2.1 1.4l/74 kW ► 09.99 with tyres 185/55 R 14 2.3 2.1 195/45 R 15 2.3 2.1 1.4l/74 kW 10.99 ► with tyres 185/55 R 14 2.3 2.1 195/45 R 15 2.3 2.1 1.6l/88 kW ► 09.99 with tyres 185/55 R 14 2.6 2.4 195/45 R 15 2.6 2.4 1.6l, 88/92 kW 10.99 ► with tyres AG. Volkswagen AG d agen oes 185/55 R 14 2.6 2.4 ksw not l o V gu by a d ra2.4 195/45 R 15 2.6 nt ise

2.5 2.5

2.8 2.8

2.5 2.5

2.8 2.8

2.5 2.5

2.8 2.8

2.8 2.8

3.0 3.0

2.8 2.8

3.0 3.0

r ho ut a ss

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2.1 2.1 2.1

2.1 2.1 2.1

2.4 2.1 2.1

2.4 2.1 2.1

2.1 2.3 2.3

1.9 2.1 2.1

AG.

2.2 2.4 2.4

Rear

2.6 2.6 2.6

2.5 2.3 2.3

2.8 2.6 2.6

2.3 2.4 2.4

2.6 2.8 2.8

2.0 2.1 2.1

2.3 2.4 2.4

2.6 2.8 2.8

2.0 2.2 2.2

2.4 2.6 2.6

2.7 2.9 2.9

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2.2 2.3 2.3

Front

2.3 2.3 2.3

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Rear

Full load

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

Vehicles with diesel engine: 42/44/47 kW ► 09.99 (not postal vehicles) with tyres 175/65 R 13 185/55 R 14 195/45 R 15 42/44/47 kW ► 09.99 (postal ve‐ hicles) with tyres 155/70 R 13 175/65 R 13 185/55 R 14 1.7l/42 kW 10.99 ► with tyres 175/65 R 13 185/55 R 14 195/45 R 15 1.9l/47 kW 10.99 ► with tyres 175/65 R 13 185/55 R 14 195/45 R 15 1.4l/55 kW 10.99 ► with tyres 175/65 R 13 185/55 R 14 195/45 R 15 Spare wheel (all engine types) Temp. spare standard wheel

Front

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Half load

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Front

4.2 Keep to the highest pressure required for the vehicle.

4. Descriptions of work:

31

Prote cted by c o p yri gh t.

C op yi

Polo 1995 ➤ Maintenance - Edition 03.2018 Spare wheel with standard tyres The spare wheel should have the highest tyre pressure deter‐ mined for the vehicle.

4.6

Brake system: inspecting for leaks and damage

lkswagen AG Check following components for leaks and . Vodamage: gen AG

does not gu ara e nte ris o eo h Brake servo (for anti-lock brake system: hydraulic unit) t u ra a c ss

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♦ Brake master cylinder d by Vo ♦

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♦ Brake pressure regulator and pe rm itte d

♦ Brake caliper

– Check brake hoses are not porous or brittle.

– Check brake hoses and lines for chafing.

– Check brake connections and fastenings for correct seating, leaks and corrosion.

WARNING

Front and rear brake pads/linings: checking thickness c o p yri gh t .

C op yi

Special tools and workshop equipment required Prote cted by

32 4. Descriptions of work:

AG.

♦ Torque wrench - V.A.G 1332-

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♦ Pliers - 3314-

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4.7

r te o iva r rp fo ng

Faults found must always be rectified (repair measure).

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

– Additionally ensure that brake hoses do not touch any vehicle components when steering is at full lock.

in t his d o cu m en

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

– Ensure that brake hoses are not twisted.

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ Electric hand torch Carry out following procedure:

4.7.1

Front brake pads:

Note ♦ Experience has shown that brake pad wear due to roadside

debris is slightly more on passenger side than on driver side.

It is therefore better to remove the passenger side front wheel to determine the remaining pad thickness.

♦ The adapter to loosen and tighten the anti-theft wheel bolts

can be found in the vehicle tool kit. Please ask the customer if the adapter is not available.

G. Volkswagen AG d oes not gu ara nte eo ra c

nA ageremove – For better evaluation of remaining pad thickness the ksw l o V front wheel on the passenger side. y b d ise

r – Mark position of wheel relative to ubrake disc. tho sa

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– If necessary, pull off wheel boltscovers using pliers - 3314- .

– Measure thickness of inner and outer pads. a - Brake pad thickness without backplate - Wear dimension: 2 mm

– Install wheel in marked position.

AG.

Prote cted by

Specified torque: 110 Nm

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c o p yri gh t.

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– Tighten wheel bolts diagonally and alternately to following specified torque:

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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!

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

– Unbolt wheel bolts and remove wheel.

– Reinstall wheel bolt covers if necessary.

4.7.2

Rear drum brake pads:

Rear brake pads ⇒ page 34 .

4. Descriptions of work:

33

Polo 1995 ➤ Maintenance - Edition 03.2018 – 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) 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!

Note

Check pads for brake fluid or grease contamination.

4.7.3

Rear brake pads:

– Illuminate area behind hole in wheel using an electric hand torch.

– Inspect outer pad to determine thickness.

– Illuminate inner pad with an electric hand torch and mirror.

– Inspect inner pad to determine thickness. a - Inner and outer pad thickness without backplate

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

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- Wear dimension: 2 mm

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

Brake system: changing brake fluid

Operation and safety notes

Note ♦ From model year 2006 a new brake fluid is used. ♦ The new brake fluid can also be used for older vehicles. ♦ For this purpose it can be mixed with the previous brake fluid.

34 4. Descriptions of work:

AG.

4.8.1

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Procedure for changing brake fluid ⇒ page 35 .

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Brake fluid specification ⇒ page 35 .

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Instructions for use and safety ⇒ page 34 .

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4.8

r te o iva r rp fo g n

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!

Polo 1995 ➤ 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‐ ture from the ambient air and should therefore always be stored in air-tight containers. ♦ Rinse off spilled brake fluid using plenty of water. ♦ Do not reuse drained (used) brake fluid. ♦ Observe relevant disposal regulations.

Carry out following procedure:

4.8.2

Brake fluid specification

Permissible brake fluid specifications: ♦ Brake fluid conforming to US standard FMVSS 116 DOT 4 (previous brake fluid) AG. Volkswagen A

n G do es n 501 14 (new brake wage to VW standard, ♦ Brake fluid conforming VW ot g olks fluid). d by V ua r e ris ho t au

4.8.3s

Procedure, changing brake fluid

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Special tools and workshop equipment required

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

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♦ Brake filling and bleeding unit - VAS 5234-

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♦ Brake pedal depressor - V.A.G 1869/2-

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⇒ Note operating instructions for brake filling and bleeding unit VAS 5234- !

– Unbolt cap from brake fluid reservoir.

4. Descriptions of work:

35

Polo 1995 ➤ Maintenance - Edition . Volkswagen AG en AG03.2018

ility ab y li an pt ce

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–

does ag ksw not Vol gu y b brake fluid as possible using suction ara hose d Extract as much nte ise r o -1- from brake filling and bleeding unit VAS 5234or using a eo h t u ra a suctionssbottle with built-in strainer. c

pe rm itte d

WARNING

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

– 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 brake filling and bleeding equipment - VAS 5234- to adapter.

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– Remove caps from bleeder screws.

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c o p yri gh t.

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– 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.

Prote cted by

7) Start at rear right of left-hand drive vehicles and at rear left of right-hand drive vehicles.

Repeat procedure on other side of vehicle at rear.

36 4. Descriptions of work:

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

Do not reuse drained (used) brake fluid.

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

8) Start at front right of left-hand drive vehicles and at front left of right-hand drive vehicles.

Repeat procedure on other side of vehicle at front.

Sequence: Wheel brake cylinders, brake calipers Rear right Rear left Front right Front left

Brake fluid quantity which must flow out of wheel brake cylinders or brake calipers: 0.5 litre 0.5 litre 0.5 litre 0.5 litre

r te o iva r rp fo ng

Total quantity: approx. 2 litre

– Fit cover caps on bleeder screws.

– Unscrew adapter from brake fluid reservoir.

AG.

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– Screw in cap of brake fluid reservoir.

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c o p yri gh t .

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– Take filler hose off adapter.

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– Set fill lever of brake filling and bleeding unit - VAS 5234- to position -B- (see operating instructions).

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

pe rm itte d

– Push collector bottle bleeder hose -1- onto front bleeder screw 8) , open bleeder screw and let appropriate quantity of brake fluid (see table) run out. Close bleed screw.

– Remove brake pedal depressor.

– Check pedal pressure and brake pedal free play. Free play: max. 1/3 of pedal travel.

4.9

Brake fluid level: checking

Instructions for use and safety ⇒ page 34 .

Brake fluid specification ⇒ page 35 .

Procedure, brake fluid level: checking ⇒ page 37 .

4.9.1

Procedure, brake fluid level: checking

Brake fluid level at delivery inspection: At delivery inspection the fluid level must be at MAX. marking -1-.

Note

To prevent that brake fluid flows out of reservoir, the MAX marking must not be exceeded.

Brake fluid level at inspection service: The fluid level must always be judged in conjunction with lining/ pad wear.

When vehicle is in use, fluid level tends to drop slightly due to lining/pad wear and automatic adjustment.

•

Recommended brake fluid level, if brake pads are almost at wear limit:

4. Descriptions of work:

37

Polo 1995 ➤ Maintenance - Edition 03.2018 “At MIN. marking or just above” “REPLENISHING IS NOT RE‐ QUIRED”.

•

Recommended brake fluid level when brake pads are new or well within wear limit:

“Between MIN and MAX marking”.

4.10

Electric windows: initialising (activation)

4.10.1

Electric windows: initialising

Note

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.

r fo ng

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!

Prote cted by

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

– 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.

4.11

Vehicle system test: carrying out test

– Connect vehicle diagnostic tester ⇒ page 20 .

– Switch on ignition – Select operating mode “Guided fault finding” on display.

– Then perform vehicle identification on tester.

The programme now automatically performs a vehicle system test and reads all control units available for this vehicle type.

– Press > button.

Now all faults are listed.

38 4. Descriptions of work:

AG.

– Close all doors and windows completely.

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c o p yri gh t .

C op yi

Carry out the following procedure to initialise the electric windows:

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WARNING

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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n AG. Volkswagen AG do es n wage s k l ot g o WARNING yV ua b d ran ir se tee o h t or u must If the fluid level is below MIN. marking, the brake system ac a s s be checked before fluid is topped up “repair measure”.

Polo 1995 ➤ Maintenance - Edition 03.2018 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r At this point it is useful thto o change to operating mode guided eo u ra functions to carry outs afurther operations with diagnostic tester c s

Note

♦

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♦ To do this, press button operating mode and then guided func‐

tions.

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

♦ For further procedure see respective work descriptions.

ility ab y li an pt ce

and to prevent a second vehicle identification on tester.

♦ To return to guided fault finding, press button operating mode

and then guided fault finding.

Caution

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

Static faults

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Sporadic faults

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– Press > button again to reach the test plan.

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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.

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If one or more static faults are found in the fault memory, we rec‐ ommend in agreement with the customer to rectify these faults using guided fault finding.

– Now close Guided Fault Finding using GoTo button and then End. All fault memories are read again.

Then the diagnosis log is sent “online” or stored on the tester.

Note ♦ If the tester is not connected to the network, the diagnosis log

is stored and will be sent when the tester is connected to the network.

♦ Logs stored and which are more than 40 days old will be

cleared automatically.

The vehicle system test is completed.

4.12

Folding fabric sunroof: cleaning and lu‐ bricating guide rails

Carry out following procedure:

4. Descriptions of work:

39

Polo 1995 ➤ Maintenance - Edition 03.2018 – Clean guide rail -arrows- and lubricate with special grease - G 000 450 02- .

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

pe rm itte d

ility ab y li an pt ce

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– Check function of folding fabric sunroof.

Carry out following procedure:

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

Boots: inspecting

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

4.13

4.15

Poly V-belt: checking condition, tension‐ ing if necessary

Poly V-belt: checking condition ⇒ page 40 .

Poly V-belt: Tension (engines without automatic tensioning roller) ⇒ page 41

4.15.1

Poly V-belt: checking condition

Carry out following procedure: – Raise vehicle.

40 4. Descriptions of work:

AG.

Inform customer if date has been exceeded.

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C op yi

With immediate effect, the expiry date of the first aid box must be checked at every inspection service.

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Checking first aid box expiry date

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4.14

r te o iva r rp fo ng

– Check outer joint protective boots -arrow- and inner joint pro‐ tective boots (not shown in illustration) for leaks and damage.

Polo 1995 ➤ Maintenance - Edition 03.2018 – Crank engine at vibration damper/belt pulley -2- using a sock‐ et.

– Check poly V-belt -1- from below for: ♦ Sub-surface cracks (cracks, core ruptures, cross sectional breaks) ♦ Layer separation (top layer, cord strands) ♦ Base break-up ♦ 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 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.

Poly V-belt: tensioning (engines without AG. Volkswagen AG d agen oes not automatic tensioning roller) by Volksw gu a d ise

ran tee or ac

Special tools and workshop equipment requiredthor

do c um en

r te o iva r rp fo g n

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

♦ Tensioning arm - 3297-

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

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♦ Torque wrench - V.A.G 1331-

ht rig py Co t.

4.15.2

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AG.

Prote cted by c o p yri gh t.

C op yi

Carry out following procedure:

4. Descriptions of work:

41

Polo 1995 ➤ Maintenance - Edition 03.2018 – Unbolt alternator securing bolts -1- and -2- at least one turn.

– Press alternator down using tensioning lever - 3297- to stop at least three times to ensure optimum ease of movement.

– Run engine at idling speed at least for 10 seconds with alter‐ nator loose.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo Observe tightening sequence when tightening the alternator h ut ra a bolts, do not lean on alternator and do not touch the poly V-belt. c s s

Note

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4.16

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

– First tighten securing bolt -2-, then tighten securing bolt -1- to 25 Nm.

Fuel filter: renewing

♦ Fuel filter: Renew, PD TDI diesel engines ⇒ page 42 ♦ Fuel filter: Renew, SD SDI diesel engines ⇒ page 43

4.16.1

Fuel filter: renewing, PD TDI diesel en‐ gines

Removing Note

♦ Ensure that no diesel fuel contacts coolant hoses. If necessa‐

– Pull off fuel hoses -3- and -4-.

– Remove bolt -5- and cap nuts -6- and pull filter slightly up‐ wards.

– Loosen cross head bolt on clamp and take out filter upwards.

42 4. Descriptions of work:

AG.

– Pull off retaining clip -1- and remove regulating valve -2- with fuel lines connected.

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C op yi

Carry out following procedure:

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♦ Please observe disposal instructions!

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ry, clean hoses immediately.

Polo 1995 ➤ Maintenance - Edition 03.2018 Installing – Fill new filter with clean Diesel. This allows the engine to start quicker.

. Volkswagen AG

– Insert filter and tighten cross head bolt on clamp. kswagen AG ol yV db – Fit new O-ring to seal regulating valve. e is un le pe rm itte d

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Note

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Fuel flow direction is marked by arrows (do not interchange con‐ nections).

– Install regulating valve -2- and fit retaining clip -1-.

– Push fuel hoses -3- and -4- over hose connections and secure hoses with hose clips.

– Tighten bolt -5- and cap nuts -6-.

– Start engine and check fuel system for leaks (visual check).

AG.

Removing

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Fuel filter: renewing, SD SDI diesel en‐ gines

ht rig py Co t.

4.16.2

do c um en

r te o iva r rp fo g n

– Operate throttle several times to bleed fuel system.

Note ♦ Ensure that no diesel fuel contacts coolant hoses. If necessa‐

ry, clean hoses immediately.

♦ Please observe disposal instructions!

Carry out following procedure:

4. Descriptions of work:

43

Polo 1995 ➤ Maintenance - Edition 03.2018 – Pull off retaining clip -1- and remove regulating valve -2- with fuel lines connected.

– Pull off fuel hoses -3- and -4-.

– Loosen cross head bolt -5- on clamp and take out filter up‐ wards.

Installing – Fit new O-ring to seal regulating valve.

Note

Fuel flow direction is marked by arrows (do not interchange con‐ nections).

AG. Volkswagen

G dstart gen oes – Fill new filter with clean Diesel. This the engineAto waallows not olks V gu y quicker. b a d

– Push fuel hoses -3- and -4- over hose connections and secure hoses with hose clips.

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c o p yri gh t .

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– Operate throttle several times. Then fuel must flow bubble-free through the transparent line -4- when engine is at idling speed.

4.17

Fuel filter: draining water (diesel engine)

♦ Fuel filter: draining water, SD SDI diesel engines ⇒ page 45

44 4. Descriptions of work:

ht rig py Co t.

r fo ng

– Start engine and check fuel system for leaks (visual check).

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

– Install regulating valve -2- and fit retaining clip -1-.

ran tee or ac ility ab y li an pt ce

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–

e ris tho u a tightening the cross head bolt -5-.

Fit filter and secure by ss

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ Fuel filter: draining water, PD TDI diesel engines ⇒ page 45

4.17.1

Fuel filter: draining water, SD SDI diesel engines

Note ♦ Ensure that no diesel fuel contacts coolant hoses. If necessa‐

ry, clean hoses immediately.

♦ Please observe disposal instructions!

Carry out following procedure: – Pull off retaining clip -1- and remove regulating valve -2- with fuel lines connected. . Volkswagen AG – Fit hose onto water drain screw connection -3-, open gen AGscrew does swa k not l o and drain approx. 0.1 l of fluid.

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ed

ris – Tighten water drain screw -3- and remove hose. tho au

or ac

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– Fit new O-ring to seal regulatingssvalve. pe rm itte d

– Install regulating valve -2- and fit retaining clip -1-.

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

– Check fuel system for leaks (visual check).

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Note

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Fuel filter: draining water, PD TDI diesel engines

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4.17.2

r te o iva r rp fo g n

– Operate throttle several times. Then fuel must flow bubble-free through the transparent line -4- when engine is at idling speed.

♦ Ensure that no diesel fuel contacts coolant hoses. If necessa‐

ry, clean hoses immediately.

♦ Please observe disposal instructions!

Carry out following procedure:

4. Descriptions of work:

45

Polo 1995 ➤ Maintenance - Edition 03.2018 – Pull off retaining clip -1- and remove regulating valve -2- with fuel lines connected.

– Remove bolt -3- and cap nuts -4- and pull filter slightly up‐ wards.

– Fit hose onto water drain screw connection -arrow-, open screw and drain approx. 0.1 l of fluid.

– Tighten water drain screw -arrow- and remove hose.

–

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– Start engine and check fuel system for leaks (visual check).

4.18

Cooling system: checking frost protec‐ tion and coolant level

Checking frost protection ⇒ page 47

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C op yi

46 4. Descriptions of work:

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Check coolant level, replenish coolant if necessary ⇒ page 47

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

– Operate throttle several times to bleed fuel system.

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

– Install regulating valve -2- and fit retaining clip -1-.

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–

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Tighten bolt -3- and is cap nuts -4-. r o eo h ut ra a c Fit new O-ringssto seal regulating valve.

Polo 1995 ➤ Maintenance - Edition 03.2018

4.18.1

Checking frost protection

Note ♦ Because of its positive characteristics only coolant additive G

12 Plus according to TL VW 774 F should be used if possible.

Identification: purple in colour.

♦ G 12 Plus can be mixed with previously used coolant additives

G 12 red and G 11.

♦ G 12 Plus is suitable as a filled-for-life filling for cast iron and

all-aluminium engines and gives optimum protection against frost, corrosion damage, scaling and overheating.

♦ G 12 Plus raises the boiling point to 135°C and ensures better G. Volkswage

n AG d oes not gu ara nte eo ra c

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en A ag heat dissipation. The coolant concentration must be at least lksw onot V 40% (frost protection up to - 25°C). It should exceed 60% y b d (frost protection up to - 40°C), otherwise ise frost protection will r tho be reduced again and cooling effectiveness will also be re‐ au s duced. s

Special tools and workshop equipment required ♦ Refractometer - T10007-

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

♦ or:

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AG.

4.18.2

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– If frost protection is insufficient, drain off the quantity indicated in frost protection table ⇒ page 48 and top-up with coolant additive.

ht rig py Co t.

– Check concentration of coolant additive using refractometer T10007- (refer to operating instructions) or with a commer‐ cially available anti-freeze tester.

do c um en

♦ Anti-freeze tester (commercially available)

Coolant level: checking, replenishing coolant if necessary

– Check coolant level on expansion tank with engine cold.

4. Descriptions of work:

47

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ Delivery inspection: Coolant level at max. marking. ♦ Inspection service: Coolant level between max. and min. markings.

– 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: Coolant additive

-25°C -35°C -40°C

approx. 40% approx. 50% approx. 60%

approx. 60% n AG. Volkswagen AG do es n wage s k l ot g o approx.

50% yV ua b d ran ir se approx. 40% tee o

th au ss

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Note

Water

♦ Coolant additives prevent frost and corrosion damage, scaling

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

and also raise boiling point of coolant. For these reasons, the cooling system must be filled all-year-round with a frost and corrosion protection additive. es, in part or in w l purpos hole ercia , is n m ot com

or ac ility ab y li an pt ce

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Frost protection to

♦ Because of its high boiling point, the coolant improves engine

reliability under heavy loads, particularly in countries with trop‐ ical climates.

♦ Do not reduce the coolant concentration by adding water even

in warmer seasons and in warmer countries. The coolant ad‐ ditive concentration must be at least 40%.

-20 -25 -30 -35

48 4. Descriptions of work:

Prote cted by

-15

AG.

-10

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3.0 3.5 2.5 3.5 2.0 3.0 1.5 2.5 1.0 2.5 2.0 1.0 0.5

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-5

-25 -35 -25 -35 -25 -35 -25 -35 -25 -35 -35 -35 -40

c o p yri gh t .

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0

Quantity to drain in litres

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Frost protection to °C Actual value Specified val‐ ue

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Frost protection table

Polo 1995 ➤ Maintenance - Edition 03.2018 Note

Please observe disposal instructions!

–

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Check coolant additive concentration after road test again. is r o eo h ut ra a c s s

Idling speed: checking and adjusting if necessary

– »Diesel injection and glow plug system« ⇒ Diesel injection and glow plug system; Rep. gr. 23 ; Repairing fuel injection system, checking and adjusting idling speed, idling speed boost and rev limit »Repairing fuel injection system, checking and adjusting idling speed, idling speed boost and rev limit«

4.20

Air filter: cleaning housing and renewing filter element

♦ Air filter for Mono Motronic engines ⇒ page 49 ♦ Air filter for 2-valve engines ⇒ page 50 ♦ Air filter for 4-valve engines ⇒ page 51

♦ Air filter for 2-valve roller rocker finger engines ⇒ page 52 ♦ Air filter for 4-valve roller rocker finger engines ⇒ page 54

4.20.1

AG.

Information on type of injection system and valve timing for the vehicle can be obtained ⇒ page 1

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Note

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♦ Air filter for PD diesel engines ⇒ page 56

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♦ Air filter for SD, SDI diesel engines ⇒ page 55

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4.19

Air filter: cleaning housing and renewing filter element, Mono Motronic engines

Removing – Open clips, lift air filter housing upper part and remove up‐ wards.

– Take out used filter element.

Note

Please observe disposal instructions!

Installing – Clean filter housing and install new filter element.

– Insert filter housing upper part and secure clips.

4. Descriptions of work:

49

Polo 1995 ➤ Maintenance - Edition 03.2018

4.20.2

Air filter: cleaning housing and renewing filter element, 2-valve engines

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 – Remove securing bolts -arrows-.

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– Take out used filter element -arrow-.

Note

Please observe disposal instructions!

Installing

– Clean filter housing and install new filter element.

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50 4. Descriptions of work:

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– Insert filter housing upper part and tighten bolts -arrows-.

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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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– Lift filter housing upper part and remove upwards.

Polo 1995 ➤ Maintenance - Edition 03.2018

4.20.3

Air filter: cleaning housing and renewing filter element, 4-valve engines

Removing – First disconnect throttle cable and earth strap from mountings -arrows-.

– Then remove hoses -1- and -2-.

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– Remove cross-head bolts -arrows-.

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– Unscrew bolts -3- and pull air filter housing upper part off up‐ wards.

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4. Descriptions of work:

51

AG.

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Polo 1995 ➤ Maintenance - Edition 03.2018 – Take out used filter element -arrow-.

Note

Please observe disposal instructions!

Installing – Clean filter housing and install new filter element.

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 the following prerequisites are fulfilled:

♦ The speed of power screwdriver must be max. 200 rpm. ♦ Setting torque of max. 3 Nm must be adjustable.

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– Screw in cross head bolts -arrows-.

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– Secure throttle cable and earth strap in mountings -arrows-.

AG.

– Then connect hoses -1- and -2-.

– Tighten bolts -arrows- to max. 3 Nm.

4.20.4

Air filter: cleaning housing and renewing filter element, 2-valve roller rocker finger engines

Special tools and workshop equipment required

52 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

♦ For this reason it is only permitted to use a power screwdriver,

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and to the intake connection, thread cutting screws are used as standard. When loosening or tightening these bolts using a power screwdriver, the thread in air filter housing upper part could be damaged. un le

♦

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara Note d nte ise r o eo h t u ra a upper part of air filter to the lower part of air filter To securessthe c

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ Pliers for spring-type clips - VAS 5024A-

Removing – Unclip caps -1- and remove bolts (below caps).

– Remove ignition cable -2- from air filter housing. swagen AG G. Volkpliers – Loosen hose clamp for spring-type clips - VAS en Ausing does wag-3s k not l 5024A- and ypull Vo hose off. gu

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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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nte ris – Pull crankcase breather hose -arrow- off air filter housing. eo tho u ra a – Pullss off exhaust gas recirculation hose on left side of airc filter housing and remove filter housing.

– Unscrew cross head bolts -1- and remove filter housing lower part.

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

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Note

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Please observe disposal instructions!

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– Take out used filter elements -arrows-.

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Installing – Clean filter housing and insert new filter elements.

4. Descriptions of work:

53

Polo 1995 ➤ Maintenance - Edition 03.2018 – Insert filter housing lower part and tighten cross head bolts -1-.

Install air filter in reverse order.

– Insert spacer sleeves -3- in upper part of air filter.

– Tighten securing bolts -2- to 10 Nm. Note

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Removing

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– Remove cross-head bolts -arrows-.

♦ 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.

54 4. Descriptions of work:

do c um en

r te o iva r rp fo g n

– Pull crankcase breather hose -arrow- off filter upper part.

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

4 - Air filter: cleaning housing and re‐ newing filter element, 4-valve roller rocker finger engines

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4.20.5

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For maintenance operation “Renewing spark plugs” the air filter housing must remain removed if necessary.

G. Volkswage

Polo 1995 ➤ Maintenance - Edition 03.2018 – Take out used filter element -arrow-.

Note

Please observe disposal instructions!

Installing – Clean filter housing and install new filter element.

– Screw in cross head bolts -arrows-.

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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

Air filter: cleaning housing and renewing filter element, SD, SDI diesel engines

Removing – Raise vehicle.

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– Release securing clips -arrows- and remove filter lower part downwards.

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

4.20.6

yV db ir se ho ut a ss

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age – Connect crankcase breather hose -arrow-oto lkswfilter upper part.

4. Descriptions of work:

55

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Polo 1995 ➤ Maintenance - Edition 03.2018 – Take out used filter element -arrow- downwards.

Note

Please observe disposal instructions!

Installing – Clean filter housing and install new filter element.

– Insert filter lower part and secure clips -arrows-.

4.20.7 Removing

Air filter: cleaning housing and renewing filter element, PD diesel engineskswagen AG. Volkswagen AG does n

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– Raise vehicle.

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Note

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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

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56 4. Descriptions of work:

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– Remove Torx bolts -arrows- and take out filter housing lower part downwards.

Polo 1995 ➤ Maintenance - Edition 03.2018 – Take out used filter element -arrow- downwards.

Note

Please observe disposal instructions!

Installing – Clean filter housing and install new filter element.

– Insert filter housing lower part and tighten Torx bolts -arrows-.

4.21

Engine cover panel -top-: removing and installing Caution

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♦ Removing and installing engine cover, 2-valve roller rocker finger engines ⇒ page 57

♦ Removing and installing engine cover, PD diesel engines ⇒ page 58

4.21.1

Engine cover, 2-valve roller rocker fin‐ ger engines: removing and installing

– See Air filter: cleaning housing and renewing filter element, 2valve roller rocker finger engines ⇒ page 52

4.21.2

Engine cover, 4-valve roller rocker fin‐ ger engines: removing and installing

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Removing:

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♦ Removing and installing engine cover, 4-valve roller rocker finger engines ⇒ page 57

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♦

AG. Volkswagen AG d agen oes ksw not l o g yV Do not push with theefist d b or a tool on the engine cover paneluara nte s i r when it is installed eo ho or engaged at securing points, it could ra be damaged. s aut c s

4. Descriptions of work:

57

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Polo 1995 ➤ Maintenance - Edition 03.2018 – Remove hexagon socket head bolts -arrows- and take off en‐ gine cover.

Installing:

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Removing:

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4.21.3

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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 hexagon socket head bolts Install engine cover and tighten ra a c s s -arrows- to 10 Nm.

Engine cover, PD diesel engines: re‐ moving and installing

– Unclip engine cover and remove upwards.

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– Fit engine cover onto securing points and press on, until they noticeably engage.

AG.

Engine cover panel, -bottom- (noise in‐ sulation): removing and installing

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4.22

Carry out following procedure: – Remove hexagon nuts and unclip securing clips -arrows-.

Swing noise insulation tray down and remove.

Note

Do not reuse securing clips, they must be renewed each time the engine compartment covers are removed.

4.23

Engine oil level: checking

Please note the following:

58 4. Descriptions of work:

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Installing:

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– Pull out oil dipstick -1- and remove oil filler cap -2-.

Polo 1995 ➤ Maintenance - Edition 03.2018 – After shutting off engine, wait at least 3 minutes so that the oil can flow back into the sump.

– Pull out dipstick and clean with a clean cloth and then push dipstick in again onto stop.

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

Note

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-C-

Do not top up oil.

Oil may be replenished. It may happen that the oil level afterwards is in the -A- region.

Oil must be replenished. It is sufficient if the oil level is in the -B- region (hatched area) after‐ wards.

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

-A-B-

There is a danger of damaging the catalytic converter if the oil level is above the -A- marking.

– If oil level is below -C- marking, replenish oil to -A- marking.

Oil specification ⇒ page 6

4.24

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

Renewing oil filter ⇒ page 61 .

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Replenishing engine oil ⇒ page 63 .

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Engine oil: draining or extracting and re‐ plenishing AG.

4.24.1

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Engine oil: draining or extracting and replenishing ⇒ page 59 .

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For dipstick as illustrated:

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– Pull dipstick out again and read oil level.

Special tools and workshop equipment required ♦ Used oil collection and extraction unit - V.A.G 1782-

4. Descriptions of work:

59

Polo 1995 ➤ 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

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

♦ Oil spill cloth - VAS 6204/1Engine oil: draining or extracting Note

♦ For engines with standing oil filter, the oil filter must be re‐

newed before changing the engine oil. When removing the filter element a valve is opened, the oil in the filter housing automatically flows into crankcase.

♦ If engine oil is drained rather than being extracted with the r te o iva r rp fo ng

used oil collection and extraction unit, replace oil drain plug.

This prevents leaks.

♦ Please observe disposal instructions!

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or

– Extract engine oil using used oil collection and extraction unit - VAS 6622- . or – Remove oil drain plug.

– Let engine oil drain.

Note

Please observe disposal instructions!

– Screw in new oil drain plug with seal hand-tight.

Capacities and filter change: ⇒ Maintenance tables or ⇒ Power unit; Rep. gr. 17 ; Engine oil – Replenish engine oil, specification ⇒ page 6 .

Specified torques for oil drain plug: The torques depend on engine code letters and can be found in ⇒ Engine mechanics; Rep. gr. 17 ; Removing and installing parts of lubrication system .

60 4. Descriptions of work:

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– Extract engine oil using used oil collection and extraction unit - V.A.G 1782- .

in t his d o cu m en

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

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♦ Used oil collector and extractor - VAS 6622-

Polo 1995 ➤ Maintenance - Edition 03.2018 WARNING

♦ Torque specifications must not be exceeded. ♦ Excessive torque can cause leaks in the area of the oil drain plug or even damage.

4.24.2

Oil filter: renewing

Renewing oil filter, 1.4 l, 1.6 l injection engines, with hexagonal flats on oil filter ⇒ page 62 .

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does wage Renewing oil filter, 1.4 l, 1.6 l injection engines, not olks without hexagonal V gu y flats on oil filter ⇒ page 62 b ara d e ris

nte eo ra c

thoengines ⇒ page 62 .

Renewing oil filter, SDI/TDI diesel au ss

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Renewing oil filter, TDI PD diesel engines ⇒ page 62 .

Special tools and workshop equipment required

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

♦ Oil filter tool - VAS 3417-

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♦ Torque wrench - V.A.G 1331/- (5 - 50 Nm)

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♦ Oil filter tool (commercially available) or ♦ Oil filter strap wrench Carry out following procedure:

4. Descriptions of work:

61

Polo 1995 ➤ Maintenance - Edition 03.2018 Renewing oil filter, 1.4 l, 1.6 l injection engines, without hexagonal flats on oil filter – Loosen oil filter -arrow- from below with strap wrench and re‐ move oil filter.

Note

Please observe disposal instructions!

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ing.

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–

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–

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d Clean engine sealing surface. ran ir se tee o h t or u Oil rubber seal lightly on new filter. Thus the oil filter can ad‐ ac a s s here better when tightening, which assures best possible seal‐

– Screw in filter and tighten hand-tight.

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

Renewing oil filter, 1.4 l, 1.6 l injection engines, with hexagonal flats on oil filter – 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.

– Screw in filter and tighten hand-tight.

Prote cted by

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.

Renewing oil filter, TDI unit injector diesel engines Removing Note ♦ Please observe disposal instructions! ♦ Oil new O-rings before installing.

62 4. Descriptions of work:

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Note

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

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Renewing oil filter, SDI/TDI diesel engines

do c um en

r te o iva r rp fo g n

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

Polo 1995 ➤ Maintenance - Edition 03.2018 Loosen cover -arrow- e.g. e.g. using 36 mm combination spanner or 36 mm socket - T10125- .

Note

Before draining or extracting, release sealing cap so that the en‐ gine oil can flow out of filter housing. . Volkswagen AG – Clean sealing surfaces on threaded cap and oil filter housing. gen AG does swa

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– Install threaded cap -arrow- and tighten to 25 Nm.

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4.24.3

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Further assembly is basically the reverse of the removal proce‐ dure.

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– Renew O-rings -2 and 4-.

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– Renew filter element -3-.

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Installing

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Engine oil: replenishing

Oil specifications see ⇒ page 6 General information Note

Please observe disposal instructions!

– After replenishing with oil, wait at least 3 minutes and then check oil level.

4. Descriptions of work:

63

Polo 1995 ➤ Maintenance - Edition 03.2018 Note for turbo engines: •

After changing engine oil and oil filter, check following after first engine start:

•

The engine must only run at idling speed as long as the oil pressure warning lamp lights up in dash panel. Do not rev up!

If the engine is revved up the turbocharger can be damaged or fail completely.

•

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

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

– Pull dipstick out again and read oil level.

Capacities and filter change: ⇒ Maintenance tables or ⇒ Power unit; Rep. gr. 17 ; Engine oil For dipstick as illustrated: A - Do not top up oil.

B - Oil may be replenished. Oil level after this measure could be in -A- region.

C - Oil must be replenished. It is sufficient if the oil level is in the -B- region (hatched area) afterwards.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h If oil level is below -C- marking, replenish oil to -A- marking. t u ra a c Oil specification ⇒ page 6 . s s

There is a danger of damaging the catalytic converter if the oil level is above the -A- marking.

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–

Engine and components in engine com‐ partment: inspecting for leaks and dam‐ age (from above and below)

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

Inspect as follows:

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pe rm itte d

4.25

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

♦ If fluid loss is greater than can be expected through normal

Carrying out road test

Which of the following can be checked depends on vehicle equip‐ ment and local conditions (urban/country).

Check the following during a road test: – Engine: output, misfiring, idling speed, acceleration

64 4. Descriptions of work:

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4.26

AG.

use, determine source and rectify (repair measure).

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♦ Arrange for defects to be rectified as repair measures.

c o p yri gh t.

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Note

in t his d o cu m en

r te o iva r rp fo ng

For leaks, abrasions, porosity and brittleness.

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– Check lines, hoses and connections of

Polo 1995 ➤ Maintenance - Edition 03.2018 – Clutch: pulling away, pedal pressure, odours – Gear selection: ease of operation, stick position – Automatic gearbox: selector lever position, shift lock / ignition key removal lock, shift behaviour.

– ABS function: pulsing must be felt at the brake pedal during ABS-regulated braking AG. – Foot brake and handbrake: function, free travel and effective‐ agen ksw l o V ness, pulling to one side, juddering, squeal by d se

– Folding fabric sunroof: function

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– Radio: Reception, GALA, interference

– Multi-function indicator (MFI): functions – Air conditioning system: function

– Vehicle: pulling to one side when travelling straight-ahead (level road) – Imbalance: wheels, drive shafts – Wheel bearings: noises – Engine: hot starting behaviour

4.27

Wheel bolts: tightening to specified tor‐ que

Removing and installing wheel bolt caps ⇒ page 65 r fo ng

AG.

Note

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Removing and installing wheel bolt caps

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Retightening wheel securing bolts ⇒ page 67

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Loosening or tightening anti-theft wheel bolts ⇒ page 66

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

– Tilting roof: function

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ri – Steering: function, steering free clearance, steering ho wheel ut a centred when vehicle is travelling straight ahead ss

Volkswagen AG does not gu ara nte eo ra c

Depending on vehicle equipment, the wheel bolts could be cov‐ ered by the following components: ♦ Wheel bolt caps ♦ Hub cap ♦ Full-size hub cap – Remove the respective wheel bolt cover, if fitted.

Note

The puller hook to remove the cover caps or the wheel hub trim is located in the vehicle tool kit.

4. Descriptions of work:

65

Polo 1995 ➤ Maintenance - Edition 03.2018 Example, removing hub cap – Hook puller hook into one drilling of wheel hub trim and pull off in -direction of arrow-.

Fitting instructions Note ♦ The cover caps protect the wheel bolts and should be recon‐

nected after the wheel securing bolts have been retightened.

♦ Ensure that on some rims the lug of the wheel hub trim locates

in the groove of the rim.

♦ After completing work, place adapter and puller hooks with

vehicle tool kit.

– On vehicles with full wheel trim install full wheel trim so that the tyre filler valve is guided through the cut-out provided -arrow-.

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♦ The adapter to loosen and tighten the anti-theft wheel bolts

can be found in the vehicle tool kit.

♦ If the adapter to loosen or tighten the anti-theft wheel bolts is

not available in the vehicle, use the adapter set for tamperproof wheel bolts - T10101- .

♦ If the adapter is not available, a new replacement adapter can

only be obtained via the code number.

Special tools and workshop equipment required

AG.

Prote cted by

66 4. Descriptions of work:

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c o p yri gh t .

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– Slide adapter into anti-theft wheel bolt onto stop.

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♦ Adapter set for wheel bolts - T10101-

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

Note

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r wheel bolts Loosening or tightening anti-theft o h t or u ac a ss

Polo 1995 ➤ Maintenance - Edition 03.2018 – Slide the wheel bolt wrench onto adapter onto stop.

– Retighten the wheel securing bolts to correct torque setting.

Retightening wheel securing bolts Special tools and workshop equipment required

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

Note

Ensure that wheel bolts are tightened diagonally and alternately.

Specified torque: 110 Nm

Radio and radio-navigation system: sticking serial number and code number onto unit card r fo ng

To release the electronic lock of the radio and radio-navigation system, the code number for the unit must be entered. c o p yri gh t.

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The code number and serial number of the unit are indicated on the unit card.

AG.

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– Stick serial number and code number onto unit card.

4.29

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The unit card is located at front of vehicle wallet.

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4.28

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 1332-

Radio/radio-navigation system: activat‐ ing anti-theft coding

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

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.

4. Descriptions of work:

67

Polo 1995 ➤ Maintenance - Edition 03.2018 – 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 from radio card. Press button 1 to enter the first digit of the code number, button 2 to enter the 2nd digit and so on.

– 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, when the ignition key is removed the diode located next to the unit name will flash. When the diode flashes the radio is readyfor-use and the anti-theft coding is activated.

On radio units “beta and gamma” activate the fixed code as fol‐ lows: n AG. Volkswagen AG age ksw Vol y b ed ris o “SAFE” appears on digital display. h ut sa After approx. 3 seconds “1000” appears ons display.

– Switch radio unit on.

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–

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

– 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.

Activating fixed code on “radio navigation system” as follows: – Switch on radio navigation system using press button -1-.

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Prote cted by

4.30

Manual gearbox/final drive: checking oil level, topping-up oil if necessary

– »Manual gearbox« ⇒ 5-speed manual gearbox 085; Rep. gr.

34 ; Checking gear oil »Checking gear oil« – »Manual gearbox« ⇒ 5-speed manual gearbox 02J; Rep. gr.

34 ; Checking gear oil »Checking gear oil«

68 4. Descriptions of work:

AG.

The LED on the top right of the radio/navigation system must flash when the ignition key is removed. If the diode flashes, the radio navigation system is ready-for-use and the anti-theft coding is activated.

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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.

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– When code has been entered fully confirm by pressing the ro‐ tary/press button -2- (at least 2 seconds).

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– Enter code by turning rotary/push button -2- until number re‐ quired on number list -3- is highlighted and confirm each number by pressing the button briefly.

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Polo 1995 ➤ Maintenance - Edition 03.2018

Headlight adjustment: checking, adjust‐ ing if necessary

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

Special tools and workshop equipment required

♦ or: Prote cted by c o py rig ht .

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♦ Headlight adjustment unit - VAS 5047-

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♦ Headlight adjustment unit - VAS 5046-

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4.31

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The following test and adjustment instructions are applicable in all countries. However, national guidelines and regulations of the respective country are to be followed. agen lksw Vo by

AG.

Conditions for testing and adjustment: ♦ 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).

The unladen weight is the weight of vehicle ready for operation with a full fuel tank (at least 90%) including weight of all equipment normally carried (e.g. spare wheel, tools, jack, fire extinguisher etc.).

If the fuel tank is not at least 90% full, then load as follows: – Read level of fuel in fuel tank on fuel gauge. Determine addi‐ tional weight from following table and place weight in luggage compartment.

4.31.1

Fuel gauge table Fuel gauge

Additional weight in kg

1/4 1/2 3/4 Full

30 20 10 0

Example: When the fuel tank is half full an additional weight of 20 kg must be placed in the luggage compartment.

4. Descriptions of work:

69

Polo 1995 ➤ Maintenance - Edition 03.2018 Note

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 on a level surface. ⇒ Operating instructions for headlight adjuster - VAS 5046- or headlight adjuster - VAS 5047- . ♦ Vehicle and headlight adjuster must be aligned. ♦ Inclination must be set.

Inclination information in “%” is stamped into trim above headlight.

Headlights must be adjusted according to this information. Per‐ centage given is based on a projection distance of 10 metres.

Example: converting a dip setting of e.g. 1.2% is equivalent to 12 cm. ♦ The headlight range control thumb wheel must be in position (-).

4.31.2

Checking headlight adjustment (using new test screen without 15° setting line)

Headlights: Please check the following: Volkswa

en AG AG.on, the ghorizontal does – Whether, with the dipped beam switched agen ksw not l o Vdividing line -1- of the test area light-dark border contacts the gu y ara db e and nte ris

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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-.

♦ For the previous test screen with 15° setting line, adjust as for r fo ng

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70 4. Descriptions of work:

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new test screen. To avoid incorrect settings, ignore the 15° setting line.

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au point -2- between the horizontal part of – Whether the breaking ss 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.

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Fog lights:

AG. Volkswagen AG d agen oes ksw not l o gu yV Polo 1995 ➤ b ara d e nte Maintenance - Edition 03.2018 is r o e th or ac au ss

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

Other additional lights: Additionally retrofitted lights of other systems must be checked and set according to valid guidelines.

4.31.3

Headlights with gas discharge bulbs

The following test and adjustment instructions are applicable in all countries. However, national guidelines and regulations of the respective country are to be followed. r fo ng

The following are prerequisites for adjusting headlights gas dis‐ charge bulbs: •

Tyre pressures OK.

•

Lenses must not be damaged or dirty.

•

Reflectors and bulbs OK.

•

Handbrake must be released and no gear selected.

•

Steering wheel must be in straight-ahead position.

•

Vehicle must not be moved during basic setting (do not “open or close” doors or lean on or enter vehicle).

•

Nobody may be in the vehicle and the vehicle must not be loaded.

•

The vehicle must be rolled forward or backward several me‐ tres or front and rear springs must be bounced fully several times so that springs settle.

•

Vehicle and headlight adjuster must be on a level surface. ⇒ Headlight adjuster operating instructions.

•

Vehicle and headlight adjuster must be aligned.

•

Inclination must be set.

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

– Check whether the upper bright/dark boundary touches the setting line and runs horizontally over the entire width of the test screen.

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Inclination information in “%” is stamped into trim above headlight.

Headlights must be adjusted according to this information. Per‐ centage given is based on a projection distance of 10 metres.

Example: converting a dip setting of e.g. 1.2% is equivalent to 12 cm.

Note ♦ Vehicles with gas discharge bulbs are equipped with automat‐

ic headlight range control. On these vehicles, the procedure “Basic setting” ⇒ page 72 or adjusting headlights must be carried out.

♦ After the headlights have been adjusted, the fault memory

must be read. Therefore, the procedure described here must be strictly followed.

4. Descriptions of work:

71

Polo 1995 ➤ Maintenance - Edition 03.2018

4.31.4

Carrying out basic setting using vehicle diagnostic tester

Carry out following procedure: – Apply handbrake.

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

– Manual gearbox: gear lever in neutral.

– Connect vehicle diagnostic tester ⇒ page 20 .

– Switch on ignition.

Indicated on display: Select operating mode: – Press button for Vehicle self-diagnosis on display -arrow-.

Note

If the display is not as shown in the procedure: ⇒ Operating in‐ structions for vehicle diagnostic tester .

Indicated on display: – Press “55 - Headlight range control” on display -arrow-.

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AG.

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C op yi

72 4. Descriptions of work:

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

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

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Indicated on display:

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Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press “04 - Initiate basic setting” on display -arrow-.

Indicated on display: – Press 001 in number block of display -arrow- (001 selects “display group number 001”).

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r ap‐ After “Wait” is indicated on display, the following message o h t or u pears: ac a ss

– Confirm entry with Q button on display number block.

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

– Now adjust headlights ⇒ page 75 .

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Indicated on display:

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– Confirm entry with Q button on display number block.

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– Press 002 in number block of display -arrow- (002 selects “display group number 002”).

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4. Descriptions of work:

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Indicated on display:

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– After adjusting headlights, press button ← -arrow- on display.

73

Prote cted by

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: The reference position of the headlight will now be “learnt” by the control unit.

– Press ← button -arrow- on display.

Indicated on display: – Press ← button -arrow- on display.

Indicated on display:

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

Any system faults that are stored will be displayed one after the other.

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

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AG.

Prote cted by

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74 4. Descriptions of work:

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– Press ← button -arrow- on display.

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Indicated on display:

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– Press “02 - Read fault memory” on display -arrow-.

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Indicated on display:

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

– Press GoTo button on display -arrow-.

Indicated on display: – Press End button on display -arrow-. r te o iva r rp fo ng

– Switch off ignition and separate diagnosis connections.

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4.31.5

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– Install ashtray insert.

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– Press End button in End menu.

Adjusting headlights vehicles ► 09.99

Left headlight A - Lateral adjustment B - Height adjustment – Adjust headlight at front using a suitable cross head screw‐ driver.

Both adjustment screws on right-hand headlight are a mirror im‐ age.

Note

Please check also that both headlights move evenly when head‐ light range control is operated.

4.31.6

Adjusting headlights vehicles 10.99 ►

Left headlights (the right headlight adjustment screws are a mirror image): 1 - Lateral adjustment 2 - Height adjustment – Adjust headlight at front using a suitable cross head screw‐ driver.

Note

Please check also that both headlights move evenly when head‐ light range control is operated.

4. Descriptions of work:

75

Polo 1995 ➤ Maintenance - Edition 03.2018

4.31.7

Vehicles ► 09.99

Left fog light: – To reduce the beam range turn adjustment screw -arrow- to the right. There is no provision for lateral adjustment.

Location of adjustment screw on right-hand headlight is a mirror image.

4.31.8

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

Vehicles 10.99 ► un le

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Right fog light

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

pe rm itte d

– Unscrew cross head bolt -arrow- and remove trim -1-.

– To adjust the range turn adjustment screw -arrow-. There is no provision for lateral adjustment. r te o iva r rp fo g n

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AG.

Prote cted by c o py rig ht .

C op yi

Sunroof: checking function, cleaning and greasing guide rails

Carry out following procedure: – Check function of sunroof.

76 4. Descriptions of work:

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4.32

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Location of adjustment screw on left-hand headlight is a mirror image.

Polo 1995 ➤ Maintenance - Edition 03.2018 – Clean guide rails -arrows- and lubricate with special grease G 000 450 02- .

4.33

Window wash/wipe system and head‐ light washer system: checking function

Check anti-freeze concentration of Windscreen Clear - G 052 164- ⇒ page 77 .

Window wash/wipe system: checking spray jet settings ⇒ page 78 .

Headlight washer system: checking spray jet settings ⇒ page 81 .

4.33.1

Windscreen wash/wipe check‐ . Volkswagsystem: en AG gen AG does swa k n l o o ing anti-freeze concentration andt gure‐ yV ara db nte ise plenishing fluid if necessary r o e h t au

or ac

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s Special tools sand workshop equipment required

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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”.

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

Note

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♦ Refractometer - T10007-

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

4. Descriptions of work:

77

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AG.

Polo 1995 ➤ Maintenance - Edition 03.2018 The scale -1- of the refractometer is calibrated for Genuine Volks‐ wagen Windscreen Clear - G 052 164- .

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

Mixing ratio:

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age ksw Vol y db 1 ripart se o h t au

1 part

2 parts 1 part

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

Starting immediately, use only Windscreen Clear - G 052 164- allyear-round when replenishing the window wash/wipe system.

Note

♦ Windscreen Clear - G 052 164- protects the spray jets, fluid

reservoir and connecting hoses from freezing.

♦ For all vehicles having fan-type spray jets, the reservoir must

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be filled with “Genuine Volkswagen Windscreen Clear” Wind‐ screen Clear - 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.

Windscreen Clear - G 052 164- ensures that the fan type spray jets remain fully functional also at low temperatures. agen lksw Vo by

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♦ Replenish genuine Windscreen Clear - G 052 164- also in the

warmer periods of the year. The powerful cleanser removes wax and oil residue from the glass.

AG.

♦ Frost protection must be guaranteed to approx. -25°C (approx.

-35°C in countries with an arctic climate) in the washer system.

4.33.2

Window washer system: checking jet setting, adjusting jets if necessary

Note ♦ If the spray field is uneven due to soiling in the spray jet, re‐

move spray jet, ⇒ Rep. gr. 92 and rinse with water opposite to direction of spray.

♦ Subsequent blowing through with compressed air against the

spraying direction is permitted.

78 4. Descriptions of work:

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

Replenishing fluid:

in t his d o cu m en

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

1 part

G do es n ot g ua ran 3 parts tee or ac ility ab y li an pt ce

-17/-18° C -22/-23° C -37/-38° C

Windscreen Clear - G 052 Water 164k s l w o a V g . en A G nA

pe rm itte d

Frost protec‐ tion to

Polo 1995 ➤ 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 Never use items to clean the spray jets! h ut ra a c s s to adjust the spray Never use a needle or a similar object

Caution

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♦

jets, otherwise the water passages in the spray jet will be damaged!

Washer jets without presetting ⇒ page 79 Preset washer jets ⇒ page 79

Washer jet for rear window washer system ⇒ page 80 Washer jets without presetting

Special tools and workshop equipment required

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Adjust spray jets so that the water jets spray onto windscreen at positions shown.

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♦ Adjusting tool - T10127-

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♦

Note

Mark the points at which water strikes the window with a watersoluble pin.

– Adjust the washer jets to the following dimensions: a b c d

280 mm 290 mm 430 mm 560 mm

e f g h

370 mm 270 mm 290 mm 560 mm

Tolerance: ± 20 mm Preset washer jets The spray jets are preset. However, small differences in height may be corrected.

Note

Two different types of washer jets have been installed.

4. Descriptions of work:

79

Polo 1995 ➤ Maintenance - Edition 03.2018 – Turn eccentric on spray jet -in direction of arrow- using a screwdriver, to adjust spray direction upwards.

– To adjust the spray direction downwards, turn eccentric on washer jet opposite to -direction of arrow-.

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 both spray fields are not at same height, adjust spray direc‐ tion upwards or downwards as follows: 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

– Adjust spray jet at adjuster -1- by hand upwards or down‐ wards.

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Spray jet for rear window washer system

Special tools and workshop equipment required

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Spray jet must spray to centre of wiped area.

– If necessary, adjust the spray jet using adjusting tool T10127- .

80 4. Descriptions of work:

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– Check jet setting.

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♦ Adjusting tool - T10127-

Polo 1995 ➤ Maintenance - Edition 03.2018

4.33.3

Headlight washer system: checking jet setting, adjusting jets if necessary

Note ♦ If the spray field is uneven due to soiling in the spray jet, re‐

move spray jet, ⇒ Rep. gr. 92 and rinse with water opposite to direction of spray.

♦ Subsequent blowing through with compressed air against the

spraying direction is permitted.

Caution

♦ Never use items to clean the spray jets! ♦ Never use a needle or a similar object to adjust the spray jets, otherwise the water passages in the spray jet will be damaged!

Special tools and workshop equipment required

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

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

pe rm itte d

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♦ Adjusting tool - T10167-

Headlight washer system: Check jet setting and adjust, vehicles ► 1999 Note

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The jet adjustment dimensions are for the left-hand headlight (right-hand headlight mirror image)

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4. Descriptions of work:

81

AG.

Prote cted by c o p yri gh t.

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Polo 1995 ➤ Maintenance - Edition 03.2018 The spray jets must be adjusted so that the water jets spray onto headlight at positions shown.

– Check jet setting. a b

15 mm from casting mark -arrow10 mm diameter Note

Mark the points at which water strikes the headlight with a watersoluble pin.

– Align spray jet to relevant spray points using adjusting tool T10167- .

Headlight washer system: Check jet setting and adjust, vehicles 2000 ► Note

The jet adjustment dimensions are for the left-hand headlight (right-hand headlight mirror image) The spray jets must be adjusted so that the water jets spray onto headlight at positions shown. a - 70 mm b - 75 mm c - 90 mm

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

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d - 75 mm

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Switch off ignition and all electrical consumers and remove igni‐ tion key.

– Pull the washer jets and cap -arrow- out of bumper cover onto stop.

Note

Mark the points at which water strikes the headlight with a watersoluble pin.

– Align spray jet -arrow- to relevant spray points using adjusting tool - T10167- . r fo ng

Prote cted by

82 4. Descriptions of work:

AG.

Wiper blades: checking setting angle, adjust if necessary ⇒ page 83

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Wiper blades: checking park position, adjust if necessary ⇒ page 83

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Wiper blades: checking park position and setting angle

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4.34

Polo 1995 ➤ Maintenance - Edition 03.2018

4.34.1

Wiper blades: checking park position, adjusting if necessary

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

4.34.2

Windscreen

– Check park position.n AG. Volkswagen AG age ksw

does n

ot g markings in the ol – Check if wiper y V blades are in park position on ua db ran e windscreen. te ris

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b - Markings for right-hand drive vehicles

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au a - Markings for left-hand drive vehicles ss

4.34.3

Rear windscreen

– Check park position.

The distance -a- between wiper blade and lower edge of wind‐ screen must be 35 mm.

– Adjust park position by moving wiper arm if necessary.

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Prote cted by c o p yri gh t.

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4.34.4

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Specified torque for wiper arm: 15 Nm

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

Wiper arm torque setting: 20 Nm

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– Adjust park position by moving wiper arm if necessary.

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 4. Descriptions of work:

83

Polo 1995 ➤ 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

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♦ Adjusting tool - 3358 B-

– Set wiper arms to rest position.

– Remove wiper blade.

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

Carry out following procedure:

– Insert wiper arm -2- into setting device - 3358 B- and secure with locking screw -3-.

– Check setting angle.

Contact angle (specifications) for LHD vehicles

Driver side Passenger side Rear window wiper9) Tolerance

- 2° - 2° 0° ± 2°

RHD vehi‐ cles + 2° + 2° 0° ± 2°

r fo ng

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

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9) from chassis number 6N-S-045 001 plastic wiper arm. Adjustment is not pos‐ sible. ht rig py Co t.

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– Fit 24 mm combination spanner - VAS 5397- -1- on setting device - 3358 B- and adjust wiper arm -2- to specification -arrows-. agen lksw Vo by

AG.

Prote cted by

– Loosen wiper arm -2- from setting device - 3358 B- and again secure with locking screw -3-.

– Check setting against table. If necessary, repeat setting and checking procedure until angle is as specified.

– Remove setting device - 3358 B- and fit wiper blade.

– Check that wiper system wipes without juddering.

4.35

Power assisted steering: checking fluid level

Carry out following procedure:

4.35.1

Cold fluid:

– Do not start engine but bring front wheels to straight-ahead position.

84 4. Descriptions of work:

Polo 1995 ➤ Maintenance - Edition 03.2018 – Fit a suitable screwdriver into cap recess -arrow- and unscrew cap with oil dipstick.

– 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.

For dipstick as illustrated: – Check fluid level: The fluid level must be in area of MIN. mark‐ ing (up to 2 mm above or below marking).

For dipstick as illustrated:

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Note

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– Checking oil level: The oil level must be within the area of the grid -A-.

♦ 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, replenish power assisted steering oil - G 002 000- .

– Screw cap on hand tight (with a screwdriver).

4.35.2

Fluid at operating temperature (above approx. 50°C) r te o iva r rp fo ng

– Screw filler cap on hand tight and unscrew again.

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– Wipe off dipstick using a clean cloth.

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– Fit a suitable screwdriver into cap recess -arrow- and unscrew cap with oil dipstick.

in t his d o cu m en

– Do not start engine but bring front wheels to straight-ahead position.

AG.

Note

The cap must be fully screwed on in order to obtain an accurate fluid level reading.

4. Descriptions of work:

85

Polo 1995 ➤ Maintenance - Edition 03.2018

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

For dipstick as illustrated:

– Checking oil level: The oil level must be between min. and max. markings.

Note

♦ If oil level is above max. marking, the excessive oil must be

extracted.

checked for leaks (repair measure). It is not sufficient just to top up with fluid. If the hydraulic system is not leaking, replen‐ ish power assisted steering oil - G 002 000- .

AG.

Prote cted by

4.36

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– Screw cap on hand tight (with a screwdriver).

Service interval display: resetting

Service interval display: resetting, vehicles ►1997 ⇒ page 86 Service interval display: resetting, vehicles 1998 ► ⇒ page 88

4.36.1

Service interval display: resetting in ve‐ hicles ►1997

♦ Vehicles with diesel engine code AEF are fitted with a flexible service interval display ⇒ page 87 . ♦ Vehicles with SDI and petrol engine are »not« fitted with a flexible interval display ⇒ page 87 .

86 4. Descriptions of work:

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r fo ng

♦ If oil level is below min. marking, the hydraulic system must be

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n AG. Volkswagen AG do es n wage s k l ot g o For dipstick as illustrated: yV ua b d ran ir se tee o – Check fluid level: The fluid level must be between MIN. and h t or u ac a MAX. marking. ss

Polo 1995 ➤ Maintenance - Edition 03.2018

4.36.2

Non-flexible display AG. Volkswagen

G dodis‐ agen not operate)Athe After switching on the ignition (engine es n wdoes olks play -arrow C- appears for a fewd bseconds in place of the odometerot gua yV ran display in the speedometer.orIfiseservice is not required, “IN-00” will tee h t or be displayed. a au un le

After a service has been performed, service types which appear in the display before that one, must also be called-up individually and reset: ♦ If the inspection service IN 02 has been performed, OIL, IN01 and IN 02 must be reset. ♦ If the inspection service IN 01 has been performed, OIL and IN 01 must be reset.

Reset the display as follows: – With ignition switched on press button arrow A below the speedometer and hold. r fo ng

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

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

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

OIL IN 01 IN 02

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ss

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

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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.

4.36.3

Flexible display

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 between 7,500 and 15,000 km or periods between 8 and 12 months.

On the flexible service interval display other display contents will be indicated compared with the non-flexible service interval dis‐ play.

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

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

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

Service event:

alternately OIL or INSP or:

Engine oil change

4. Descriptions of work:

87

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display:

Service event:

INSP-1

Inspection service every 12 months

or: INSP-2

Inspection service every 30,000 km

After a service has been performed, also the previous type of service must be called-up individually and reset. ♦ If 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.

Reset the display as follows: – With ignition switched on press button arrow A below the speedometer and hold.

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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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–

n AG. Volkswagen AG do es n wage s k l ot g o is Switch off ignition and release button. The inscriptionb“OIL” yV ua d ran indicated in the display. ir se tee o h t or u ac a ss

– 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.

Prote cted by

♦ a time recorder and ♦ two distance recorders.

The electronics evaluates both recorders so that the customer ♦ after a predetermined time period is exceeded or or ♦ after a predetermined distance is reached

88 4. Descriptions of work:

AG.

The service interval display electronics is comprised of, amongst other items:

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Functional description

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Service interval display: resetting, vehi‐ cles 1998►

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4.36.4

r fo ng

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

Polo 1995 ➤ Maintenance - Edition 03.2018 is informed via the service interval display that a service is re‐ quired (whichever occurs first).

Note

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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AG. Volkswagen AG d agen oes ksw not l o V gu On vehicles 1998► by with engine code AEF, the thermal ara load and d e nte is soot load oforengine oil are additionally used for calculating the eo h service intervals. ut ra a c ss

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

4. Descriptions of work:

89

agen lksw Vo by

AG.

Prote cted by c o p yri gh t.

C op yi

Polo 1995 ➤ Maintenance - Edition 03.2018 Service interval display Between services, only the total distance and distance travelled (trip recorder) is shown in the distance display -2-.

If a service is due, the following is indicated in the distance display -2- below the total mileage: ♦ with ignition switched off “service”. ♦ after the ignition is switched on and up to 3 minutes after the engine is started the type of service (see table).

Indicated on display:

Service event:

Distance and service OIL or: Distance and service INSP

Oil change service every 15,000 km

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

One or both service types must be reset depending on which service was completed, therefore: en AG. Volkswagen AG ag lksw

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o ♦ If a “service OIL” (oil change service every 15,000 km)otisgucar‐ yV ara db nte ried out, only “service ir se OIL” must be reset. o h ut

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Note

♦ The service interval display can be reset using different meth‐

ods:

♦ With adjustment button for distance display on dash panel in‐

sert ⇒ page 90

r te o iva r rp fo ng

♦ With diagnostic tester ⇒ page 92 Resetting service interval display with adjustment button for dis‐ tance display on dash panel insert With adjustment button for distance display on dash panel insert, vehicles ►09.99 ⇒ page 90

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With adjustment button for distance display on dash panel insert, vehicles 10.99► ⇒ page 91 agen lksw Vo by

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With adjustment button for distance display on dash panel insert, vehicles ►09.99 ♦ delivery inspection ♦ every oil change service ♦ every inspection service service interval display must be reset.

90 4. Descriptions of work:

AG.

For

in t his d o cu m en

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

Resetting service interval display

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

♦ 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.

eo ra c ility ab y li an pt ce

a ♦ If a “service INSP” (inspection service every 12 months or ev‐ ss ery 30,000 km) has been performed “service INSP” and “serv‐ ice OIL” must be reset.

Polo 1995 ➤ Maintenance - Edition 03.2018 Note

Each service must be reset individually as only the distance re‐ corder and time counter of the actual service can be reset.

Reset the display as follows: – Switch off ignition.

– Press and hold button 1 next to speedometer.

– 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.

– Release button 1 .

– Switch off ignition.

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

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♦ To reset a further service, repeat these steps. es, in part or in w l purpos hole ercia , is n m ot com

For

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

With adjustment button for distance display on dash panel insert, vehicles 10.99►

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be reset.

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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 Note that only the actual service type indicated on display can c s s

♦ every oil change service ♦ every inspection service service interval display must be reset.

Note

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

♦ Each service must be reset individually as only the distance

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

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– Switch off ignition.

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Reset the display as follows:

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

4. Descriptions of work:

91

Polo 1995 ➤ Maintenance - Edition 03.2018 – Press and hold button 1 below the distance display.

– 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.

– Release button 1 .

– Switch off ignition.

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.

4.36.5

Service interval display: lkswagen AG with AG. Voresetting does agen ksw tester not l o vehicle diagnostic V gu y b a

ed ris o h t au ss delivery inspection

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♦ every oil change service

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service interval display must be reset.

– Apply handbrake.

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

– Manual gearbox: gear lever in neutral.

– Connect vehicle diagnostic tester ⇒ page 20 .

Resetting service interval display ⇒ page 92 Adaption table ⇒ page 94 Resetting service interval display r te o iva r rp fo ng

Select operating mode: – Press button for »Vehicle self-diagnosis« on display -arrow-. c o p yri gh t.

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If the display is not as shown in the procedure: ⇒ Operating in‐ structions for diagnostic tester

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92 4. Descriptions of work:

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Note

in t his d o cu m en

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

♦ every inspection service

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: Select vehicle system: – Press “17 - Dash panel insert” on display -arrow-.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d The control unit identificationriand nte se coding are displayed -arrow-. o eo h t u ra a c s s

Indicated on display:

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Indicated on display:

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r te o iva r rp fo g n

– Press “10 - Adaption” on display -arrow-.

4. Descriptions of work:

93

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AG.

Prote cted by

c o p yri gh t.

C op yi

Polo 1995 ➤ Maintenance - Edition 03.2018

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte se i r Press the adaption channel for the service which is to be reset o eo h t u ra a on the display number block -arrow-: c s s

Indicated on display:

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–

for display “service INSP” on dash panel insert channel 10, 11 and 12 Service event:

Adaption channel:

service OIL service INSP service INSP

10 11 12

Note

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

Adaption table:

Counter Adaption value to reset: contents: Distance in 100s of km Distance in 100s of km Time in days

150 300 360

♦ Entering the relevant adaption values for the distance recorder r fo ng

♦ The procedure is the same for vehicles with a distance display Prote cted by

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

days.

Resetting service interval display service OIL (oil change service) ⇒ page 94 service INSP (inspection every 12 months) ⇒ page 95 service INSP (inspection every 30,000 km) ⇒ page 97 service OIL (oil change service) Indicated on display: – Press buttons 1 and 0 on display number block -arrow-.

– Confirm entry with Q key on display number block.

94 4. Descriptions of work:

AG.

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

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♦ The entered values count down to 0 km.

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

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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

for display “service OIL” on dash panel insert channel 10

Polo 1995 ➤ Maintenance - Edition 03.2018 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.

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 .

Service INSP (inspection every 12 months)

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– Confirm entry with Q key on display number block.

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

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Indicated on display:

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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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Note

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– Press the Save button on display -4-.

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

4. Descriptions of work:

95

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: – Move the position indicator -arrow- on the display until -1- 360 is displayed over the scroll bar (equates 360 days).

Note

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

– Press the Save button on display -4-.

Indicated on display:

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dicator moves the value to the previous number.

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♦

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♦

n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b Pressing the scroll bar briefly to the right -2- of the position ran ed s i tee r indicator moves the value to the next number. o h t or u ac a ss in‐ Pressing the scroll bar briefly on the left -3- of the position

– Press the »Accept« button on display -arrow-.

If an inspection service has been performed without an oil change, then end output ⇒ page 101 .

Prote cted by

96 4. Descriptions of work:

AG.

– Press “10 - Adaption” on display -arrow-.

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Indicated on display:

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– Press arrow button on display.

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Indicated on display:

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If an inspection service has been performed with an oil change, then continue as described:

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press buttons 1 and 0 on display number block -arrow-.

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Indicated on display:

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– Confirm entry with Q key on display number block.

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

Note

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

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

r te o iva r rp fo ng

AG.

– Press the Accept button on display -arrow-.

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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.

in t his d o cu m en

Note

– End output ⇒ page 101 .

Service INSP (inspection every 30,000 km)

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

– Confirm entry with Q key on display number block.

4. Descriptions of work:

97

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: – Move the position indicator -arrow- on the display until 300 is displayed over the scroll bar -1- (equates to 30,000 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

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:

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

pe rm itte d

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– Press the Accept button on display -arrow-.

Indicated on display:

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

– Press arrow button on display.

Indicated on display: r te o iva r rp fo ng

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c o p yri gh t .

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98 4. Descriptions of work:

in t his d o cu m en

– Press “10 - Adaption” on display -arrow-.

Indicated on display:

AG. Volkswagen AG d Polo 1995 ➤ agen oes ksw not l o V Maintenance Edition 03.2018 g y u ara db nte ise r eo tho ra au c s s

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pe rm itte d

ility ab y li an pt ce

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

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

Indicated on display:

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

– Confirm entry with Q key on display number block.

Note

♦ Pressing the scroll bar briefly to the right -2- of the position c o p yri gh t.

C op yi

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

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– Press the Save button on display -4-.

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dicator moves the value to the previous number.

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indicator moves the value to the next number.

do c um en

r te o iva r rp fo g n

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

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

Indicated on display: – Press arrow button on display.

4. Descriptions of work:

99

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press “10 - Adaption” on display -arrow-.

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

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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– Confirm entry with Q key on display number block.

pe rm itte d

Indicated on display:

♦ 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-.

r te o iva r rp fo ng

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. agen lksw Vo by

c o p yri gh t .

C op yi

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– Press the Accept button on display -arrow-.

100 4. Descriptions of work:

AG.

– End output.

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Indicated on display:

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

Note

in t his d o cu m en

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

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

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press GoTo button on display -arrow-.

Indicated on display: – Press End button on display -arrow-.

– Press End button in End menu.

– 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.

ility ab y li an pt ce

4.37

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–

Track rod ends: checking clearance, firm seating and boots

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

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 boots are not damaged and are seated correctly.

r fo ng

Dust and pollen filter: renewing filter el‐ ement c o p yri gh t.

C op yi

The filter is located on right in the plenum chamber under a cover. agen lksw Vo by

AG.

Prote cted by

Carry out following procedure:

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4.38

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 V gu y Switch off ignition. b ara d nte ise r o eo h Install cover in front of fuse strip. t u ra a c s s

4. Descriptions of work:

101

Polo 1995 ➤ Maintenance - Edition 03.2018

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h From the right-hand side of plenum chamber coverapull ut rubber ra c s seal -1- off upwards to vehicle centre. s

4.38.1

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–

Removing:

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

pe rm itte d

– Unclip plenum chamber cover -2- -arrows- and pull out up‐ wards.

Prote cted by

Installing:

– 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.

– Clip in plenum chamber cover and press on rubber seal.

4.39

Door arrester: lubricating

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

– Grease door arrester in side area -arrow A- with solid grease - G 000 150- .

– Grease securing pins -arrow B- with lock cylinder lubricant spray - G 052 778 A2- .

102 4. Descriptions of work:

AG.

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4.38.2

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Please observe disposal instructions!

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Note

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– Separate filter element from frame.

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– Press filter housing lugs -B- in direction of arrow and take filter element with frame out upwards.

AG. Volkswagen AG d Polo 1995 ➤ agen oes ksw not l o V Maintenance Edition 03.2018 g y ua db ran ise t r e eo tho ra au c s s

4.40.1

Vehicles ► 1997

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Clock: setting to correct time

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4.40

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

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Carry out adjustment as follows:

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:

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With the minute button the clock can be set exactly to the second:

AG.

Carry out adjustment as follows:

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Vehicles 1998 ►

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4.40.2

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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.

in t his d o cu m en

– Press briefly, preferably with a ball pen on lower button, to advance the time one minute. Pressing the button continu‐ ously speeds up selection of minutes.

Setting hours: – Turn setting knob -1- (on lower right next to rev counter) anticlockwise.

By turning the setting knob shortly, the clock will be altered by one hour. By turning and holding the knob the alteration will be con‐ tinuous.

Setting minutes: – Turn setting knob -1- clockwise.

By turning the setting knob shortly, the clock will be altered by one minute. By turning and holding the setting knob the alteration will be continuous.

With the setting knob -1- the clock can be set exactly to the second as follows: – Turn setting knob to right until the time is one minute before time to be set.

– Turn button to the right at the moment when the seconds in‐ dicator of accurate clock shows a full minute.

4.40.3

Vehicles 2000 ►

Set clock Polo GTI 2000 ► ⇒ page 104 .

Carry out adjustment as follows: Setting hours:

4. Descriptions of work:

103

Polo 1995 ➤ Maintenance - Edition 03.2018 – 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: – 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.

4.40.4

Set clock Polo GTI vehicles 2000 ►

Carry out adjustment as follows: – Press the button briefly -2-, to advance the time one minute.

Pressing the button continuously speeds up selection of mi‐ nutes and hours clockwise.

Underbody protection: visual check for damage

During visual check the floor pan, wheel housings, side members and especially all cover caps fitted -arrows- must be checked for damage!

Note

♦ Faults found must always be rectified (repair measure). This

inhibits corrosion and rusting through.

♦ ⇒ ElsaWin; Technical information; “Paint manual”; 4. Corro‐

sion protection .

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Toothed belt: checking for wear

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104 4. Descriptions of work:

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4.42

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

4.41

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– Press the button briefly -1-, to reset the time one minute.

Pressing the button continuously speeds up selection of mi‐ nutes and hours anti-clockwise.

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ Workshop vernier caliper - VAS 5276-

SDI engines

– Open clips -1- on upper toothed belt guard.

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

– Unhook toothed belt guard -2- and pull to side.

– Measure the width of toothed belt with a workshop vernier cal‐ iper - VAS 5276- .

AG.

Note

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21 mm 22 mm

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AHG, AKU AGD

Wear limit ht rig py Co t.

Engine code

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Carry out following procedure:

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4.42.1

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

♦ When a toothed belt has reached a width of 21 mm or 22 mm

respectively, the wear limit has been reached and it must be renewed (repair measure). Inform customer!

♦ 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.

4.42.2

TDI engines

Carry out following procedure:

4. Descriptions of work:

105

Polo 1995 ➤ Maintenance - Edition 03.2018 – Pull out oil dipstick -1- and remove oil filler cap -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

– Open clips -1- on upper toothed belt guard.

– Unhook toothed belt guard -2- and pull to side.

Prote cted by

limit has been reached and it must be renewed (repair meas‐ ure). Inform customer!

♦ 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.

4.43

Camshaft drive toothed belt and ten‐ sioning roller: renewing, PD diesel en‐ gine

– Carry out procedure:»Power unit« ⇒ Engine cylinder head, valve gear; Rep. gr. 15 ; Removing, installing and tensioning toothed belt »Removing, installing and tensioning toothed belt«

4.44

Toothed belt: renewing

Diesel engine codes AGD, AHG, AKU, ASX – Carry out procedure:»Engine mechanics« ⇒ Engine cylinder head, valve gear; Rep. gr. 15 ; Removing, installing and ten‐ sioning toothed belt »Removing, installing and tensioning toothed belt«

106 4. Descriptions of work:

AG.

♦ When a toothed belt has reached a width of 27 mm, the wear

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Note

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Wear limit: 27 mm

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– Measure the width of toothed belt with a workshop vernier cal‐ iper - VAS 5276- .

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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– Unclip engine cover and remove upwards.

Polo 1995 ➤ Maintenance - Edition 03.2018

4.45

Toothed belt: checking condition and tensioning, tensioning toothed belt if necessary

Diesel engine code AEF

4.45.1

Toothed belt: checking condition

– Remove air filter/intake manifold connecting hose.

AG. Volkswagen AG d oes not gu ara nte eo ra c

n agecover.

– Open clips for upper toothed belt guard and remove lksw

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♦ Cracks, cross sectional breaks

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– Check condition of toothed belt for:

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♦ Layer separation (toothed belt body, tensile cords) ♦ Toothed belt body breakup

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

♦ 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:

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Note

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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)

To check the toothed belt tension, the upper toothed belt cover must remain removed.

4.45.2

Toothed belt tension: checking

Before checking the toothed belt tension, the semi-automatic ten‐ sioning device must be checked for correct function as follows:

4. Descriptions of work:

107

Polo 1995 ➤ Maintenance - Edition 03.2018 – Press toothed belt with force using thumb. Notch and raised mark -arrows- should move.

– Check tensioning roller for damage and wear. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b Note d ran ir se tee o h t or u ac a If damage is determined on tensioning ss roller, the toothed belt ten‐ pe rm itte d

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sioning roller must always be renewed (repair measure).

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

– Relieve 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.

4.45.3

Toothed belt: tensioning

– »Engine mechanics« ⇒ Engine cylinder head, valve gear; Rep. gr. 15 ; Removing, installing and tensioning toothed belt »Removing, installing and tensioning toothed belt«

4.46

Spark plugs: renewing r te o iva r rp fo ng

♦ Spark plugs: renewing, 2-valve engines ⇒ page 109

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♦ Torque wrench - V.A.G 1331/- (5 - 50 Nm)

♦ Spark plug socket - 3122 B-

108 4. Descriptions of work:

AG.

Special tools and workshop equipment required

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c o p yri gh t .

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♦ Spark plugs: renewing, 4-valve roller rocker finger engines ⇒ page 111

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♦ Spark plugs: renewing, 2-valve roller rocker finger engines ⇒ page 110

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♦ Spark plugs: renewing, Mono Motronic engines ⇒ page 109

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ Spark plug connector pliers - V.A.G 1922-

4.46.1

Spark plugs: renewing, Mono Motronic engines

– Remove air filter complete ⇒ Mono Motronic injection and ig‐ nition system; Rep. gr. 24 ; Dismantling and assembling air filter .

– 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 ♦ Spark plug designation and torque setting ⇒ Mono Motronic

injection and ignition system; Rep. gr. 28 ; Repairing ignition system, adjustment data, spark plugs , Removing and instal‐ ling parts of ignition system; test data, spark plugs.

olkswagen AG en AG. V does not gu ara nte eo ra c

♦ Please observe disposal instructions! olkswag yV – Install air filter.

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Spark plugs: renewing, 2-valve engines 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

4.46.2

b ed ris o th au 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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♦ Specified torque: max. 3 Nm

4. Descriptions of work:

109

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Polo 1995 ➤ 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

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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– 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

♦ Spark plug designation and torque setting ⇒ Motronic injection

and ignition system; Rep. gr. 28 ; Repairing ignition system, adjustment data, spark plugs Repairing ignition system; ad‐ justment data, spark plugs. r fo ng

Spark plugs: renewing, 2-valve roller rocker finger engines

– Remove air filter housing ⇒ page 52 .

110 4. Descriptions of work:

AG.

4.46.3

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– Connect hose for intake air preheating -arrow- on exhaust manifold.

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– Insert filter housing and tighten cross head bolts -arrows-.

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♦ Please observe disposal instructions!

Polo 1995 ➤ 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- .

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h Spark plug designation and torque setting ⇒ Injection and ig‐ ut ra a c s nition system; Rep. gr. 28 ; Repairing ignitions system, adjust‐

Note

♦

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ment data, spark plugs Repairing ignition system; adjustment data, spark plugs.

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

– Fit spark plug connectors.

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

♦ Please observe disposal instructions!

– Install air filter housing ⇒ page 52 .

4.46.4

Spark plugs: renewing, 4-valve roller rocker finger engines

– Take off oil sealing cap -1-.

– Take ignition cables -2- out of cover -3- and pull cover upwards slightly.

r te o iva r rp fo ng

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AG.

Prote cted by c o py rig ht .

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– Unscrew spark plugs using spark plug socket - VAS 3122B- .

in t his d o cu m en

– Pull off spark plug connectors and place ignition cables with cover to side.

Note ♦ Spark plug designation and torque setting ⇒ Injection and ig‐

nition system; Rep. gr. 28 ; Repairing ignition system, adjust‐ ment data, spark plugs Repairing ignition system; adjustment data, spark plugs.

♦ Please observe disposal instructions!

– Screw in new spark plugs using spark plug socket and exten‐ sion - VAS 3122B- .

– Install spark plug cover.

4. Descriptions of work:

111

Polo 1995 ➤ Maintenance - Edition 03.2018 – Fit oil sealing cap -1-.

– Fit spark plug connectors.

– Press ignition cables -2- into channels in spark plug cover.

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Camshaft drive toothed belt: checking (4-cylinder petrol engine)

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4.47

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

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

Toothed belt: checking condition

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

– Removing and installing toothed belt guard upper part ⇒ 4cylinder injection engine, mechanics; Rep. gr. 13 ; Disman‐ tling and assembling engine »Dismantling and assembling engine« – Check condition of toothed belt for: ♦ Cracks, cross sectional breaks ♦ Layer separation (toothed belt body, tensile cords) ♦ Toothed belt body breakup ♦ Frayed cord strands

A - Cracks (coating) B - Side contact C - Fraying D - Cracks (in teeth base)

112 4. Descriptions of work:

AG.

When checking condition, especially watch for following damage:

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Prote cted by c o py rig ht .

C op yi

If faults are found, always renew toothed belt. This can avoid breakdowns and malfunctions. The replacement of a toothed belt is a repair measure.

ht rig py Co t.

Note

in t his d o cu m en

♦ Traces of oil and grease

r te o iva r rp fo ng

♦ Surface cracks (synthetic coating)

Polo 1995 ➤ Maintenance - Edition 03.2018

4.48

Driver and front passenger airbags: gen AG AG. Volkswavis‐ does agen ksw not l o ual check of airbag units V gu by a ss

ed ris ho t au

ran tee or ac

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

– 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.

Front passenger airbag:

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– Carry out visual check of the dash panel surface -2- for exterior damage.

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AG.

WARNING

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The airbag recognition is the inscription “AIRBAG” on the righthand side of dash panel (front passenger side).

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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

The airbag recognition is the inscription “AIRBAG” on the steering wheel padded plate.

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Driver side airbag:

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Vehicles ▶ 1999

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

Vehicles 2000 ▶ Driver side airbag: The airbag recognition is 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.

Front passenger airbag:

4. Descriptions of work:

113

Polo 1995 ➤ Maintenance - Edition 03.2018 The airbag recognition is the inscription “AIRBAG” on the righthand side of dash panel (front passenger side).

– 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‐ bag is guaranteed. Ensure the customer is aware of these instructions.

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

ht rig py Co t.

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AG.

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114 4. Descriptions of work:

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r te o iva r rp fo ng

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

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

Polo 1995 ➤ 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 Exhaust emissions test for petrol engines without OBD s

Exhaust emissions test

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⇒ page 115

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

5

Exhaust emissions test for petrol engines with OBD ⇒ page 134

Note

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

Exhaust emissions test for diesel engines without OBD ⇒ page 137

♦ Please observe the country specific legal regulations. ♦ The exhaust emissions test described below has been created

according to the legal regulations valid in Germany.

♦ If the vehicle is equipped with or without OBD, see ⇒ page 1 .

Exhaust emissions test for petrol en‐ gines without OBD r fo ng

AG.

Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐ CAUTIONS” in the operating instructions for VAS 6300.

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•

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Caution

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Vehicles which are fitted with or without onboard diagnosis can be found in the engine list ⇒ page 1 .

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5.1

Note ♦ All test conditions and data required for exhaust emissions

test: ⇒ Data sheets for exhaust emissions test

♦ The ignition timing is determined by the control unit and cannot

be displayed. Adjustment is not possible.

♦ Idling speed and CO content are not adjustable (only check).

For deviations from test value: carry out repair measures.

♦ The CO content is regulated by the lambda regulation. Faults

in the lambda regulation are detected in self-diagnosis 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.

♦ The following description refers to vehicles equipped without

OBD with regulated catalytic converter.

Special tools and workshop equipment required

5. Exhaust emissions test

115

Polo 1995 ➤ Maintenance - Edition 03.2018 ♦ Emissions testing station - VAS 6300-

AG. Volkswagen AG d agen oes

♦ Diagnostic cable - VAS 5051/6A-Volksw

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y db ise ♦ Adapter for older vehicles -orVAS 5051/2h ut a or ss

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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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♦ Engine speed adapter - VAS 5087 A-

♦ It is only possible to carry out an exhaust emissions test when

all units of the emissions testing 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 emissions testing

station - VAS 6300- .

Prerequisites for testing:

For bar code reading the EET data sheet must be printed out.

•

Apply handbrake.

•

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

•

Manual gearbox: gear lever in neutral.

•

Install engine speed adjuster - V.A.G 1788/10- .

r te o iva r rp fo g n

•

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AG.

Prote cted by c o p yri gh t.

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– Perform exhaust emissions test according to instructions on display.

Initial screen: – Select button -arrow- “exhaust emissions test”.

116 5. Exhaust emissions test

ht rig py Co t.

All test conditions and data required for exhaust emissions test: ⇒ Data sheets for exhaust emissions test for respective engine.

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•

Polo 1995 ➤ Maintenance - Edition 03.2018 An overview is displayed to select the respective EET type.

– Select “EET petrol” -arrow-.

The display for warm-up phase appears.

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– If the EET specification selection is displayed, select respec‐ tive “EET specification selection” -arrow-. es, in part or in w l purpos hole ercia , is n m ot com

♦ 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

♦ For new models the document previously known as the vehicle ♦ For new models the document previously known as the vehicle

log book is now called the vehicle registration certificate part 2.

do c um en

r te o iva r rp fo g n

registration document is now called the vehicle registration certificate part 1.

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

♦ When exhaust emissions test is performed for the first time, either select “Standard values”,

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r Continue exhaust emissions test according to instructions on dis‐ o h t or u play. ac a ss

5. Exhaust emissions test

117

ht rig py Co t.

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c o p yri gh t .

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Polo 1995 ➤ Maintenance - Edition 03.2018

♦

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♦ -2- Vehicle type: “e.g. Golf”

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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 -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ac a ss

♦ -3- Key number to 1: “e.g. 11”

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

♦ -4- Key number to 2: “e.g. 0603” (vehicle registration docu‐ ment) ♦ -4- Key number to 2.1 (code to 2): “e.g. 0603” (vehicle regis‐ tration certificate part 1) ♦ -5- Key number to 3: “e.g. 358” (vehicle registration document) ♦ -5- Key number for 2.2 (code to D2): “e.g. 358” (vehicle regis‐ tration certificate part 1) ♦ -6- Engine code “e.g. AQY”

♦ -7- Registration number: “e.g. WOB-HH 1234” ♦ -8- Vehicle identification number: “e.g.

WVWZZZ1JZYW123456” r te o iva r rp fo ng

♦ The test can be terminated using GoTo button.

Prote cted by

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 Note ♦ To use the ELSA web service, the diagnostic tester which is

used for the exhaust emissions test, must be integrated in the workshop network.

♦ For the ELSA web service the vehicle specified data are au‐

tomatically transmitted via the network to the respective mask.

Manual specified data input for EET: Note

All test conditions and data required for exhaust emissions test ⇒ Data sheets for exhaust emissions test for respective engine.

– Perform manual data input according to instructions on dis‐ play.

118 5. Exhaust emissions test

AG.

– Select “without OBD”, -arrow-.

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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”.

Polo 1995 ➤ 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

6-

Lambda at increased idling speed

7-

Idling speed

8-

Select regulating probe type, either “step-type probe”, or “broad-band probe” -item 1-.

9-

Lambda probe value

– When all data have 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.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d – Press → button -arrow- to proceed. nte ise r o eo h t u ra a Visual inspection: c s s

All data required are shown on display.

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Follow instructions on display:

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– Perform visual check.

5. Exhaust emissions test

119

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Polo 1995 ➤ Maintenance - Edition 03.2018 – If visual check is OK press “OK” button -arrow-.

Note

When "not OK" button is pressed a check will be carried out The visual check is displayed with the request to connect the ca‐ bles to the vehicle.

Follow instructions on display: – Switch off ignition.

– Connect adapter for older vehicles - VAS 5051/2- or engine speed adapter - VAS 5087/- or diagnostic cable - VAS 5051/6A- to the vehicle.

Note ♦ On some engines the inductive sender for cylinder 1 cannot

be connected.

♦ The engine speed adapter - VAS 5087/- can be used for these

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d On some vehicles the engine speed adapter - VAS 5087/e nte is r o eo must be used. h ut ra a c s s

engines.

♦

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

– Start engine.

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– Switch ignition on.

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– Connect diagnostic cable connector to diagnostic connection ⇒ page 20 .

– Insert emission probe in exhaust tail pipe.

Note

The exhaust emissions test is only continued when the test probe is in the exhaust tail pipe.

It is automatically switched to test for readiness of operation.

Catalytic converter conditioning:

120 5. Exhaust emissions test

AG.

The remaining time to perform the warm-up phase is displayed -arrow A-.

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– Maintain engine speed in required engine speed range.

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Measurement starts when the engine speed has reached the re‐ quired level.

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– Follow instructions on display.

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It is automatically switched to warm-up phase of catalytic con‐ verter.

Polo 1995 ➤ Maintenance - Edition 03.2018 Warm-up phase: It is automatically switched to display for measuring engine tem‐ perature.

– Follow instructions on display.

Note

This is only indicated on display if engine temperature has not reached 80°C. – Bring engine to required temperature.

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 ♦ Measurement can be skipped using → button, i.e. the exhaust

emissions test has failed.

♦ Measured values are reset using ← button, and the test can

be repeated.

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a – Maintain engine speed in required engine speed range. ksw Vol y db

ss

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ise The remaining time to perform measurement isordisplayed th -arrow A-. u a

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Measuring idling speed and CO content:

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

The system switches automatically to the 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-.

Regulating probe test:

It is automatically switched to display for regulating probe test.

Note

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AG.

The remaining time to perform measurement is displayed -arrow A-.

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c o p yri gh t.

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– Maintain engine speed in required engine speed range.

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Measurement starts when the engine speed has reached the re‐ quired level.

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If “Control circuit test - alternative proc.” is indicated on display, the disturbance variable relevant for the engine code must be ac‐ tivated ⇒ page 122 .

5. Exhaust emissions test

121

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Polo 1995 ➤ Maintenance - Edition 03.2018 Evaluation: When the exhaust emissions test has been performed, the log is shown on display.

The test result is displayed.

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 -arrow B- “EET sticker issued” in drop-down menu and date.

– 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‐ AG. Volkswagen AG d view ”. agen o

es n ot g ua ran tee or ac

w olks yV b ed ris ho Take emission probe out of exhaust tailautpipe. ss

– Follow instructions on display.

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–

– Then press → button -arrow B-

Engine code Disturbance variable AQQ ⇒ page 123 ADX, AEA, AEV ⇒ page 123 AEE, AER, AEX, AKK, AKV, ALL, ANX, APQ, ⇒ page 124 AUD AFK ⇒ page 125 AFH ⇒ page 126 AHW ⇒ page 127 AJV ⇒ page 128 ALD ⇒ page 129 APE ⇒ page 130

122 5. Exhaust emissions test

AG.

Activate disturbance variable.

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Exhaust emissions test for petrol en‐ gines, methods to activate disturbance variable for control circuit test

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5.1.1

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The exhaust emissions test is completed, a new exhaust emis‐ sions test can be performed.

Polo 1995 ➤

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Carry out “Control circuit test basic procedure” as follows: – 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.

Note

– Fit connector on coolant temperature sender - G62- with cool‐ ant temperature sender - G2- . agen lksw Vo by

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Note

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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.

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

Engine code: AQQ

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

5.1.2

⇒ page 133

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ARC AUA, AUB AUC

Maintenance - Edition 03.2018 AG. Volkswagen AG d agen oes ksw not l o gu yV ara db ⇒ page 131 nte ise r o eo h ⇒ page 132 ut ra a c s s

When connecting the connector always ensure that it is fitted properly and engages noticeably.

If actual figures deviate from specifications: Repair measures and again perform exhaust emissions test!

After completing exhaust emissions test note the following: ♦ 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.

5.1.3

Engine codes: ADX, AEA, AEV,

Carry out “Control circuit test basic procedure” as follows: Activate disturbance variable within 60 seconds as follows:

5. Exhaust emissions test

123

Polo 1995 ➤ Maintenance - Edition 03.2018 – Pull vacuum hose off injection part towards intake air preheat‐ ing temperature selector -arrow-.

The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

If this message appears on the display: – Reconnect vacuum hose.

The control unit must recognise deactivation of the disturbance variable and eliminate through regulation within 60 seconds.

Note ♦ The control circuit test is also completed when the disturbance

variable has been recognised in one direction and has been eliminated through regulation.

♦ If disturbance variable has not been recognised, repeat Lamb‐

da control circuit test.

If actual figures deviate from specifications: Repair measures and again perform exhaust emissions test!

AG. Volkswagen AG d agen oes

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♦

by ed isbeen Reconnect all hoses and connections that have discon‐ r ho ut purposes. nected or separated for checking and adjusting a ss

Engine codes: AEE, AER, AEX, AKK, AKV, ALL, ANX, APQ, AUD

Carry out “Control circuit test basic procedure” as follows:

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124 5. Exhaust emissions test

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Activate disturbance variable within 60 seconds as follows:

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

5.1.4

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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♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

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Polo 1995 ➤ Maintenance - Edition 03.2018 – Pull 4-pin connector -1- off coolant temperature sender 00522-2312) - G62- -2-. . Volkswage

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– Reconnect 4-pin connector.

Note

When connecting the connector always ensure that it is fitted properly and engages noticeably.

Note

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The control unit must recognise deactivation of the disturbance variable and eliminate through regulation within 60 seconds.

♦ The control circuit test is also passed when the disturbance c o p yri gh t .

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♦ If the disturbance variable has not been recognised (lambda

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change insufficient) repeat lambda control circuit test.

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variable has been recognised in one direction and has been eliminated through regulation.

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

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.

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If actual figures deviate from specifications: Repair measures and again perform exhaust emissions test!

After completing exhaust emissions test note the following:

♦ 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.

5.1.5

Engine code: AFK

Carry out “Control circuit test basic procedure” as follows: Activate disturbance variable within 60 seconds as follows:

5. Exhaust emissions test

125

Polo 1995 ➤ Maintenance - Edition 03.2018 – 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.

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.

– Fit connector on coolant temperature sender - G62- with cool‐ ant temperature sender - G2- .

Note

When connecting the connector always ensure that it is fitted properly and engages noticeably.

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n AG d A agen The control unit must recognise deactivation of the disturbance oes ksw not l o V regulation within 60 seconds. gu variable and eliminate through by a

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♦ 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.

5.1.6

Engine code: AFH

Carry out “Control circuit test basic procedure” as follows:

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C op yi

126 5. Exhaust emissions test

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– Activate disturbance variable within 60 seconds as follows:

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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

After completing exhaust emissions test note the following:

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r If actual figures deviate ho from specifications: Carry out repair ut a measures and again perform exhaust emissions test! ss

Polo 1995 ➤ Maintenance - Edition 03.2018 Volkswagen AG AG.coolant – Pull 4-pin connectorwa-1temperature sender - G62genoff does s k not l o with coolant temperature sender G2-2-.

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tee and ris must recognise the disturbance variable The controlthounit or u ac a eliminates through regulation within 60 seconds.

Note

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– Reconnect 4-pin connector.

Note

When connecting the connector always ensure that it is fitted properly and engages noticeably.

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Note

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♦ The control circuit test is also passed when the disturbance

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

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.

variable has been recognised in one direction and has been eliminated through regulation. ht rig py Co t.

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♦ If the disturbance variable has not been recognised (lambda

change insufficient) repeat lambda control circuit test. agen lksw Vo by

AG.

If actual figures deviate from specifications: Repair measures and again perform exhaust emissions test!

After completing exhaust emissions test note the following: ♦ 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.

5.1.7

Engine code: AHW

Carry out “Control circuit test basic procedure” as follows: – Activate disturbance variable within 60 seconds as follows:

5. Exhaust emissions test

127

Polo 1995 ➤ Maintenance - Edition 03.2018 – Pull 4-pin connector -arrow- off coolant temperature sender G62- with coolant temperature sender - G2- .

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.

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–

AG. Volkswagen AG d agen oes ksw not l o gu yV b Fit connector on coolant temperature sender - G62- with cool‐ ara d e nte s i r ant temperature sender - G2- . o eo h ut ra a c s s pe rm itte d

Note

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

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.

Note

♦ The control circuit test is also passed when the disturbance

variable has been recognised in one direction and has been eliminated through regulation.

♦ If the disturbance variable has not been recognised (lambda If actual figures deviate from specifications: Repair measures and again perform exhaust emissions test!

5.1.8

Engine code: AJV

Carry out “Control circuit test basic procedure” as follows: ♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

– Activate disturbance variable within 60 seconds as follows:

128 5. Exhaust emissions test

AG.

♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

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♦ Reconnect all hoses and connections that have been discon‐ nected or separated for checking and adjusting purposes.

ht rig py Co t.

After completing exhaust emissions test note the following:

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change insufficient) repeat lambda control circuit test.

Polo 1995 ➤ Maintenance - Edition 03.2018 – Pull connector -arrow- off coolant temperature sender - G62with coolant temperature sender - G2- .

The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

– Reconnect connector of coolant temperature sender - G62with coolant temperature sender - G2- .

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.

Note ♦ The control circuit test is also passed when the disturbance

variable has been recognised in one direction and has been eliminated through regulation.

♦ If the disturbance variable has not been recognised (lambda

change insufficient) repeat lambda control circuit test.

If actual figures deviate from specifications: Repair measures and again perform exhaust emissions test!

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tg yV After completing exhaust d b emissions test note the following: uar

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Engine code: ALD

Carry out “Control circuit test basic procedure” as follows:

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– Activate disturbance variable within 60 seconds as follows:

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

5.1.9

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

♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

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tho ♦ Reconnect all hoses and connections that have been discon‐e or ac au s nected or separated for checking and adjusting purposes. s

5. Exhaust emissions test

129

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Polo 1995 ➤ Maintenance - Edition 03.2018 – 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. . Volkswage

n AG d en AG – Fit connector on coolant sender o-esG62- with cool‐ wagtemperature not olks - G2- .

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Note

If disturbance variable has not been recognised, repeat Lambda control circuit test.

If actual figures deviate from specifications: Repair measures and again perform exhaust emissions test!

After completing exhaust emissions test note the following: ♦ 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.

5.1.10

Engine code: APE

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– Activate disturbance variable within 60 seconds as follows:

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130 5. Exhaust emissions test

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Carry out “Control circuit test basic procedure” as follows:

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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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tee r The control unit ho must recognise deactivation of the disturbance or ut a a variable and ss eliminate through regulation within 60 seconds. c

Polo 1995 ➤ Maintenance - Edition 03.2018 – 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.

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.

– Fit connector on coolant temperature sender - G62- with cool‐ ant temperature sender - G2- .

Note

When connecting the connector always ensure that it is fitted properly and engages noticeably.

The control unit must recognise deactivation of the disturbance olkswagen Awithin variable and eliminate through regulation 60 seconds. .V Gd gen AG a lksw

oes n

ot g o y V test is also completed when the ♦ The control circuit uadisturbance db ran e is been recognised only in one direction. variable has tee r o

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♦ 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.

5.1.11

Engine code: ARC

Carry out “Control circuit test basic procedure” as follows:

do c um en

ht rig py Co t.

r fo ng

– Activate disturbance variable within 60 seconds as follows:

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

After completing exhaust emissions test note the following:

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ac a If actualssfigures deviate from specifications: Carry out repair measures and again perform exhaust emissions test!

5. Exhaust emissions test

131

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AG.

Prote cted by c o p yri gh t.

C op yi

Polo 1995 ➤ Maintenance - Edition 03.2018 – 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.

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.

– Fit connector on coolant temperature sender - G62- with cool‐ ant temperature sender - G2- .

Note

When connecting the connector always ensure that it is fitted properly and engages noticeably. ♦ The control circuit test is also completed when the disturbance variable has been recognised only in one direction.

AG. Volkswagen AG d oes not gu ara e nte ris o eo h have been discon‐ Reconnect all hoses and connections that t u ra a c nected or separated for checking andssadjusting purposes.

n If actual figures deviate from specifications: Carry outlksrepair wage o V y measures and again perform exhaust emissionsd btest!

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♦

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5.1.12

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

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♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

Engine codes: AUA, AUB

Carry out “Control circuit test basic procedure” as follows:

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132 5. Exhaust emissions test

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– Activate disturbance variable within 60 seconds as follows:

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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

– Pull 4-pin connector off coolant temperature sender - G62with coolant temperature sender - G2- -arrow-.

Note

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

The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

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.

– Fit connector on coolant temperature sender - G62- with cool‐ ant temperature sender - G2- .

Note

r fo ng

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AG.

If actual figures deviate from specifications: Carry out repair measures and again perform exhaust emissions test!

ht rig py Co t.

♦ The control circuit test is also completed when the disturbance variable has been recognised only in one direction.

do c um en

When connecting the connector always ensure that it is fitted properly and engages noticeably.

♦ 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.

5.1.13

Engine code: AUC

Carry out “Control circuit test basic procedure” as follows: – Activate disturbance variable within 60 seconds as follows:

5. Exhaust emissions test

133

Polo 1995 ➤ Maintenance - Edition 03.2018 – 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.

Note olkswagen AG en AG. V does not gu ara nte eo ra c

ag The throttle valve must not be operated during the test, otherwise ksw Vol y b the disconnected connector will be recognised as faulteby d the selfris diagnosis and stored in the fault memory. tho au ss

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– Fit connector on coolant temperature sender - G62- with cool‐ ant temperature sender - G2- .

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

When connecting the connector always ensure that it is fitted properly and engages noticeably. ♦ The control circuit test is also completed when the disturbance variable has been recognised only in one direction.

If actual figures deviate from specifications: Carry out repair measures and again perform exhaust emissions test! ♦ Reconnect all hoses and connections that have been discon‐ nected or separated for checking and adjusting purposes. r te o iva r rp fo g n

Exhaust emissions test for petrol en‐ gines with OBD Prote cted by

♦ Exhaust gas testing station L - VAS 7320 ANote ♦ 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.

•

For bar code reading the EET data sheet must be printed out.

134 5. Exhaust emissions test

AG.

Special tools and workshop equipment required

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Vehicles which are fitted with or without “Onboard diagnosis” can be found in the engine list ⇒ page 1 .

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♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

Polo 1995 ➤ Maintenance - Edition 03.2018 •

Automatic gearbox: selector lever in position “P” or “N”.

•

Manual gearbox: gear lever in neutral

•

Parking brake applied

•

12V battery fully charged (if battery charge is too low, raise idling speed if necessary).

– Perform exhaust emissions test according to instructions on display.

Vehicle data input – Enter the following ndata: AG. Volkswagen A

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lk Vonumber ♦ Registration by d se

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ss ♦ Vehicle identification number

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♦ Fuel type

The following vehicle data can be found in the vehicle registration certificate part 1:

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♦ Registration number: “e.g. WOB-HH 1234” ♦ Emission key number “Field 14.1 (code for field 14)”

♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)” ♦ Vehicle identification number “field E”

♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for field D.2)” Specified data input for EET ♦ 1. By manual input ♦ 2. By bar code input from EET data sheet ♦ 3. Through ELSA web service agen lksw Vo by

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Note

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There are different ways to enter the specified data:

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♦ Mileage

♦ 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

All test conditions and data required for exhaust emissions test can be found in the ⇒ Data sheets for exhaust emissions test for respective engine.

– 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:

5. Exhaust emissions test

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Polo 1995 ➤ Maintenance - Edition 03.2018 1-

Test speed (idling speed)

2-

Warm-up phase for catalytic converter

3-

Engine temperature

4-

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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5-

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6-

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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.

Inspection

– Inspect all exhaust emissions relevant components.

– Check if exhaust system is fitted and complete and check for leaks and damage.

Procedure

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Engine codes: AQQ, AVY

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Carry out “Control circuit test basic procedure” as follows: AG.

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136 5. Exhaust emissions test

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– Activate disturbance variable within 60 seconds as follows:

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5.2.1

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– Follow instructions from exhaust gas testing station .

Polo 1995 ➤ Maintenance - Edition 03.2018 – 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.

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.

– Fit connector on coolant temperature sender - G62- with cool‐ ant temperature sender - G2- .

Note

When connecting the connector always ensure that it is fitted properly and engages noticeably. en AG. Volkswagen AG

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♦ Reconnect all hoses and connections that have been discon‐ nected or separated for checking and adjusting purposes.

Exhaust emissions test for diesel en‐ gines without OBD

Exhaust emissions test for diesel engines without OBD with emis‐ sions testing station VAS 6300 ⇒ page 144

Exhaust emissions test for diesel en‐ gines without OBD with diesel tester V.A.G 1743

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5.3.1

Special tools and workshop equipment required ♦ Diesel tester - V.A.G 1743-

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5.3

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♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

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does ag ksw not Vol gu y b ar d If actual figures deviate from ise specifications: Repair measures andante r o eo again perform exhaust emissions test! h t ra au c s s After completing exhaust emissions test note the following:

5. Exhaust emissions test

137

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d Polo 1995 ➤ e nte is r o eo h Maintenance - Edition 03.2018 ut ra a c s s

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♦ Engine speed adapter - VAS 5087-

Note

♦ All test conditions and data required for emissions test ⇒ Data

sheets for exhaust emissions test

AG.

♦ 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, ⇒ Data sheets for ex‐ haust emissions test – Performing visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

With ignition switched off, connect testers as follows: – Apply handbrake.

– Manual gearbox: gear lever in neutral.

138 5. Exhaust emissions test

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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.

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♦ If possible, the test should be completed outdoors following a

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♦ Adapter cable - VAS 5087/3-

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

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Connect engine speed adapter - VAS 5087- as follows: Note

♦ Observe ⇒ operating instructions for engine speed adapter -

VAS 5087- !

♦ Strictly follow the safety precautions in the operating instruc‐

tions!

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– Using adapter cable - VAS 5087/3- , connect “Output” of en‐ gine speed adapter - VAS 5087- to pick-up clamp input of diesel tester - V.A.G 1743- .

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

– Connect diesel tester - V.A.G 1743- according to operating instructions with ignition switched off.

Polo 1995 ➤ Maintenance - Edition 03.2018

– Turn switch for number of cylinders to respective number of cylinders. ht rig py Co t.

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– Connect a wire from adapter - VAS 5087/1- to -VAS 5087(socket -VAS 5087/1- ). agen lksw Vo by

– Using the other wires from adapter - VAS 5087/1- make a connection to the vehicle battery, by connecting: AG.

♦ Red clamp to positive ♦ Black clamp to negative – Start engine and run it at idling speed.

– Press the Start button on engine speed adapter - VAS 5087- . The red signal lamp must flash for about 10 seconds.

Then the green signal lamp must light up.

The engine speed must now be displayed on diesel tester V.A.G 1743- .

If the engine speed is displayed incorrectly or not at all: ⇒ Oper‐ ating instructions for VAS 5087 .

Perform exhaust emissions test according to instructions on die‐ sel tester - V.A.G 1743- display.

If this message appears on the display: Please insert vehicle identity card!!

Manual input with -> button

5. Exhaust emissions test

139

Polo 1995 ➤ Maintenance - Edition 03.2018

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♦ Registration number

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–

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran Enter vehicle identification data from vehicle identification ir se tee o documents using keyboard as follows h (press <-' button after t or u ac a each entry): ss

♦ Vehicle manufacturer -A♦ Vehicle type -C-

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

♦ Key number -B-

♦ Key number -D- (the first 3 digits) ♦ For vehicle identification number (chassis number) -E♦ Engine code

– Enter odometer reading using keyboard.

– Confirm entry of vehicle identification data by pressing Q but‐ ton.

Check input with -> button Continue with Q button

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– 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

– Confirm vehicle data entered or read using Q button.

If this message appears on the display: Visual check OK = y not OK = n

– Enter result of visual check.

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.

Checking idling speed: If this message appears on the display: Idling speed -> Speed ACT. xxxx rpm SPEC. xxxx rpm

– Press → button.

Idling speed not within specified range:

140 5. Exhaust emissions test

AG.

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– Enter specifications with bar code reader of data reader, to do this slide bar code reader over respective bar code of data sheet in ⇒ Data sheets for exhaust emissions test binder.

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Read bar code Manual input with the -> button

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If this message appears on the display:

Polo 1995 ➤ Maintenance - Edition 03.2018 Adjusting idling speed, engine code AEF: – Adjust idling speed by turning the idling speed adjustment screw -1-.

Note

The bolt -2- must on no account be turned!

Adjusting idling speed, engine codes AGD, AHG, AKU,AMF, Volkswa gen AG . gen AG does ASX: swa

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Note

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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.

Continued for all vehicles: Checking rev limit:

– 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

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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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If the rev limit is exceeded, lift off accelerator pedal immediately and adjust rev limit to specification or perform repair measures.

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WARNING

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– Depress accelerator pedal fully and hold for specified time.

– Release accelerator pedal.

– Check actual figures, to do this switch further the actual display using → button.

Rev limit not within specified range: Adjusting rev limit: engine code AEF – Remove locking wire and plastic protective cap.

5. Exhaust emissions test

141

Polo 1995 ➤ Maintenance - Edition 03.2018 – Open the throttle and adjust speed by turning the adjustment screw -1-.

– Lock adjustment screw.

– Fit plastic protective cap and secure with locking wire.

Adjusting rev limit: engine codes AGD, AHG, AKU,AMF, ASX – If the values are not within specified range, a repair measure must be made.

Continued for all vehicles: – 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

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.

If this message appears on the display:

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Idling speed 2nd measurement 15 sec olksw V Speed ACT. xxxx rpm SPEC. xxx...xxxx by rpm

–

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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.

If this message appears on the display: Idling speed 3rd measurement 15 sec Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm

– Release accelerator pedal.

If this message appears on the display: c o p yri gh t.

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Data transfer to diesel tester Depress accelerator quickly

AG.

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142 5. Exhaust emissions test

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– Depress accelerator pedal fully and hold.

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The data reader accepts the actual figures within 15 seconds.

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The data reader accepts the actual figures within 15 seconds.

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ed ris o h t Release accelerator pedal. au ss

Polo 1995 ➤ Maintenance - Edition 03.2018 Indicated on display: Data transfer to diesel tester Neutral accel. running

– Continue to depress and hold accelerator pedal.

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 edisplay: n AG. Volkswagen AG ag lksw

Vo Data transfer to dieselbytester d Depress acceleratorsequickly

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–

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Indicated on display:

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Data transfer to diesel tester Neutral accel. running

– Continue to depress and hold accelerator pedal.

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:

– Press → button.

If this message appears on the display: Prote cted by c o p yri gh t.

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AG.

If this message appears on the display:

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– Press → button.

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Opacity band width -> ACT. x.xx rpm SPEC. x...x.xx rpm

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Average opacity figure -> ACT. x.xx rpm SPEC. x...x.xx rpm

Test OK Continue with Q button Repeat test with F1 button

– 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.

5. Exhaust emissions test

143

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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 Polo u1995 ➤ t ra a c s Maintenance - Edition 03.2018 s

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.

– Press → button.

– End test by pressing the F2 button.

5.3.2

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Caution

Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐ CAUTIONS” in the operating instructions for VAS 6300. agen lksw Vo by

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Note

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•

Exhaust emissions test for diesel en‐ gines without OBD with emissions test‐ ing station VAS 6300

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If this message appears on the display:

The following description refers to vehicles not fitted with “On‐ board diagnosis”, OBD. Special tools and workshop equipment required ♦ Emissions testing station - VAS 6300-

♦ OBD adapter cable - VAS 5052/16Note ♦ It is only possible to carry out an exhaust emissions test when

all units of the emissions testing 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 emissions testing

station - VAS 6300- .

Prerequisites for testing: •

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.

144 5. Exhaust emissions test

Polo 1995 ➤ Maintenance - Edition 03.2018 AG. Volkswagen AG d agen oes

Automatic gearbox: selector lever in position “P” or “N”.Volksw

•

Manual gearbox: gear lever in neutral

•

Parking brake applied

ss

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•

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Initial screen:

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– Perform exhaust emissions test according to instructions on display.

– Select button “Exhaust emissions test” -arrow-.

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– Select “EET diesel” -arrow-.

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An overview is displayed to select the respective EET type.

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The display for warm-up phase appears.

5. Exhaust emissions test

145

Polo 1995 ➤ 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, n AG. Volkswagen AG do es n wage either select “Standard values”, o olks V by

ed ♦ Or “Last vehicle” when an exhaust ris emissions test is to be car‐ ho ried out again. t u

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– Select “Continue” -item 1- on display.

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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.

♦ For new models the document previously known as the vehicle

log book is now called the vehicle registration certificate part 2.

♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ♦ -2- Vehicle type: “e.g. Golf” ♦ -4- Key number to 2: “e.g. 0603” (vehicle registration docu‐ ment) Prote cted by c o py rig ht .

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♦ -4- Key number to 2.1 (code to 2): “e.g. 0603” (vehicle regis‐ tration certificate part 1)

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♦ -5- Key number to 3: “e.g. 358” (vehicle registration document) ♦ -5- Key number for 2.2 (code to D2): “e.g. 358” (vehicle regis‐ tration 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 at -item 9- “e.g. 32000”.

Note ♦ Further functions can be called up using GoTo button. ♦ The test can be interrupted using GoTo button.

146 5. Exhaust emissions test

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♦ -3- Key number to 1: “e.g. 11”

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Vehicle data input:

Polo 1995 ➤ Maintenance - Edition 03.2018 – Select “diesel below 3.5t” or “diesel above 3.5t” -arrow-.

Specified data input for EET: There are different ways to enter the specified data: AG. Volkswagen AG d agen oes ksw not l o gu yV b ara dsheet e 2. By bar code input from EET data nte is r o eo th u ra a 3. Through ELSA web services c s

♦ 1. By manual input ♦

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♦

Note

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♦ To use the ELSA web service, the diagnostic tester which is

used for the exhaust emissions test, must be integrated in the workshop network.

♦ For the ELSA web service the vehicle specified data are au‐

tomatically transmitted via the network to the respective mask.

Manual specified data input for EET: Note

– Perform manual data input according to instructions on dis‐ play.

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)

AG.

Speed for conditioning

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1-

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– Enter displayed values on EET data sheet in column “Test values for exhaust emissions test” on display as follows:

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All test conditions and data required for exhaust emissions test ⇒ Data sheets for exhaust emissions test for respective engine.

10 - Select measuring mode 11 - Measured period portion – When all data have 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

147

Polo 1995 ➤ Maintenance - Edition 03.2018 All required data is shown on display -1-.

– Press → button -arrow- to continue procedure.

Visual inspection: – Follow instructions on display.

– Perform visual check.

– If visual check is OK, press “OK” button -arrow-.

Note

Pressing "not OK" button causes a check to be carried out.

Connecting diagnostic connector: •

Ignition is switched off.

– Follow instructions on display -arrow A- and -arrow B-.

– Connect diagnostic cable connector to EOBD connection ⇒ page 20 .

Conditioning: – Start engine.

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148 5. Exhaust emissions test

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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.

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AG. Volkswagen AG d agen oes ksw not l o gu The visual check is displayed with the request to connectd bthe y V di‐ ara e nte agnostic connector -arrow Ais r o eo h ut ra a c s s

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– 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.

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♦ This is only indicated on display if engine temperature has not AG.

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♦ Do not insert emission probe into exhaust tail pipe.

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reached 80℃.

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Note

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– Follow instructions on display.

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– Follow instructions on display.

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o Polo 1995 ➤ eo h t u ra a c Maintenance Edition 03.2018 s s

♦ Using button “Alternative input” -arrow- other measured value

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!

– Bring engine to required temperature.

Measuring idling speed: It is automatically switched to display for measuring the idling speed.

5. Exhaust emissions test

149

Polo 1995 ➤ 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-.

Measuring rev limit: It is automatically switched to display for measuring rev limit. . Volkswage Measurement starts when the engine speed has gen AG the re‐ n AG doe areached s no ksw l o t gu quired level.

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The remaining time to perform measurement is displayed -arrow-.

Note

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ri – Operate throttle until the measurement is carried out. To do ho ut a this, immediately depress accelerator pedal. s

♦ 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.

Air quality check:

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. r te o iva r rp fo ng

It is automatically switched to display for “Free acceleration”.

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Free acceleration - phase 1:

150 5. Exhaust emissions test

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The “Free acceleration” test consists of at least four throttle bursts.

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During “Free acceleration” the engine is revved up to rev limit without load as quickly as possible.

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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

Polo 1995 ➤ 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: – Follow instructions on display -arrow B-.

– Depress accelerator pedal fully when prompted and hold until the prompt for idling is shown on display.

Free acceleration - phase 3: – Remove foot from accelerator pedal as soon as the prompt for idling is shown on display -arrow B- and run engine at idling . Volkswagen AG speed. gen AG does swa k Vol

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Note

♦ If the field is coloured white the measured value is within tol‐

erance.

♦ If the field is coloured red the measured value is outside tol‐

erance.

♦ If the field is coloured yellow the measured value is outside

tolerance, but can be assessed by the operator.

Further throttle bursts:

– Follow instructions on display -arrow B-.

Now the next throttle burst follows, starting with phase 1 of “Free acceleration”. ♦ Three “Free accelerations” have been completed in succes‐ sion and the range of acceleration is OK. agen lksw Vo by

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♦ 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).

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Many “Free accelerations” can be carried out until:

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by The test results and information on the latest ed “Free acceleration” ris o are shown on display -arrow A-. If the measured values are not th au the “Free acceleration” OK, here you can obtain information swhy s has failed.

♦ 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

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The test result is displayed.

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 -arrow B- “EET sticker issued” in drop-down menu and date.

– 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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The exhaust emissions test is completed, a new exhaust emis‐ sions test can be performed.

152 5. Exhaust emissions test

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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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When the exhaust emissions test has been performed, the log is shown on display.

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AG. Volkswagen AG d agen oes ksw not l o V Polo 1995 ➤ gu y b ara d nte ise Maintenance - Edition 03.2018 r o eo h t u ra a c s s Evaluation:

Polo 1995 ➤ Maintenance - Edition 03.2018

6

Glossary

These explanations only apply to “Maintenance Manual”. They are not necessarily generally valid!

Term

Explanation

ABS

CN DIN Part no.

EN

(Anti-lock brake system); the ABS is a regulating system in the brake system, that pre‐ vents locking when braking. This helps to maintain directional stability and steerability.

(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 com‐ pletely (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

Term

Explanation

ATF ATF level CO

EOBD FAME FSI TFSI MIL

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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 combi-instrument ♦ Engine oil level sensor ♦ Brake lining wear indicator

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The LongLife service is not factory-activated. This means, vehicles have a non-flexible service 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

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QG2

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♦ Brake lining wear indicator

8-digit binary code which indicates if all exhaust relevant diagnoses have been per‐ formed by the engine management.

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Readiness code

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European Onboard Diagnosis Fatty acid methyl ester Fuel stratified injection Turbo fuel stratified injection (Malfunction indicator light); American designation for exhaust emissions warning lamp K83 OBD Onboard diagnosis, the OBD monitors all components influencing the exhaust emis‐ Volkswagen AG en AG.quality. gsions does a w s k not l o gu yV b OBD-II American Onboard Diagnosis ara d e nte ris o eo h Unit injector Unit injector for diesel engines t u ra c sa s PR No. Abbreviation for production control number. Identifies among other things optional equipment and country-specific deviations PM (Particulate matter); soot particulate value for diesel engine emissions QG0 Vehicles are “not” factory-fitted with components for LongLife service. For maintenance, the intervals based on time and distance (non-flexible intervals) apply.

6. Glossary

153

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Polo 1995 ➤ Maintenance - Edition 03.2018

SD SDI TDI DP ULEV

(Research octane number); measurement unit of the knock resistance of petrol (Society of Automotive Engineers); society which creates proposals/guidelines for im‐ plementing legal requirements (e.g. standards).

Naturally aspirated diesel engine Naturally aspirated diesel direct injection engine Turbodiesel direct injection Distributor injection pump Ultra low emission vehicle

Term

Explanation

ESI Common rail

Extended service interval Refers to a common high-pressure injection line (rail), which supplies all cylinders of the relevant cylinder bank with fuel.

Diesel particulate filter, the particulate filter is installed behind the catalytic converter and filters soot particles of emissions.

The LongLife service enables extremely long inspection or oil change intervals, de‐ 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 “Rest of world”

154 6. Glossary

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TPMS, TPLI RoW

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Broad-band probe

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Step-type probe

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LongLife service

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RON SAE

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Explanation

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Term

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