DOWNLOAD PDF Volkswagen Polo 2002 Maintenance Manual

Service

Maintenance Polo 2002 ➤

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Service Department. Technical Information

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Edition 02.2018

Service Maintenance

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

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6. Glossary

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. agen lksw Vo by

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Copyright © 2018 Volkswagen AG, Wolfsburg

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All rights reserved.

No reproduction without prior agreement from publisher.

P0050352920

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

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

Information on LongLife service and time or distance dependent service . . . . . . . . . . . . . .

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

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

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

Interval service 2008► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection ►2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection service 2008► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time or distance dependent additional work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service intervals with market-specific deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Removable towing bracket: checking and cleaning if necessary . . . . . . . . . . . . . . . . . . . .

Swivel joints and suspension link mountings: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic gearbox: checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic gearbox: changing ATF (09G gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . .

Battery: Checking using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . .

Brake and clutch system: Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Front passenger airbag: checking key switch and “On/Off function” . . . . . . . . . . . . . . . . . .

Tyres: checking condition, wear pattern, tread depth, tyre pressure and age . . . . . . . . . .

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

Brakes, front and rear: checking thickness of brake pads and condition of brake discs . .

Electric windows: Carry out initialisation (activation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle system test: Carry out test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bonnet: greasing arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding multi-purpose additive G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Checking expiry date of first-aid kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . .

Poly V-belt: Checking tension, adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Checking number plate on vehicle bumper (Polo Cross) . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filter: Renewing (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Engine oil level: Check, replenish engine oil if necessary . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 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 4.26 4.27 4.28

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Contents

Contents

1 5 5 7 11 13 14 16 18 20 24 26 26 27 28 29 31 32 32 33 33 34 34 36 37 39 40 40 41 42 42 47 48 49 58 59 63 63 64 64 65 65 65 65 65 66 66 67 69 71 74 75

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Polo 2002 ➤ Maintenance - Edition 02.2018

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ii Contents

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4.52 4.53 4.54 4.55 4.56 5 5.1 5.2 6

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4.35 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 4.49 4.50 4.51

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4.30 4.31 4.32 4.33 4.34

Engine and components in engine compartment: inspecting for leaks and damage (from above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Removing and installing engine cover panel -top- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Removing and installing engine cover -bottom- (noise insulation) . . . . . . . . . . . . . . . . . . . . 84 Road test: performing (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 85 Wheel securing bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Radio/radio navigation system: entering PIN of anti-theft coding and storing local radio stations to station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Radio code: reading using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Tyre repair set: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Tyre Pressure Loss Indicator: performing basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Manual gearbox/final drive: Checking oil level, replenishing oil if necessary . . . . . . . . . . . . 90 Window wiper and washer system and headlight washer system: Checking function . . . . 90 Wiper blade protection: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Headlight adjustment: Check, adjust headlights if necessary . . . . . . . . . . . . . . . . . . . . . . 98 Sunroof: checking function, cleaning and greasing guide rails . . . . . . . . . . . . . . . . . . . . . . 103 Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Service interval display: recoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 107 Dust and pollen filter: renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Door arrester: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Transportation device: Remove blocking pieces from front axle springs . . . . . . . . . . . . . . 109 Recoding dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Clock: setting to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Underseal: inspecting for damage to underseal, underbody cladding, routing of lines and plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Toothed belt and tensioning roller: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Camshaft drive toothed belt: Renewing (4-cylinder 5-valve petrol engine) . . . . . . . . . . . . 112 Camshaft drive toothed belt: Checkn(4-cylinder petrol . Volkswage n AG d engine) not for engine code AXU . . 112 ge AG Renewing spark plugs . . .Vo. lk.s.w.a . . . . . . . . . . . . . . . .oe. s.n.ot. . . . . . . . . . . . . . . . . . . . . . . . . . 112 gu y db Diesel particulate filter:isecheck. . . . . . . . . . . . . . . . . . . . . . . a. ra. n. . . . . . . . . . . . . . . . . . . . . . 119 tee r ho Exhaust emissionsauttest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . . 120 ss test for petrol engines . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . 120 Exhaust emissions Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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Polo 2002 ➤ Maintenance - Edition 02.2018

1

Engine list

(VIGG001120; Edition 02.2018) This chapter provides information on the following subjects: ♦ Petrol engines ⇒ page 1 ♦ Diesel engines ⇒ page 3 Note

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

Petrol engines ⇒ I

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

min.

Camshaft drive

Petrol engine AUA 1,4

Petrol engine AUB 1,4

Petrol engine AWY 1,2

Petrol engine AXU 1,4

4/4

4/4

3/2

4/4

55/5000 126/3800 76,5 75,6 10,5 Magneti Marelli 4MV manifold inj.

74/6000 128/4400 76,5 75,6 10,5 Magneti Marelli 4MV manifold inj. olksw

40/4750 106/3000 76,5 86,9 10,8 Simos 3 PD manifold inj.

63/5000 130/3750 76,5 75,6 10,5 Motronic MED 7.5.11 FSI

oes 2) not 98 unleaded 95 unleaded1) gu ara Toothed belt Chain nte

98 unleaded2) Chain

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

Petrol engine BBU 1,8

Petrol engine BBY 1,4

3/4

3/2

4/5

4/4

47/5400 112/3000 76,5 86,9 10,4 Simos 3 PD manifold inj.

44/5200 108/3000 76,5 86,9 10,3 Simos 9.1 manifold inj.

95 unleaded1)

95 unleaded1)

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RON

Petrol engine BBM 1,2

min.

AG.

I

Petrol engine AZQ 1,2

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Engines Engine code Displace‐ ment

132/5800 55/5000 235/1950 to 5000 126/3800 81,0 76,5 86,4 75,6 9,5 10,5 Motronic ME 7.5 Magneti Marelli manifold inj.

4MV manifold inj. in t his d o cu m en

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2) In exceptional circumstances at least 95 RON permitted, but with reduced out‐ put

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Engines Engine code Displace‐ ment

98 unleaded2)

95 unleaded1) 1. Engine list

1

Polo 2002 ➤ Maintenance - Edition 02.2018 Engines Engine code Displace‐ ment

⇒ I

Petrol engine AZQ 1,2

Petrol engine BBM 1,2

Petrol engine BBU 1,8

Petrol engine BBY 1,4

Chain

Chain

Toothed belt

Toothed belt

Camshaft drive

1) In exceptional circumstances at least 91 RON permitted, but with reduced out‐ put 2) In exceptional circumstances at least 95 RON permitted, but with reduced out‐ put

Engines Engine code Displace‐ ment

⇒ I

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

Petrol engine BBZ 1,4

Petrol engine BJX 1,8

Petrol engine BKY 1,4

Petrol engine BMD 1,2

4/4

4/5

4/4

3/2

55/5000 126/3800 76,5 75,6 10,5 Magneti Marelli 4TV manifold inj.

40/4750 108/3000 76,5 86,9 10,3 Simos 9.1 manifold inj.

ua ran 95 unleaded1) 95 unleaded1) tee or Toothed belt Toothed belt a

95 unleaded1) Chain

74/6000 110/5500 128/4400 220/2000 76,5 81,0 75,6 86,4 10,5 9,5 Magneti Marelli Motronic ME 7.5 4MV G. Volkswagemanifold inj. n AG d A agen inj. manifold oes n lksw Vo

RON

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ss 1) In exceptional circumstances at least 91 RON permitted, but with reduced out‐ put es, in part or in w l purpos hole ercia , is n m ot com

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Camshaft drive

2 1. Engine list

Petrol engine BZG 1,2

3/4

4/4

4/4

3/4

47/5400 112/3000 76,5 86,9 10,5 Simos 9.1 manifold inj.

77/5600 153/3800 76,5 86,9 10,5 Motronic ME 7.5.20 manifold inj.

59/5000 132/3800 76,5 75,6 10,5 Magneti Marelli 4HV manifold inj.

51/5400 112/3000 76,5 86,9 10,5 Simos 9.1 manifold inj.

95 unleaded1) Chain

951 Chain

951 Toothed belt

95 unleaded1) Chain

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RON

Petrol engine BUD 1,4

min.

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

Petrol engine BTS 1,6

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Petrol engine BME 1,2

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Engines Engine code Displace‐ ment

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2) In exceptional circumstances at least 95 RON permitted, but with reduced out‐ put

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I

Engines Engine code Displace‐ ment

⇒ I

3/2

4/2

4/2

55/4000 195/2200

47/4000 125/1600 to 2800

96/4000 310/1900

79,5 95,5 19,5 TDI unit injector

79,5 95,5 19,0 TDI unit injector

No Toothed belt

79,5 86,4 19,5 (SDI) Nat. aspirated diesel direct injection No Toothed belt

74/4000 240/1800 to 2400 79,5 86,4 19,0 TDI unit injector

No Toothed belt

No Toothed belt

Diesel engine AXR 1,9

Diesel engine BAY 1,4

Diesel engine BLT 1,9

Diesel engine BMS 1,4

3/2

4/2

3/2

55/4000 195/2200 79,5 95,5 19,5 TDI unit injector No Toothed belt

96/4000 310/1900 79,5 95,5 19,0 TDI unit injector No Toothed belt

59/4000 195/2200 79,5 95,5 19,5 TDI unit injector Yes Toothed belt

Diesel engine BMT 1,9

Diesel engine BNM 1,4

Diesel engine BNV 1,4

Diesel engine BWB 1,4

4/2

3/2

3/2

3/2

74/4000

51/4000

59/4000

51/4000

No. of cylinders/valves per 4/2 cylinder Power kW at rpm 74/4000 Torque Nm at rpm 240/1800 to 2400 Bore ∅ mm 79,5 Stroke mm 95,5 Compression ratio 19,0 Injection/ignition TDI unit injector Diesel particle filters No Camshaft drive Toothed belt

Engines Engine code Displace‐ ment

⇒ I

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

AG.

Diesel particle filters Camshaft drive

Diesel engine ASZ 1,9

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Bore ∅ mm Stroke mm Compression ratio Injection/ignition

Diesel engine ASY 1,9

Diesel engine ATD 1,9

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

Diesel engine AMF 1,4

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Engines Engine code Displace‐ ment

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

Diesel engines

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2) In exceptional circumstances at least 95 RON permitted, but with reduced out‐ put

4/2

1. Engine list

3

Polo 2002 ➤ Maintenance - Edition 02.2018 Diesel engine BMT 1,9

Diesel engine BNM 1,4

Diesel engine BNV 1,4

Diesel engine BWB 1,4

Nm at rpm

240/1800

155/2200

195/2200

Bore ∅ mm Stroke mm Compression ratio Injection/ignition

79,5 95,5 19,0 TDI unit injector Yes Toothed belt

79,5 95,5 19,5 TDI unit injector No Toothed belt

79,5 95,5 19,5 TDI unit injector No Toothed belt

155/1600 to 2800 79,5 95,5 19,5 TDI unit injector Yes Toothed belt

Torque

⇒ I

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4 1. Engine list

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

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Diesel particle filters Camshaft drive

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Engines Engine code Displace‐ ment

Polo 2002 ➤ Maintenance - Edition 02.2018

2

Service work

This chapter provides information on the following subjects: Information on LongLife service and time or distance dependent service ⇒ page 5 Service tables ⇒ page 7 Delivery inspection ⇒ page 11 Oil change service ⇒ page 13 Interval service 2008► ⇒ page 14 Inspection ►2007 ⇒ page 16 Inspection 2008► ⇒ page 18 Time or distance dependent additional work ⇒ page 20 olkswagen AG Service intervals with market-specific deviations ⇒gepage n AG. V24 d

2.1

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Service identification ⇒ page 5 LongLife service ⇒ page 5

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Time or distance dependent service ⇒ page 6 Service interval display ⇒ page 6

2.1.1

Service identification

– Check vehicle data sticker ⇒ page 32 to determine whether the vehicle is equipped with PR number “QG0”, “QG1” or “QG2”. The PR number is decisive for the service intervals. ⇒ page 8 Vehicle IDs with the following PR number “QG1” indicates LongLife service “QG0” or “QG2” indicates time or distance dependent service.

LongLife service

Vehicles with PR number “QG1”

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The LongLife service enables long service intervals, depending on individual driving style and the conditions under which the ve‐ hicle is used.

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2.1.2

For the LongLife service a special LongLife engine oil is required ⇒ page 9 Vehicles with PR number “QG1” are fitted at the factory with active LongLife service. This means that these vehicles have a flexible service interval display and are fitted with the following compo‐ nents: ♦ Flexible service interval display in dash panel insert ♦ Engine oil level sensor ♦ Brake pad wear indicator (if fitted)

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Polo 2002 ➤ Maintenance - Edition 02.2018

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara dis deter‐ e For vehicles with LongLife service the service interval nte is r o eo h interval mined by the control unit and is indicated on service ut ra a c display (SID) ⇒ page 6 . s s 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

Therefore the service intervals for LongLife service are flexible.

2.1.3

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These flexible service intervals apply to all types of service in‐ cluding an engine oil change.

Time or distance dependent service

For vehicles with time or distance dependent service with PR number “QG0/QG2” the non-flexible service intervals are set by Volkswagen according to predetermined mileage or time values.

For normal operating conditions achieving these service intervals is technically assured.

Therefore the service intervals for time or distance dependent service are non-flexible.

For vehicles

♦ Which were delivered without extended servicing intervals (ESI) (PR number “QG0” = without ESI, PR number “QG2” = ESI cannot be activated) r fo ng

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the time or distance dependent service applies.

Vehicles are “not” factory-fitted with components for LongLife service. For maintenance the time or distance dependent inter‐ vals (non-flexible intervals) apply.

Vehicles with PR number “QG2” For these vehicles the LongLife service is not factory-activated.

Therefore, these vehicles have a non-flexible service interval dis‐ play (SID) ⇒ page 6 and for maintenance the time or distance dependent intervals (non-flexible intervals) apply. These vehicles are fitted with the following components: ♦ Non-flexible service interval display in dash panel insert ♦ Engine oil level sensor ♦ Brake pad wear indicator (if fitted)

2.1.4

Service interval display

Introduction of extended servicing intervals (ESI) ⇒ page 6 Flexible service interval display (only vehicles with LongLife serv‐ ice, PR number QG1) ⇒ page 6 Non-flexible service interval display (only vehicles with time or distance dependent service intervals, PR number “QG0/QG2)” ⇒ page 7 Service interval display: resetting ⇒ page 103 Service interval display: recoding ⇒ page 106 Introduction of extended servicing intervals (ESI) Ask your importer if the extended servicing interval (ESI) is avail‐ able for your country.

6 2. Service work

AG.

Vehicles with PR number “QG0”

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These non-flexible service intervals apply to all types of service including an engine oil change.

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♦ When no LongLife engine oil was used

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♦ or for which the extended servicing interval (ESI) was stopped

Polo 2002 ➤ Maintenance - Edition 02.2018 Flexible service interval display (only vehicles with LongLife serv‐ ice, PR number QG1) Calculation of service intervals: ♦ To calculate the service intervals for vehicles with LongLife service, input values such as distance driven, fuel consump‐ tion, oil temperature and load of diesel particulate filter are evaluated. ♦ The result of the evaluation is a value for the deterioration of the oil due to thermal loading. ♦ The oil deterioration is the deciding factor concerning the dis‐ tance that can still be driven to the next service.

Note

For vehicles with LongLife service (PR number QG1) but which are serviced according to time or distance dependent intervals, the service interval display need not be recoded to “non-flexible” ⇒ page 106 .

Non-flexible service interval display (only vehicles with time or distance dependent service intervals, PR number “QG0/QG2”) Calculation of service intervals: ♦ To calculate the service interval for vehicles with time or dis‐ tance dependent service, the non-flexible service intervals are set by Volkswagen according to predetermined mileage or time values. ♦ For normal operating conditions achieving these service in‐ tervals is technically assured.

2.2

Service tables

Service intervals ⇒ page 8 VW engine oil standards ⇒ page 9

AG. Volkswagen AG d agen oes ksw not l o gu yV Filter change intervals ⇒ page 10 b ara d e nte is r o eo h Toothed belt change intervals ⇒ page ut 10 ra a c s s

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Spark plug change intervals ⇒ page 11

♦ For combined kilometre and time display applies: whichever

occurs first.

♦ Depending on conditions under which the vehicle is used

⇒ page 34 and vehicle equipment, extra service work must be performed in addition to the interval service, inspection service or interval service inspection.

♦ It is also possible, to perform additional work outside the serv‐

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ice intervals with regard to the entries in the service schedule (or sticker: your next service).

2. Service work

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Polo 2002 ➤ Maintenance - Edition 02.2018

2.2.1

SERVICE INTERVALS Caution

Applies only to diesel engines •

In some countries, diesel has a higher sulphur content.

•

The high sulphur content leads to excessive wear of cyl‐ inders and it considerably reduces the cleanliness of pis‐ tons.

♦ Therefore change engine oil every 7,500 km in countries where the diesel has a high sulphur content. ♦ Countries where diesel has a high sulphur content. ⇒ page 32

Note ♦ If an extremely uneconomical driving style is adopted or the

vehicle is used in extreme conditions ⇒ page 34 , the short‐ est interval for an oil change service is “7,500 km or 1 year”.

♦ However, other intervals apply for other countries. Your im‐

porter will inform you about this.

from-to

POLO 2002► SERVICE INTERVALS ►2007 Engine/Engine code/ Service/intervals PR No./Remarks

Diesel in countries where sul‐ Oil change service YES phur content in fuel is high every 7,500 km or 1 ayear n AG. Volkswagen AG do e g es n ksw ⇒ page 32 ot g Vol ua by d e Petrol and diesel: Oil change YESrante risservice o eo h t QG0/QG2 or QG1 vehicles every 15,000 km or 1 year ra au c s coded to non-flexible interval Inspection: s time or distance de‐ YES pendent every 30,000 km or 2 years Petrol: QG1 Inspection service: LongLife YES flexible from 15,000 km to max.

30,000 km or 2 years From in‐ Diesel: QG1 Inspection service: LongLife YES troduc‐ flexible from 15,000 km to max. tion 50,000 km or 2 years ►2005 2006►20 Diesel: QG1 Inspection service: LongLife YES 07 flexible from 15,000 km to max.

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Since in‐ Diesel in countries where sul‐ Oil change service troduc‐ phur content in fuel is high every 7,500 km or 1 year ⇒ page 32 tion

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Engine/Engine code/ PR No./Remarks

POLO 2002► SERVICE INTERVALS 2008► Service/intervals

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Since in‐ troduc‐ tion From in‐ troduc‐ tion ►2007

Indicated on service interval display SID (includes oil change)

Polo 2002 ➤ Maintenance - Edition 02.2018

from-to

POLO 2002► SERVICE INTERVALS 2008► Service/intervals

Engine/Engine code/ PR No./Remarks

Indicated on service interval display SID (includes oil change)

th au s s

YES NO

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YES

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For combined kilometre and time display applies: whichever oc‐ curs first.

2.2.2

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2008► Petrol and diesel: Oil change service QG0/QG2 or QG1 vehicles every 15,000 km or 1 year coded to non-flexible interval Interval service: every 30,000 km or 2 years Petrol and diesel: Interval service: QG1 vehicles flexible from 15,000 km or 1 year up to max. 30,000 km or 2 years Petrol and diesel: n AG. VInspection olkswagen AGservice: does age w all vehicles after 3 years/max. s k no 60,000 km, Vol y ua every then every 2 yearst gor b d ran ise tee 60,000 km r o

VW ENGINE OIL STANDARDS Caution

Only engine oils approved by VW may be used, up-to-date in‐ formation ⇒ ServiceNet, Technical information, Inspection and maintenance, Approved oils r te o iva r rp fo ng

3 and 4-cylinder en‐ gines ►2007 3 and 4-cylinder en‐ gines 2008►

501 01/502 00

507 001 alternative 3 506 01

Diesel engines without diesel particulate filter

505 01

507 001)

Diesel engines with diesel particulate filter

507 001)

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Diesel engines with diesel particulate filter

503 00

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DIESEL ENGINES Diesel engines without diesel particulate filter

Without LongLife service (QG0, QG2)

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POLO 2002► VW ENGINE OIL STANDARDS

502 00

1) Combination product: 504 00/507 00 2) Combination product: 503 00/506 00 3) Combination product: 503 00/506 00/506 01

2. Service work

9

Polo 2002 ➤ Maintenance - Edition 02.2018 Note

Vehicles with retrofitted diesel particulate filter are allocated in the table to diesel engines without diesel particulate filter. Vehicles with factory-fitted diesel particulate filter can be identified by PR number 7GG on the vehicle data sticker.

2.2.3

FILTER CHANGE INTERVALS POLO 2002► FILTER CHANGE INTERVALS

ENGINE OIL FILTER 1) 2) Vehicles with LongLife service QG1 All other vehicles AIR FILTER All engine types FUEL FILTER All diesel engines

According to service interval display Every 15,000 km or 1 year Every 60,000 km or 4 years

Diesel con‐ Diesel not conforming Biodiesel (RME) forming to EN to EN 590 590 Change Every Every 30,000 km Every 30,000 km 60,000 km Drain water Every Every 15,000 km Every 15,000 km 30,000 km For unit injector engines draining water is deleted.

DUST AND POLLEN FILTER All engine types Every 30,000 km or 2 years

n AG. Volkswagen AG do es n wage 1) A new engine oil filter must be installed at every engine oil s k l ot g o yV ua b d change. ran ir se tee o h t or 2) Only applies to diesel engines: in some countries, u diesel has a ac a ss

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2.2.4

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high sulphur content. The high sulphur content leads to excessive wear of cylinders and it considerably reduces the cleanliness of pistons. Therefore change engine oil every 7,500 km in countries where the diesel has a high sulphur content. Countries where diesel has a high sulphur content. ⇒ page 32

TOOTHED BELT CHANGE INTERVALS

If the engine is fitted with toothed belt or timing chain can be found in the engine list.

Note

The camshaft drive with timing chain is maintenance-free!

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►2002

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ASY

Change interval Tensioning roll‐ Idler roller er Every --Every 120,000 km 120,000 km agen lksw Vo by

SDI

Model year

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DIESEL ENGINES Engine type

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POLO 2002► TOOTHED BELT CHANGE INTERVALS

Polo 2002 ➤ Maintenance - Edition 02.2018 POLO 2002► TOOTHED BELT CHANGE INTERVALS

TDI - unit injec‐ tor

ASY

2003►

AMF, BAY, ATD, AXR

►2003

ATD, AXR, ASZ, BLT

2004►

Every 150,000 km Every 90,000 km Every 120,000 km Every 120,000 km Every 150,000 km

AMF, BAY, BNM, BNV, 2004 -2006 BMS, BWB AMF, BAY, BNM, BNV, 2007► BMS, BWB, BMT PETROL ENGINES 1.8 l BJX, BBU Since intro‐ Every duction 180,000 km 1.4 l AUA, AUB, BBY, BBZ, Since intro‐ No prescribed BKY, BUD duction change interval, toothed belt drive with test interval, see time and/or distance depend‐ ent additional work ⇒ page 20

2.2.5 •

---

---

Every 90,000 km Every 240,000 km Every 240,000 km 300,000 km

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Spark plug change intervals

Spark plug designation and specified torque: Power unit ⇒ Rep. gr. 28 → Repairing ignition system → Test data. olkswagen AG en AG. V Note

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POLO 2002► Spark plug change intervals

Engine type Petrol engines

Change intervals EVERY 60,000 km • Mileage more than 60,000 km in 4 years EVERY 4 years • Mileage less than 60,000 km in 4 years

Delivery inspection

Page

⇒ page 41 ⇒ page 42

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– Battery: Check battery terminals by hand for tightness – Battery: Check with battery tester and printer VAS 5097A or VAS 6161 (always see workshop manual) – Service interval display: Reset Prote cted by

Only applies to stock vehicles and vehicles in storage

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⇒ page 103

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Scope of work

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2.3

Engine code All engine codes

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For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information.

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2. Service work

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Polo 2002 ➤ Maintenance - Edition 02.2018 Scope of work

Page

– Radio code: Read using vehicle diagnostic tester Only valid for vehicles with radio units from RCD 200

– Radio/radio navigation system: Enter PIN of anti-theft coding and store local radio stations to station buttons – Radio card (part of radio/radio-navigation system operating instructions): Attach radio serial number and fixed code number sticker onto radio card – Dash panel insert: Recode

⇒ page 87

⇒ page 110

•

In countries with sulphur content in diesel fuel

•

AG. V Your importer will inform you which countries have diesel with a high ssul‐ agen k w l o V phur content. by

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⇒ page 63

⇒ page 66

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12 2. Service work

⇒ page 95 ⇒ page 85 ⇒ page 49 ⇒ page 89 ⇒ page 109 ⇒ page 81

⇒ page 111 ⇒ page 90 ⇒ page 74 ⇒ page 81 ⇒ page 69 ⇒ page 47

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– Check vehicle exterior for cleanliness: Paintwork, decorative parts, win‐ dows, wiper blades – Wiper blade protection: removing – Wheel bolts: tightening to specified torque – Tyre pressure of all 4 wheels and spare wheel: Set to correct pressures (in the factory the tyres are inflated to 3.5 bar) – Tyre pressure loss indicator: performing basic setting – Transportation devices: removing blocking pieces from springs on front axle – 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 re‐ moving engine compartment cover for noise insulation) – Vehicle underside (floor pan): Visual check for damage – Windscreen wipe/wash and headlight washer system: Check function and spray jet settings; replenish fluid -G 052 164- to maximum – Engine oil level: Check, top-up with engine oil if necessary; observe oil specifications!

– Engine and components in engine compartment: visual check for leaks and damage (from above) – Coolant level: Check it is at maximum – Brake fluid level: Check level is at maximum – Number and function of keys: Check, wipe off grease if necessary

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– Turn switch to “ON” – Electric windows: Carry out initialisation (activation) – 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 number plate on rear bumper of vehicle.

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– Clock: setting to correct time – Front passenger airbag: Check key switch and “On/Off function”

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–

ed ris o h t Check func‐ All switches, electrical consumers, gauges and other controls: au tion ss

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⇒ page 88

Polo 2002 ➤ Maintenance - Edition 02.2018 Scope of work

Page

– LongLife engine oil sticker: Attach to right side of lock carrier •

⇒ page 26

Valid only for vehicles with LongLife service, PR number QG1

Note: Gradual deletion from week 04/07 – Hotline sticker: Apply to the inside of glove box cover

⇒ page 27

Note: Gradual deletion ♦ Service schedule: – Enter delivery inspection and enter a cross for the first service: ♦ Interval service for vehicles with LongLife service (PR No. QG1) 1) ♦ Oil change service for vehicles with flexible service (PR No. QG0/QG2)1) – Complete vehicle data in service schedule, see “Vehicle delivery docu‐ mentation” – Owner's literature: check that literature is complete and prepare for delivery to customer.

– Road test: performing (driving behaviour, noises, air conditioner etc.)

⇒ page 85

1) Service identification ⇒ page 5

2.4

Oil change service Note un le

♦ The oil change service is always a time or distance dependent 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

service “QG0/QG2” ⇒ page 6

♦ Inform the customer if faults are found during service and re‐

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pair measures are necessary.

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Caution

Applies only to diesel engines •

In some countries, diesel has a higher sulphur content.

•

The high sulphur content leads to excessive wear of cyl‐ inders and it considerably reduces the cleanliness of pis‐ tons.

♦ Therefore change engine oil every 7,500 km in countries where the diesel has a high sulphur content.

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New wiper blades

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

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– Ask the customer if he requires:

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♦ Countries where diesel has a high sulphur content. ⇒ page 32

AG.

– Check if storage life date of first-aid kit has been exceeded and if warning triangle is fitted.

– Removing and installing engine compartment cover -bottom(noise insulation) ⇒ page 84

2. Service work

13

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Polo 2002 ➤ Maintenance - Edition 02.2018

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and optimised and should therefore be adhered to in order to pre‐ vent unnecessary work interruptions

Page

– Engine oil: Drain or extract, renew oil filter – Fuel filter: drain water

⇒ page 75 ⇒ page 67

Vehicles with diesel engine using biodiesel according to EN 14214

– – – –

Front and rear brake pads/linings: Check thickness Engine oil: Replenish, observe oil specification Service interval display: Reset Service interval display: Recode to non-flexible intervals

•

Only vehicles with PR number QG1

⇒ page 59 ⇒ page 75 ⇒ page 103 ⇒ page 106

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Interval service 2008► Note

♦ The interval service is a time or distance dependent service

“QG0/QG2” ⇒ page 6 and also a LongLife service. ⇒ page 5

♦ The interval service always includes an engine oil change!

Additional type-specific tests ensure an extended oil change service.

♦ If the interval service is performed together with an inspection

service, see chapter for additional work to be carried out. ⇒ page 18

♦ The prerequisites for the interval service with a running period

of max. 2 years or 30,000 km can only be fulfilled if LongLife engine oil is filled or replenished.

♦ Inform the customer if faults are found during service and re‐

pair measures are necessary.

14 2. Service work

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2.5

⇒ page 26

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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/odom‐ eter reading; if necessary, enter a cross at the position for supplemen‐ tary information (e.g. renew toothed belt) and changing brake fluid and enter date/odometer reading; attach sticker to driver side door pillar (Bpillar)

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Oil change service – scope of work

Polo 2002 ➤ Maintenance - Edition 02.2018 Caution

Applies only to diesel engines •

In some countries, diesel has a higher sulphur content.

•

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♦ Countries where diesel has a high sulphur content. ⇒ page 32

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a ♦ Therefore change ss engine oil every 7,500 km in countries where the diesel has a high sulphur content.

– Ask the customer if he requires: •

New wiper blades

•

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

– Check if storage life date of first-aid kit has been exceeded and if warning triangle is fitted.

– Removing and installing engine compartment cover -bottom(noise insulation) ⇒ page 84

r te o iva r rp fo ng

Interval service – scope of work

in t his d o cu m en

The sequence of the individual service positions has been tested and optimised and should therefore be adhered to in order to pre‐ vent unnecessary work interruptions

– Battery: Check with battery tester and printer VAS 5097A or VAS 6161 (always see workshop manual) – Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre ____ – Tyre pressure of all 4 wheels and spare wheel: Correct – Spare wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Tyre repair set: Check if bottle is damaged or used; check and enter use-by date of tyre sealant __________ ht rig py Co t.

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⇒ page 42

⇒ page 49 ⇒ page 49 ⇒ page 89

If part of equipment

– Tyre pressure loss indicator: performing basic setting •

Page

⇒ page 89

If part of equipment

– Rear right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Engine oil: Drain or extract, renew oil filter – Front and rear brake pads/linings: Check thickness – Brake system: inspect for leaks and damage.

– Engine oil: Replenish, observe oil specification – Brake fluid level (dependent upon brake pad/lining wear): check.

⇒ page 49 ⇒ page 49 ⇒ page 49 ⇒ page 49 ⇒ page 75 ⇒ page 59 ⇒ page 58 ⇒ page 75 ⇒ page 47 2. Service work

15

Polo 2002 ➤ Maintenance - Edition 02.2018 Interval service – scope of work

Page

– Service interval display: Reset – “Next service” sticker: Enter a cross at the position for next service due, oil change service or interval service according to flexible service in‐ terval display or month/year/km and enter date/odometer reading as necessary; enter a cross at the position for supplementary information (e.g. renew toothed belt) and changing brake fluid and enter date/od‐ ometer reading; attach sticker to driver side door pillar (B-pillar).

2.6

⇒ page 103 ⇒ page 26

Inspection ►2007

Inspection intervals Vehicles with LongLife service according to flexible service inter‐ val display.

Vehicles with time or distance dependent service intervals ac‐ cording to service interval display (non-flexible)/every 24 months or every 30,000 km.

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Applies only to diesel engines •

In some countries, diesel has a higher sulphur content.

•

The high sulphur content leads to excessive wear of cyl‐ inders and it considerably reduces the cleanliness of pis‐ tons.

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

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Caution

♦ Therefore change engine oil every 7,500 km in countries where the diesel has a high sulphur content. ♦ Countries where diesel has a high sulphur content. ⇒ page 32 – Ask the customer if he requires: Replenish Windscreen Clear G 052 164 (cleanser and antifreeze). r fo ng

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– Check if storage life date of first-aid kit has been exceeded and if warning triangle is fitted.

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– Removing and installing engine compartment cover -bottom(noise insulation) ⇒ page 84

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New wiper blades

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•

AG.

Prote cted by

The sequence of the individual service positions has been tested and optimised and should therefore be adhered to in order to pre‐ vent unnecessary work interruptions Scope of work Electrics – Battery: Check with battery tester and printer VAS 5097A or VAS 6161 (al‐ ways see workshop manual) – Front lights - Check function: Side lights, dipped beam, main beam, fog lights, turn signals, hazard warning lights

16 2. Service work

Page ⇒ page 42

Polo 2002 ➤ Maintenance - Edition 02.2018 Scope of work

Page

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

– Tyre pressure loss indicator: performing basic setting If part of equipment

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•

⇒ page 89

– Rear right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm Underside of vehicle – Engine oil: Drain or extract; renew oil filter – Engine and components in engine compartment: inspect for leaks and dam‐ age (from below).

– Poly V-belt: checking condition – Gearbox, final drive and drive shaft boots: inspect for leaks and damage.

– Manual gearbox/final drive: checking oil level – Swivel joints: Visual check of swivel joint boots for leaks and damage – Brake system: inspect for leaks and damage.

– Front and rear brake pads/linings: Check thickness – Track rod ends: checking clearance, firm seating and boots – Exhaust system: inspect for leaks, firm seating and damage.

– Underseal: inspecting for damage to underseal, underbody cladding, rout‐ ing of lines and plugs Engine compartment – Engine oil: Replenish

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If part of equipment

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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– Rear lights - check function: Brake lights (including 3rd brake light), tail lights, reversing lights, rear fog light, number plate light, turn signals, hazard warning lights, luggage/load compartment lights – Interior and glove compartment lights, cigarette lighter, warning lamps and AG. Volkswagen AG d horn: Check function agen oes ksw not l o V gu by – Vehicle system test: Carry out test ⇒ page 63 ara d e nte is r o e h – Service interval display: Reset t or⇒ page 103 ac au ss Vehicle exterior – Sunroof: Check function, clean guide rails and lubricate with special grease ⇒ page 103 -G 000 450 02– Window wiper and washer system and headlight washer system: Check ⇒ page 90 function, spray jet settings and for damage – Door arrester: grease. ⇒ page 108 Tyres – Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre ____ – Tyre pressure of all 4 wheels and spare wheel: Check ⇒ page 49 – Spare wheel: Check condition and wear pattern of tyre; enter tread depth: ⇒ page 49 _______ mm – Tyre repair set: Check if bottle is damaged or used; check and enter use⇒ page 89 by date of tyre sealant __________

⇒ page 49 ⇒ page 49 ⇒ page 49 ⇒ page 49

⇒ page 75 ⇒ page 81 ⇒ page 65 ⇒ page 65 ⇒ page 90 ⇒ page 39 ⇒ page 58 ⇒ page 59 ⇒ page 107 ⇒ page 111

⇒ page 75

2. Service work

17

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Polo 2002 ➤ AG. Volkswagen AG d Maintenance - Edition 02.2018 agen oes ksw n ol yV db e ris tho au

ot g ua ran tee Scope of work or a – Engine and components in engine compartment: visual check for leaks cand ss

Specification -25°C (in countries with arctic climate -35°C)/actual value (meas‐ ured value): ____°C – Fuel filter: Drain water ♦ Only diesel engines with DP ♦ At 30,000 km, 90,000 km, 150,000 km etc. ♦ Only for vehicles using diesel fuel according to EN 590

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Inspection service 2008► Note

♦ The inspection service does not include an oil change and is

not indicated on the service interval display (SID) ⇒ page 6 .

♦ Inform the customer if faults are found during service and re‐

pair measures are necessary.

Caution

Applies only to diesel engines •

In some countries, diesel has a higher sulphur content.

•

The high sulphur content leads to excessive wear of cyl‐ inders and it considerably reduces the cleanliness of pis‐ tons.

♦ Therefore change engine oil every 7,500 km in countries where the diesel has a high sulphur content. ♦ Countries where diesel has a high sulphur content. ⇒ page 32 – Ask the customer if he requires: •

New wiper blades

18 2. Service work

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2.7

in t his d o cu m en

– Poly V-belt: Check condition – Poly V-belt: Check tension, adjust if necessary – Brake fluid level (dependent upon brake pad/lining wear): check.

Final checks – Headlights: Check adjustment – “Next service” sticker: Enter a cross at the position for next service due, oil change service or interval service according to flexible service interval dis‐ play or month/year/km and enter date/odometer reading as necessary; enter a cross at the position for supplementary information (e.g. renew toothed belt) and changing brake fluid and enter date/odometer reading; attach sticker to driver side door pillar (B-pillar).

– Road test: performing (driving behaviour, noises, air conditioner etc.)

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damage (from above) – Window wiper and washer system: Replenish fluid -G 052 164- (only if cus‐ tomer requires) – Cooling system: Checking frost protection and coolant level

Page ⇒ page 81 ⇒ page 90 ⇒ page 69

⇒ page 67

⇒ page 65 ⇒ page 65 ⇒ page 47 ⇒ page 98 ⇒ page 26

⇒ page 85

Polo 2002 ➤ Maintenance - Edition 02.2018 •

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

– Check if storage life date of first-aid kit has been exceeded and if warning triangle is fitted.

– Removing and installing engine compartment cover -bottom(noise insulation) ⇒ page 84 The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid unnecessary interruptions in the work.

Scope of work

Page

If part of equipment

– Tyre pressure loss indicator: performing basic setting – Rear right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm Underside of vehicle – Automatic gearbox: Check ATF level, replenish if necessary – Engine and components in engine compartment: inspect for leaks and dam‐ age (from below).

– Poly V-belt: checking condition – Poly V-belt: Check tension, adjust if necessary – Gearbox, final drive and drive shaft boots: inspect for leaks and damage.

– Manual gearbox/final drive: Check oil level, replenish if necessary – Swivel joints: Visual check of swivel joint boots for leaks and damage – Track rod ends: checking clearance, firm seating and boots ht rig py Co t.

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⇒ page 90 ⇒ page 103 ⇒ page 108

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•

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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, reversing lights, rear fog light, number plate light, turn signals, hazard warning lights, luggage/load compartment lights – Interior and glove compartment lights, cigarette lighter, warning lamps and horn: Check function AG. Volkswagen AG d Vehicle exterior agen oes ksw not l o V gu y b aCheck – Window wiper and washer system and headlight washer system: d ran ise for damage tee r function, spray jet settings and o h or ut ac a – Sunroof: Check function, ss clean guide rails and lubricate with special grease -G 000 450 02– Door arrester: grease.

Tyres – Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre ____ – Tyre pressure of all 4 wheels and spare wheel: Check – Spare wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Tyre repair set: Check if bottle is damaged or used; check and enter useby date of tyre sealant __________

⇒ page 49 ⇒ page 49 ⇒ page 89

⇒ page 89 ⇒ page 49 ⇒ page 49 ⇒ page 49 ⇒ page 49

⇒ page 40 ⇒ page 81 ⇒ page 65 ⇒ page 65 ⇒ page 65 ⇒ page 90 ⇒ page 39 ⇒ page 107 2. Service work

19

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Polo 2002 ➤ Maintenance - Edition 02.2018 Scope of work

Page

– Exhaust system: inspect for leaks, firm seating and damage.

– Underseal: inspecting for damage to underseal, underbody cladding, rout‐ ing of lines and plugs Engine compartment – Engine and components in engine compartment: visual check for leaks and damage (from above) – Window wiper and washer system: Replenish fluid -G 052 164- (only if cus‐ tomer requires) – Cooling system: checking frost protection and coolant level

⇒ page 111

⇒ page 81 ⇒ page 90 ⇒ page 69

Specification: -25°C (in countries with arctic climate: -35°C)/actual value (measured value): ____°C, replenish if necessary.

Final checks – Headlights: Check adjustment – “Next service” sticker: Enter a cross at the position for next service due, oil change service or interval service according to flexible service interval dis‐ play or month/year/km and enter date/odometer reading as necessary; enter a cross at the position for supplementary information (e.g. renew toothed belt) and changing brake fluid and enter date/odometer reading; attach sticker to driver side door pillar (B-pillar).

– Road test: performing (driving behaviour, noises, air conditioner etc.)

2.8

⇒ page 98 ⇒ page 26

⇒ page 85

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

Time or distance dependent additional work un le

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Depending on conditions under which the vehicle is used ⇒ page 34 and vehicle equipment, extra servicing work must be performed in addition to the oil change service, interval service or inspection service.

Note

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It is also possible, to perform additional work outside the service intervals with regard to the entries in the service schedule (or sticker: your next service).

♦ As of model year 2008 a new maintenance concept will be

introduced which changes the accounting procedures for cer‐ tain additional work. The times for renewing the pollen filter, air filter, fuel filter and spark plugs were integrated up to model year 2007 in repair operations in the 30,000 km and 60,000 km inspection services.

♦ From model year 2008 this is no longer valid. These opera‐

r fo ng

Additional work – Dust and pollen filter: cleaning housing and renewing filter element •

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

20 2. Service work

AG.

Every 30,000 km

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operation for an inspection service.

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♦ All service operations are integrated as previously in the repair

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tions are carried out as separate charge, which can be recog‐ nised in the maintenance table, signified by the red mark. This is also valid when changing the brake fluid, renewing the toothed belt, tensioning roller and when performing the ex‐ haust emissions test.

Page ⇒ page 108

Polo 2002 ➤ Maintenance - Edition 02.2018 Additional work

Page

– Fuel filter: Renew

⇒ page 66

•

Only valid for vehicles with diesel engine using biodiesel according to EN 14214

•

Only valid for vehicles with diesel engine using diesel not conforming to EN 590

Every 60,000 km Additional work

Page

– Spark plugs: renew

⇒ page 112

•

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

•

Spark plug designation: “Power unit” ⇒ Rep. gr. 28 “Test data, spark plugs”

– Fuel filter: Renew •

⇒ page 66

Only valid for vehicles with diesel engine using diesel according to EN 590

n AG. Volkswagen AG do – Air filter: Clean housing and renew es wagefilter element

•

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– Automatic gearbox: Change ATF

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•

⇒ page 71

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•

Only applies to vehicles from model year 2009

•

Applies only to 09G gearboxes in countries with hot climates, China and USA

Every 90,000 km Additional work

– Camshaft drive toothed belt: renew.

Only valid for vehicles with diesel engine ►2003 with engine codes AMF, BAY, ATD, AXR

•

Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

– Camshaft drive tensioning roller: Renew

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Only valid for vehicles with diesel engine ►2003 with engine codes AMF, BAY, ATD, AXR

•

Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

⇒ page 40

⇒ page 40

Page ⇒ page 111

⇒ page 111

2. Service work

21

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Polo 2002 ➤ Maintenance - Edition 02.2018 At 90,000 km, then every 30,000 km thereafter Additional work

Page

– Camshaft drive toothed belt: Check •

⇒ page 112

Only valid for vehicles with petrol engine and toothed belt drive without prescribed change interval

Every 120,000 km Additional work

Page

– Camshaft drive toothed belt: renew.

⇒ page 111

•

Only valid for vehicles with diesel engine ►2002 with engine code ASY

•

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Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

– Camshaft drive toothed belt: renew.

•

⇒ page 111

Only valid for vehicles with diesel engine model year 2004 - 2006 with engine codes AMF, BAY, BNM, BNV, BMS, BWB Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

At 120,000 km, then every 30,000 km thereafter Additional work ht rig py Co t.

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– Diesel particulate filter: check.

in t his d o cu m en

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•

⇒ page 111

Only valid for vehicles with diesel engine 2004► with engine codes ATD, AXR, ASZ, BLT rrectness o f i t to the co n f orm spec atio h re n wit

•

⇒ page 111

•

Only valid for RHD vehicles

•

Only valid for vehicles with diesel engines and factory-fitted diesel particulate filter ⇒ page 1

Page ⇒ page 119

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Every 150,000 km Additional work – Camshaft drive toothed belt: renew.

•

Only valid for vehicles with diesel engine 2003► with engine code ASY

•

Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

22 2. Service work

Page ⇒ page 111

Polo 2002 ➤ Maintenance - Edition 02.2018 Additional work

Page

– Camshaft drive toothed belt: renew.

⇒ page 111

•

Only valid for vehicles with diesel engine 2007► with engine codes AMF, BAY, BNM, BNV, BMS, BWB, BMT

•

Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

At 150,000 km, then every 30,000 km thereafter Additional work

Page

– Diesel particulate filter: check.

⇒ page 119

•

Only valid for LHD vehicles

•

Only valid for vehicles with diesel engines and factory-fitted diesel particulate filter ⇒ page 1

Every 180,000 km Additional work

Page

– Camshaft drive toothed belt: renew.

•

⇒ page 112

Only valid for vehicles with 1.8 l 5V petrol engine

Every 240,000 km

AG. Volkswagen AG d agen oes ksw not l o V gu Additional work by ara d e nte is r o eo – Camshaft drive tensioning roller: Renew h ut ra a c s s

Page ⇒ page 111

Only valid for vehicles with diesel engine 2004► with engine codes ATD, AXR, ASZ, BLT

•

Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

– Camshaft drive tensioning roller: Renew

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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•

•

Only valid for vehicles with diesel engine model year 2004 - 2006 with engine codes AMF, BAY, BNM, BNV, BMS, BWB

•

Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

Every 300,000 km Additional work

– Camshaft drive tensioning roller: Renew

Only valid for vehicles with diesel engine model year 2007► with engine codes AMF, BAY, BNM, BNV, BMS, BWB, BMT

•

Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life

ht rig py Co t.

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•

⇒ page 111

Page ⇒ page 111

2. Service work

23

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Polo 2002 ➤ Maintenance - Edition 02.2018

Every 12 months Additional work

Page

– Exhaust emissions test (EET): Perform

⇒ page 120

•

For vehicles used for commercial passenger transport, e.g. taxis

•

Applies only to Germany

Every 2 years Additional work

Page

– Brake and clutch system: Change brake fluid Only applies to vehicles ►2007

– Dust and pollen filter: cleaning housing and renewing filter element •

⇒ page 108

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. Volkswagen AG gen AG does wayears not lks2 Only valid for vehicles driving less than 30,000 kmVoin gu y b ara d e nte ris o eo h t u ra a c ss

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3 years after initial registration and then every 2 years Additional work

Page

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

•

⇒ page 42

Only applies to vehicles 2008►

– Exhaust emissions test (EET): Perform •

Applies only to Germany

Every 4 years Additional work

⇒ page 120

Page

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⇒ page 71

For vehicles driving less than 60,000 km in 4 years c o p yri gh t .

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– Spark plugs: Renew

⇒ page 112

•

For vehicles driving less than 60,000 km in 4 years

•

Spark plug designation: “Power unit” ⇒ Rep. gr. 28 “Test data, spark plugs” Prote cted by

Note

This chapter only provides information on market-specific devia‐ tions. This means that all maintenance points that are not shown here are to be found in the normal service tables.

24 2. Service work

AG.

Service intervals with market-specific deviations

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2.9

in t his d o cu m en

– Air filter: Clean housing and renew filter element •

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

– Brake and clutch system: Change brake fluid

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•

⇒ page 42

Polo 2002 ➤ Maintenance - Edition 02.2018 Russian market from model year 2010

Interval service (QG0/QG2) (appears on service interval display) Inspection service (does not appears on service interval display) – Adding multi-purpose additive G17 •

Interval

Description of work

Every 15,000 km or 1 year1) Every 30,000 km or 2 years 1) At every service

→ Mainte‐ nance tables

Every 15,000 km or 1 year1) Every 30,000 km or 2 years 1) Every 30,000 km Every 30,000 km or 2 years 1)

⇒ page 108

→ Mainte‐ nance tables ⇒ page 64

Applies only to petrol engines

– Dust and pollen filter (cabin filter): renew.

– Spark plugs: renew – Fuel filter: Renew – Air filter element: check; renew as needed and clean housing.

⇒ page 112 ⇒ page 66 ⇒ page 71

in t his d o cu m en

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n AG. Volkswagen AG do es n wage s k l ot g o 1) Whichever occurs first. yV ua b d ran ir se tee o h t or u ac a ss

2. Service work

25

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Polo 2002 ➤ Maintenance - Edition 02.2018

3

General information

Sticker ⇒ page 26 Entries in service schedule ⇒ page 27 Connecting vehicle diagnosis tester ⇒ page 28 Raising vehicle with lifting platform or trolley jack ⇒ page 29 Vehicle identification number ⇒ page 31 Vehicle data sticker ⇒ page 32 Countries where diesel has a high sulphur content ⇒ page 32 Engine code and engine number ⇒ page 33 RME fuel (biodiesel) ⇒ page 33 Severe operating conditions ⇒ page 34 Type plate ⇒ page 34

3.1

Stickers

In this chapter there are stickers which apply for the German market. The stickers determined for your country can be obtained from your importer.

Attach “Your next service” sticker. ⇒ page 26 Attach “data sticker” in customer service schedule. ⇒ page 27 Attach hotline sticker. ⇒ page 27

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Attaching “Your next service” sticker 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

3.1.1

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 at i h re o n wit in t his

The sticker “Your first service” has been discontinued, therefore sticker “Your next service” must be used for the delivery inspec‐ tion.

– Your “next service dates” sticker: Enter a cross in position for next oil change service or inspection service (next service due) and enter date/odometer reading

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26 3. General information

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Service intervals ⇒ page 8

Polo 2002 ➤ Maintenance - Edition 02.2018 – Attach sticker to driver side door pillar (B-pillar) -arrow-.

3.1.2

Attaching “data sticker” in customer service schedule

3.1.3

Attaching hotline sticker

– Attach hotline sticker to the inside of glove box cover as shown.

3.2

r fo ng

Applies only to Germany

Entries in service schedule ht rig py Co t.

•

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– Attach the lower of the two data stickers -arrow- in the service schedule.

If a component is changed which has a change interval prescribed by the manufacturer, e.g. the toothed belt, the new change inter‐ val begins at the time the component is changed. agen lksw Vo by

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•

Therefore it is very important, every time a component is changed, to document this in the service schedule.

•

This also applies to components which were changed before the regular change interval.

AG.

Note ♦ When using “Genuine parts kits” it must be taken into account

whether it is technically necessary to change all the compo‐ nents included in the genuine parts kits.

♦ If more components are renewed than is technically necessa‐

ry, inform the customer before repair!

3. General information

27

Polo 2002 ➤ Maintenance - Edition 02.2018

Connecting vehicle diagnostic tester

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Special tools and workshop equipment required

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3.3

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

AG.

28 3. General information

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♦ Vehicle diagnostic and service information system - VAS 5052- or successor

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♦ Diagnostic cable - VAS 5051/6A-

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♦ Vehicle diagnostic tester - VAS 5051B-

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Diagnostic cable - VAS 5052/3-

Note lkswageisn A Ensure that the selected vehicle diagnostic used n AG. Votester G do only es n wage s k l ot g o with the respective diagnostic cable.

V y u b ed ris o th au WARNING ss

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♦ During a road test, you must always secure testing and measuring equipment on the back seat.

– Carry out following procedure: – Connect diagnosis cable connector to diagnostic connection.

– Switch on vehicle diagnostic tester .

– Switch on ignition.

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3.4

in t his d o cu m en

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Now follow information given on screen to start desired functions.

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♦ Only a passenger may operate these devices while the vehicle is in motion. es, in part or in w l purpos hole ercia , is n m ot com

or ac

Raising vehicle with lifting platform or trolley jack

Safety notes ⇒ page 30 Lifting points for lifting platform or trolley jack ⇒ page 30

3. General information

29

Polo 2002 ➤ Maintenance - Edition 02.2018

3.4.1

Safety notes: WARNING

♦ Before driving onto a lifting platform, ensure that there is sufficient clearance between low-lying components and lifting platform. ♦ Before driving a vehicle onto a lifting platform it must be ensured that the vehicle weight does not exceed the per‐ missible lifting capacity of the platform. ♦ To avoid damage to the underbody and prevent the vehi‐ cle from tipping over, ensure that the vehicle is only lifted at the indicated jacking points. ♦ 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.

3.4.2

Lifting points for lifting platform or trolley jack: olkswagen AG en AG. V

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Trolley jack:

Lifting points for trolley jack

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

On side member at positions marked by an indentation.

Lifting platform:

Before driving onto a lifting platform, ensure that there is sufficient clearance between low-lying vehicle components and lifting plat‐ form.

Caution

Under no circumstances must the vehicle be raised at front on vertical reinforcement of side member.

Lifting points for Polo GTI Cup Edition

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30 3. General information

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Rear: Remove sill cover if necessary.

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Front: Remove sill cover if necessary by pulling down in -direction of arrow-.

Polo 2002 ➤ Maintenance - Edition 02.2018 On alignment point, covered by a black rubber plug. This need not be removed.

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Rear: On vertical reinforcement of side member.

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Front: On alignment point, covered by a black rubber plug. This need not be removed.

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Or at the alignment points, covered by black rubber plugs. This is necessary, for example, for Polo Cross or Polo Fun. The black rubber plugs do not have to be removed. agen lksw Vo by

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3.5

Vehicle identification number

The vehicle identification number -1- is located on the right sus‐ pension turret.

Significance of vehicle identification number

WVW

ZZZ

9N

Manufacturer code

Filler char‐ acters

Mo del

Z

2

D (Y)

Filler char‐ From mod‐ Production loca‐ acters el year tion 2002

000 001 Serial number

3. General information

31

Polo 2002 ➤ Maintenance - Edition 02.2018

3.6

Vehicle data sticker

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n AG. Volkswagen AG do es n wage s k l ot g The vehicle data sticker -1- is located in rear of vehicle on the lefty Vo ua b d ran in spare wheel recess. The vehicle data sticker is also foundisein tee r o the service schedule for the customer. h t or u ac a ss

The sticker contains the following data of the vehicle 1 - Vehicle identification number (chassis number) 2 - Vehicle type, engine output, gearbox

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3.7

Countries where diesel has a high sul‐ phur content

Applies only to diesel engines, as diesel fuel in some countries has a high sulphur content The high sulphur content leads to ex‐ cessive wear of cylinders and it considerably reduces the clean‐ liness of pistons. Therefore change engine oil every 7,500 km in countries where the diesel has a high sulphur content.

Afghanistan Egypt Algeria Angola

Ghana Guatemala Honduras Indonesia

Cuba Kuwait Laos Lebanon

Argentina Armenia Bangladesh Bolivia

Iraq Iran Jamaica Jordan

Libya Madagascar Mali Mauritius

32 3. General information

Saudi Arabia Senegal Zimbabwe Sri Lanka and the Mal‐ dives Sudan Surinam Syria Tajikistan

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The sticker in service schedule includes the same data. The leg‐ end can be found below the sticker.

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4 - Optional equipment, PR numbers

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3 - Engine and gearbox code letters, paint number, interior equip‐ ment

Polo 2002 ➤ Maintenance - Edition 02.2018 Brazil Brunei Dominican Republic Ecuador Ivory Coast El Salvador Gabon China

3.8

Cambodia Cameroon Kazakhstan Qatar Kenya Kyrgyz Republic Columbia Republic of Congo

Mongolia Myanmar (Burma) Nigeria Pakistan Paraguay Peru Russian Federation Pacific islands, driving on left

Tanzania Trinidad and Tobago Tunisia Uruguay Uzbekistan Venezuela Vietnam

Engine code and engine number

Engine code and engine number are located: ♦ On vehicle data sticker ⇒ page 32 . ♦ or ♦ »Power unit« ⇒ Power unit; Rep. gr. 00 ; Technical data, engine number »Technical data, engine number«.

3.9

RME fuel (biodiesel)

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Caution

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♦ 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 EN 14214 (FAME)! ♦ When biodiesel is used which does not conform to the re‐ quired standard, the fuel filter can become blocked.

RME fuel must conform to EN 14214 (FAME). ♦ RME means “Rapeseed Methyl Ester”. ♦ EN means “Euro standard”. ♦ FAME means “Fatty Acid Methyl Ester”. r te o iva r rp fo ng

♦ Performance can slightly be lower when using biodiesel. ♦ Fuel consumption can slightly be higher when using biodiesel.

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Characteristics of RME fuel

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♦ RME can be used in winter at temperatures to approx. -10 °C agen lksw Vo by

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

3. General information

33

AG.

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♦ When using biodiesel observe the changed intervals for drain‐

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ing and changing the fuel filter ⇒ page 16 .

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

is recommended to fill the tank with conventional diesel be‐ forehand and drive approx. 50 km, to prevent damage to the fuel injection system.

3.10

Severe operating conditions

If the vehicle is used under severe operating conditions some jobs will have to be performed before the next service due or at shorter service intervals.

Severe operating conditions

High percentage of cold starts

•

Vehicle is used in areas with winter temperatures over a long period

•

Regular long periods of idling (e.g. taxis)

•

Vehicle is often driven at full throttle with high payload or whilst towing a trailer

•

Using diesel with elevated sulphur content

•

Regular operation in areas with high levels of dust

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– The type plate -2- is located on the left suspension turret.

34 3. General information

AG.

Type plate

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3.11

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Regular short trips or stop and go operation in urban traffic

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Polo 2002 ➤ Maintenance - Edition 02.2018

4. Descriptions of work:

35

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Descriptions of work: es, in part or in w l purpos hole ercia , is n m ot com

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Removable towing bracket: checking and cleaning if necessary ⇒ page 37

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Swivel joints and axle mountings: inspecting ⇒ page 39 Automatic gearbox: checking ATF level ⇒ page 40 Automatic gearbox: changing ATF (09G gearbox) ⇒ page 40 Battery: checking battery terminal clamps for secure seating ⇒ page 41 Battery: check using battery tester with printer VAS 5097A or VAS 6161 ⇒ page 42 Brake and clutch system: changing brake fluid ⇒ page 42 Brake fluid level: checking ⇒ page 47 r te o iva r rp fo g n

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Brakes, front and rear: checking thickness of brake pads and condition of brake discs ⇒ page 59

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Diesel particulate filter: checking ⇒ page 119

Electric windows: perform initialisation (activation) ⇒ page 63 Vehicle system test: Carry out test ⇒ page 63 Front passenger airbag: checking key switch and “On/Off func‐ tion” ⇒ page 48 Bonnet: greasing catch hook ⇒ page 64 Adding multi-purpose additive G17 ⇒ page 64 Protective bellows: inspecting ⇒ page 65 Checking expiry date of first-aid kit ⇒ page 65 Interior and exterior body: inspecting for corrosion when doors and flaps are open ⇒ page 65 Checking number plate on vehicle bumper (Polo Cross) ⇒ page 66 Poly V-belt: checking tension, adjusting if necessary ⇒ page 65 Poly V-belt: checking condition ⇒ page 65 Fuel filter: renew (diesel engine) ⇒ page 66 Fuel filter: Draining water (diesel engine) ⇒ page 67 Cooling system: checking frost protection and coolant level ⇒ page 69 Air filter: cleaning housing and renewing filter element ⇒ page 71 Engine oil level: Check, replenish engine oil if necessary ⇒ page 74 Engine oil: Drain or extract and top up; Renew oil filter ⇒ page 75 Engine and components in engine compartment: inspecting for leaks and damage (from above and below) ⇒ page 81 Removing and installing engine cover panel -top- ⇒ page 81

36 4. Descriptions of work:

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Brake system and shock absorbers: inspecting for leaks and damage ⇒ page 58

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Tyres: checking condition, wear pattern, tread depth, tyre pres‐ sure and age ⇒ page 49

Polo 2002 ➤ Maintenance - Edition 02.2018 Removing and installing engine compartment cover -bottom(noise insulation) ⇒ page 84 Perform road test (driving behaviour, noises, air conditioner etc.) ⇒ page 85 Wheel securing bolts: tightening to specified torque ⇒ page 85 Radio/radio navigation system: entering PIN of anti-theft coding and storing local radio stations to station buttons ⇒ page 87

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Manual gearbox/final drive: Check oil level, replenish oil if nec‐ essary ⇒ page 90 Window wiper and washer system and headlight washer system: checking function ⇒ page 90 Wiper blade protection: removing ⇒ page 95 Headlight adjustment: Check, adjust headlights if necessary ⇒ page 98 Sunroof: checking function, cleaning and lubricating guide rails ⇒ page 103 Service interval display: resetting ⇒ page 103 Service interval display: recoding ⇒ page 106 r te o iva r rp fo ng

Dust and pollen filter: Renew filter element ⇒ page 108

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Clock: setting to correct time ⇒ page 111

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Dash panel insert: Recode ⇒ page 110

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Transportation device: Remove blocking pieces from front axle springs ⇒ page 109

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Door arrester: lubricating ⇒ page 108

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Track rod ends: checking clearance, security and boots ⇒ page 107

Underseal: inspecting for damage to underseal, underbody clad‐ ding, routing of lines and plugs ⇒ page 111 Toothed belt and tensioning roller: Renew ⇒ page 111 Camshaft drive toothed belt: Renew (4-cylinder 5-valve petrol en‐ gine) ⇒ page 112 Camshaft drive toothed belt: Check (4-cylinder petrol engine) not for engine code AXU ⇒ page 112 Spark plugs: renewing ⇒ page 112

4.1

Removable towing bracket: checking and cleaning if necessary

This chapter describes how to check and repair a removable tow‐ ing bracket.

Note

Note that checking towing bracket is included in the respective service. However, a repair is charged separately and must be re‐ quired by the customer.

4. Descriptions of work:

37

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

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– Detach cover -1-.

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Polo 2002 ➤ Maintenance - Edition 02.2018

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– Pull off protective cap -1- from ball head mounting -2-.

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Repair procedure: – Check contact surfaces -arrows- of ball head mounting for corrosion.

– If contact surfaces are corroded, eliminate corrosion with a tri‐ angular scraper and clean the treated areas with silicone remover.

– Apply a thin coat of lubricating paste G 000 650 or G 000 150 on cleaned surfaces.

38 4. Descriptions of work:

AG.

If a repair has to be performed, it has only to be in agreement with the customer. A repair must be charged separately.

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Note

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After ball head has been inserted, green mark on hand wheel must be aligned with white mark on ball head. Hand wheel must be entirely in contact. Afterwards, it must be possible to close the towing bracket lock by removing the key. If this is not possible, the following repair procedure must be performed.

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– Insert ball head into mounting.

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remover.

– Apply a thin coat of lubricating paste G 000 650 or G 000 150 on cleaned surfaces.

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– Check again ball head seat in mounting ⇒ page 38 .

– After checking, fit protective cap -1- into ball head mounting -2-.

Note

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If protective cap is damaged or not available, a new protective cap must be fitted to protect ball head mounting against corrosion. ⇒ ETKA

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– Insert cover -1-.

4.2

Swivel joints and suspension link mountings: inspecting

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

4. Descriptions of work:

39

Polo 2002 ➤ Maintenance - Edition 02.2018

4.3

Automatic gearbox: checking ATF level

Procedure »Power transmission« ⇒ Power transmission; Rep. gr. 37 ; Checking ATF level and topping up »Checking ATF level and topping up«

4.4

Automatic gearbox: changing ATF (09G gearbox)

– »Power transmission/automatic gearbox« ⇒ Power transmis‐ sion/automatic gearbox; Rep. gr. 37 ; Checking ATF level and replenishing ATF/Draining and filling ATF »Checking ATF lev‐ el and replenishing ATF/Draining and filling ATF« Note

In particularly hot climates, transmission fluid in the gearbox must be changed. The deterioration of transmission fluid in these cli‐ matic conditions is especially high. All affected countries are listed in the table below.

Countries with hot climate Algeria Ethiopia Benin (Dahomey) Burkina Faso (Upper Volta) Dem. Rep. Congo Ivory Coast Gambia Guinea-Bissau Iraq Japan Cameroon Congo Lebanon Madagascar Mali Mauritius Namibia Oman (AGCC) Rwanda Senegal Singapore Sudan Tanzania Chad Uganda West Sahara

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40 4. Descriptions of work:

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Afghanistan Egypt Angola Equatorial Guinea Australia Bahrain (AGCC) Botswana . Volkswagen AG AGBrunei does agen ksw not l o Burundi China V gu y b ara d nte ise r Djibouti Dubai (AGCC) o eo h t u ra a c Eritrea Gabon s s Ghana Guinea India Indonesia / (Borneo) Iran Israel Yemen (AGCC) Jordan Qatar (AGCC) Kenya Kuwait (AGCC) Lesotho Liberia Libya Malawi Malaysia Morocco Mauritania Mexico Mozambique Niger Nigeria Palestine Puerto Rico Zambia Saudi Arabia (AGCC) Sierra Leone Zimbabwe Somalia South Africa Swaziland Syria Thailand Togo Tunisia Turkey USA United Arab Emirates / Abu Dhabi (AGCC) Central African Republic

Polo 2002 ➤ Maintenance - Edition 02.2018

4.5

Battery: checking battery terminal clamps for secure seating

Special tools and workshop equipment required

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

Carry out following procedure:

– Press lug -arrow- together and open cover out forwards.

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– Check whether battery clamps are secure on battery terminals by moving battery positive cable and battery negative cable back and forth.

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– Push retaining tab of positive terminal cover in -direction of arrow-.

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If necessary:

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

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:

41

Polo 2002 ➤ Maintenance - Edition 02.2018 – Disconnect battery clamp from battery negative terminal first.

– Tighten battery terminal clamp on battery positive terminal to 6 Nm.

– If bolt -B- is not seated securely also tighten to the prescribed torque of 6 Nm. – Then reconnect battery negative terminal and tighten to 6 Nm. If the battery clamp on negative terminal is not seated securely: – Tighten negative terminal to 6 Nm. Notes for operation: Note

♦ ♦

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♦ When the battery is reconnected, do not forget to check the

4.6

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

vehicle equipment (radio, clock, convenience electrics, elec‐ tric windows etc.) as per workshop manual and/or the operat‐ ing instructions.

Battery: Checking using battery tester with printer VAS 5097A or VAS 6161

Procedure: »Electrical system general information« ⇒ Electrical system general information; Rep. gr. 27 ; Checking battery »Checking battery«

Brake and clutch system: Changing brake fluid WARNING

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♦ Rinse off spilled brake fluid using plenty of water. ♦ Observe relevant disposal regulations.

42 4. Descriptions of work:

AG.

♦ Brake fluid is hygroscopic, which means it absorbs mois‐ ture from the ambient air and should therefore always be stored in air-tight containers.

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♦ Brake fluid is poisonous. In addition, due to its corrosive nature, it must not come into contact with paint.

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♦ Never allow brake fluid to come into contact with fluids that contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐ eral oils will damage seals and rubber grommets of brake system.

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4.7

Polo 2002 ➤ Maintenance - Edition 02.2018 Caution

•

For this particular vehicle, use the brake fluid VW 501 14 - B 000 750- or US Norm FMVSS 116 DOT 4 (old brake fluid).

Special tools and workshop equipment required

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♦ Brake bleeding wrench - VAS 5519-

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♦ Brake bleeding tool - VAS 6564-

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♦ Brake filling and bleeding equipment - VAS 5234-

4. Descriptions of work:

43

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Polo 2002 ➤ Maintenance - Edition 02.2018 – Unscrew cap -1- from brake fluid reservoir.

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– Adjust correct pressure on brake filling and bleeding equip‐ ment - VAS 5234- : Running gear, brake systems ⇒ Running gear, brake systems; Rep. gr. 47 ; Bleeding brake system → Bleeding brake system.

– Connect filling hose from brake filling and bleeding equipment - VAS 5234- to adapter -1-.

Note

Use suitable bleeder hose. It must sit tightly on the bleeder valve so that no air can enter the brake system.

44 4. Descriptions of work:

AG.

Observe ⇒ operating instructions for -VAS 5234- !

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– Screw adapter -1- onto brake fluid reservoir.

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Do not reuse extracted brake fluid!

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The strainer in brake fluid reservoir must remain in place.

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Note

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– Extract as much brake fluid as possible using suction hose from brake filling and bleeding equipment - VAS 5234- .

Polo 2002 ➤ Maintenance - Edition 02.2018 – Remove cover cap -1- from bleeder valve of front left brake caliper.

– Push collector bottle bleeder hose -1- onto front left bleeder valve, open bleeder valve and let appropriate quantity of brake fluid run out (see table). Close bleeder valve. Torque: Running gear → Brake systems ⇒ Rep. gr. 47 → Repairing front brake caliper.

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– Remove cover cap -1- from bleeder valve of rear left brake caliper.

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by – If necessary, remove both wheels on rear ed axle to reach the ris bleed screw. o th

4. Descriptions of work:

45

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Polo 2002 ➤ Maintenance - Edition 02.2018 – Push collector bottle bleeder hose -1- onto rear left bleeder valve.

– Open bleeder valve and let appropriate quantity of brake fluid run out (see table). Close bleeder valve. Torque: Running gear → Brake systems ⇒ Rep. gr. 47 → Repairing rear brake caliper.

– Fit again cover cap on bleeder valve of rear left brake caliper.

– Repeat procedure on right-hand side of vehicle at rear.

For vehicles with manual gearbox Remove air filter housing.

Procedure: – Power unit ⇒ Rep. gr. 23 → Diesel direct injection system → Assembly overview - air filter Or – Power unit ⇒ Rep. gr. 24 → Injection system → Removing and installing air filter.

Note

For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information. n – Push bleeder hose onto bleeder valve -arrow- of clutch slave wage olks V y cylinder -1-. db e ris

ho – Open valve and allow approx. 50 ml of brake fluid to flow ut out.

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– Close valve and depress clutch pedal 10 to 15 timessquickly in succession.

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– Open valve again and allow approx. 50 ml of brake fluid to flow out.

– Close valve, remove bleeder hose and depress clutch pedal several times.

– Install air filter housing accordingly in reverse order.

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Clutch slave cylinder

Total quantity: approx. 1.15 litres including the amount extracted from the brake fluid reservoir – Set fill lever of brake filling and bleeding unit - VAS 5234- to position “B” (see operating instructions).

– Take filler hose off adapter.

46 4. Descriptions of work:

0.30 l 0.30 l 0.10 l

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Rear left Rear right

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Wheel brake cylinder/brake caliper

0.20 l 0.20 l

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Front left Front right

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Brake caliper

Brake fluid quantity which must flow out of bleeder valves:

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Sequence bleeder valves:

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Sequence and quantity of brake fluid

Polo 2002 ➤ Maintenance - Edition 02.2018 – Unscrew adapter from brake fluid reservoir.

– Check brake fluid level and correct if necessary. It must be between position -1- and -2-.

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– Screw on cap -1- of brake fluid reservoir.

– Reinstall rear wheels, if removed previously.

– Perform functional check during road test.

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

4.8

Brake fluid level: checking

Operation and safety notes ⇒ page 42 Brake fluid specification ⇒ page 42

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For delivery inspection fluid level must be at MAX. marking.

AG.

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Brake fluid level at delivery inspection:

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Procedure, brake fluid level (dependent upon lining/pad wear): checking

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4.8.1

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Procedure, brake fluid level (dependent upon lining/pad wear): check ⇒ page 47 .

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:

47

Polo 2002 ➤ Maintenance - Edition 02.2018 “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”.

WARNING

If the fluid level is below MIN. marking, the brake system must be checked before fluid is topped up “repair measure”.

4.9

Front passenger airbag: checking key switch and “On/Off function” Note

The “Airbag ON/OFF” switch is located in the glove compartment -1-.

The front passenger airbag can be deactivated using the key switch. The front passenger side airbag and all other airbags in the vehicle remain functional.

– Check “On / Off function” of key switch as follows: Deactivating front passenger airbag (deactivated) – Switch off ignition.

do c um en

r fo ng

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

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48 4. Descriptions of work:

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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 Using vehicle key, turn key switch to aposition -2- “Airbag Off”. u ac ss

Polo 2002 ➤ Maintenance - Edition 02.2018 – Switch on ignition.

The “airbag deactivated warning lamp (K145)” in the dash panel must also light up after self-test.

– Switch off ignition.

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– Using ignition key, turn key switch to position -1- “Airbag ON”.

– Switch on ignition. 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

“Airbag deactivated warning lamp (K145)” goes out after self-test.

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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 Activating front passenger airbag (activated) u ac a ss

– Switch off ignition.

WARNING

The front passenger airbag must only be deactivated if in ex‐ ceptional cases a child is transported in a rear-facing child seat on the front passenger seat.

Tyres: checking condition, wear pattern, tread depth, tyre pressure and age

In this chapter you will obtain information on the following sub‐ jects: c o p yri gh t .

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Checking tyre wear pattern ⇒ page 50 Checking tyre tread depth (including spare wheel) ⇒ page 50

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Checking condition ⇒ page 49

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4.10

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Checking tyre pressure (including spare wheel) and correcting if necessary ⇒ page 50 AG.

Note

For safety reasons, only tyres of same type and tread pattern should be fitted on a vehicle!

4.10.1

Checking condition

Carry out following procedure: Delivery inspection: – Check tyre treads and side walls for damage and remove for‐ eign bodies such as, for example, nails or glass splinters.

Note

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

4. Descriptions of work:

49

Polo 2002 ➤ Maintenance - Edition 02.2018 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.

Note

The customer must be informed of any faults found.

4.10.2

Checking tyre wear pattern

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).

4.10.3

Checking tyre tread depth (including spare wheel)

– Check tyre tread depth.

Minimum tread depth: 1.6 mm Note

♦

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worn down level with the 1.6 mm high tread wear indicators positioned at intervals around the tyre. pe rm itte d

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♦

AG. Volkswagen AG d agen oes ksw not l o V gu This figure may vary according to legislation in individual coun‐ y b ara d nte tries. ise r o eo h t u ra a The minimum tread depth is reached when the tyres have c s s

4.10.4

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

inform the customer.

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

♦ If the tread depth is approaching the minimum allowed depth,

Tyre pressure (including spare wheel): Checking, correcting if necessary WARNING

♦ For safety reasons, only tyres of same type and tread pat‐ tern should be fitted on a vehicle! Approved wheel and tyre combinations, e.g. ⇒ Running gear; Rep. gr. 44 ; Polo as of model year 2002 r te o iva r rp fo ng

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AG.

Prote cted by

50 4. Descriptions of work:

c o p yri gh t.

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♦ Tyre pressure gauge

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Special tools and workshop equipment required

in t his d o cu m en

♦ On four-wheel drive vehicles, tyres of the same type and tread pattern must be used. Otherwise the centre differ‐ ential may be damaged.

Polo 2002 ➤ Maintenance - Edition 02.2018 Note ♦ Tyre pressures for the relevant model can also be found on a

sticker. This is attached to the inside of the tank flap or on the B-pillar.

AG. Volkswagen AG d agen o es n o

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flate the spare wheel to the highest inflation pressure for the vehicle. found in »Wheels and Tyres Guide« ⇒ Running gear; Rep. gr. 44 ; Recommended winter tyres »General«.

♦ If winter tyres are fitted, a sticker, visible for the customer and

indicating the speed limit, must be applied in the interior of the vehicle.

♦ For winter tyres, the tyre pressure does not have be increased.

However, this only applies if the winter tyre used corresponds exactly to the standard summer tyre size and the speed index is no higher than “H”. If this is not the case, please refer to the recommendation of the tyre manufacturer.

Polo 9N1 to ►2004 ⇒ page 51 Polo “Fun” and “Cross” ⇒ page 53 Polo GTI Cup Edition ⇒ page 58

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Note

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Polo 9N3 from 2005► ⇒ page 54

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

♦ Important information on recommended winter tyres can be

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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

♦ If no inflation pressure is shown for the spare wheel, then in‐

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♦ Adjust thesstyre pressure to suit the vehicle load.

The mandatory tyre pressures for the respective model can be found on a sticker attached to the inside of tank flap or to the Bpillar.

Check tyre pressure using tyre inflator - VAS 5216- , correct if necessary.

Tyre pressure table for Polo 9N1 up to ►2004 For all factory fitted tyre sizes Tyre pressures in bar Petrol engine 1.2l/40 kW Petrol engine 1.2l/47 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

155/80 R13 165/70 R14 185/60 R14 195/55 R15 205/45 R16

2,3 2,0

2,1 1,9

2,3 2,2

2,8 2,6

1,9 2,0

1,9 1,9

2,1 2,2

2,5 2,6

4. Descriptions of work:

51

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

un le

Petrol engine 1.4l/55 kW

Full load bar

Tyre size

Front

Rear

Front

165/70 R14 185/60 R14 195/55 R15 205/45 R16

2,2

2,0

2,4

1,9 2,2

1,9 2,0

2,1 2,4

Petrol engine 1.4l/63 kW Petrol engine 1.4l/74 kW

Rear

Front

2,2 1,9 2,2

2,0 1,9 2,0

2,4 2,1 2,4

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Front

Prote cted by c o p yri gh t.

C op yi

185/60 R14 195/55 R15 205/45 R16

Rear 2,8 2,5 2,8

Full load bar

ht rig py Co t.

Tyre size

Half load bar

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

Half load bar

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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

ility ab y li an pt ce

Polo 2002 ➤ Maintenance - Edition 02.2018

Rear 2,8 2,5 2,8

Diesel engine 1.4l/55 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

165/70 R14 185/60 R14 195/55 R15 205/45 R16

2,3

2,1

2,6

3,0

2,0 2,3

1,9 2,1

2,2 2,6

2,6 3,0

Diesel engine 1.9l/74 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

185/60 R14 195/55 R15 205/45 R16

2,4 2,2 2,4

2,2 2,0 2,2

2,7 2,4 2,7

3,1 2,8 3,1

Diesel engine 1.9l/47 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

165/70 R14 185/60 R14 195/55 R15 205/45 R16

2,2

2,0

2,5

2,9

2,0 2,2

1,9 2,0

2,2 2,5

2,6 2,9

52 4. Descriptions of work:

Polo 2002 ➤ Maintenance - Edition 02.2018 Diesel engine 1.9l/96 kW Half load bar Front

195/55 R15 205/45 R16

2,4 y db 2,6 ise r o

Rear

Front

Rear

2,4

gu 2,6 ara nte 2,8 eo ra c

3,0 3,2

AG. Volkswagen AG d agen oes ksw not l 2,2 o V

th au s s

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Tyre size

Full load bar

Half load bar Front

Temporary spare wheel Spare wheel -stand‐ ard tyre-

Full load bar

Rear

Front 4,2

Half load bar

Full load bar

Rear

2,0

1,9

Front

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Front

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AG.

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Petrol engine 1.2l/40 kW Petrol engine 1.2l/44 kW Petrol engine 1.2l/47 kW

c o p yri gh t.

C op yi

215/40 R17

Rear

Keep to the highest pressure required for the vehicle.

Polo “Fun” and “Cross”

Tyre size

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

Tyre size

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

Spare wheel (all engine types)

2,2

Rear 2,6

Petrol engine 1.2l/51 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

215/40 R17

2,0

1,9

2,2

2,7

Petrol engine 1.4l/55 kW Petrol engine 1.4l/59 kW Petrol engine 1.4l/63 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

215/40 R17 185/60 R15

2,1 2,1

1,9 1,9

2,3 2,3

2,7 2,7

4. Descriptions of work:

53

Polo 2002 ➤ Maintenance - Edition 02.2018 Petrol engine 1.4l/74 kW Petrol engine 1.4l/77 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

215/40 R17

2,2

2,0

2,4

2,8

Diesel engine 1.4l/51 kW Diesel engine 1.4l/55 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

215/40 R17

2,3

2,1

2,5

2,9

bar

Front

Rear

Front

2,4

2,2

2,6

Spare wheel (all engine types)

Tyre size

Half load bar Front

Temporary spare wheel Spare wheel -stand‐ ard tyre-

Rear

Front

Rear

4,2

Keep to the highest pressure required for the vehicle.

r fo ng

1,9 2,0 2,1

Prote cted by

2,3 2,0

Full load bar

Front

Rear

2,1 1,9

2,3 2,2

2,8 2,6

1,9 1,9 1,9

2,1 2,2 2,3

2,5 2,6 2,7

AG.

155/80 R13 165/70 R14 185/60 R14 195/55 R15 205/45 R16 205/40 R17

Rear

agen lksw Vo by

c o p yri gh t .

C op yi

Front

ht rig py Co t.

Tyre size

do c um en

Half load bar

54 4. Descriptions of work:

3,0

Full load bar

Polo 9N3 from 2005►

Petrol engine 1.2l/40 kW

Rear

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

215/40 R17

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

Tyre size

bar

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Diesel engine 1.9l/74 kW

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 Half load Full load

Polo 2002 ➤ Maintenance - Edition 02.2018 Petrol engine 1.2l/44 kW Half load bar

Full load bar

Front

Rear

Front

Rear

165/70 R14 185/60 R14 185/55 R15 195/50 R15 195/55 R15 205/45 R16 205/40 R17

2,1

1,9

2,3

2,7

2,2 2,2 2,1 2,3 2,4

2,6 2,5 2,5 2,7 2,8

ed ris ho t au ss

2,1 1,9 1,9 1,9 1,9 1,9 k s l w o age1,9 n AG d 2,1 AG. V agen oes not lksw o V gu 2,0 y b2,2 a

ran tee or ac

ility ab y li an pt ce

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Tyre size

Half load bar

Tyre size

Front

Rear

Front

165/70 R14 185/60 R14 195/55 R15 205/45 R16 205/40 R17

2,1

1,9

2,3

1,9 2,1 2,2

1,9 1,9 2,0

2,1 2,3 2,4

Front

Rear

2,1

1,9

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c o p yri gh t .

C op yi

1,9 2,1 2,2

1,9 1,9 2,0

ht rig py Co t.

165/70 R14 185/60 R14 195/55 R15 205/45 R16 205/40 R17

Half load bar

do c um en

Tyre size

r fo ng

Petrol engine 1.2l/47 kW Petrol engine 1.2l/59 kW

Full load bar

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

Petrol engine 1.2l/51 kW

Rear 2,7 2,5 2,7 2,8

Full load bar

Front

Rear

2,3

2,7

2,1 2,3 2,4

2,5 2,7 2,8

Petrol engine 1.4l/55 kW Petrol engine 1.4l/63 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

165/70 R14 185/60 R14 195/55 R15 205/45 R16

2,3

2,1

2,5

2,9

2,0 2,3

1,9 2,1

2,2 2,5

2,6 2,9

4. Descriptions of work:

55

Polo 2002 ➤ Maintenance - Edition 02.2018 Petrol engine 1.4l/55 kW Petrol engine 1.4l/63 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

205/40 R17

2,4

2,2

2,6

3,0

Petrol engine 1.4l/74 kW Half load bar

185/60 R14 195/55 R15 205/45 R16

2,2 2,0 2,2

Rear

Front

Rear

ility ab y li an pt ce

AG. Volkswagen AG d agen oes 2,8 2,0 2,4 ksw not l o V gu y b d 1,9 2,2 2,6 arant ise r ee ho or 2,0 s aut 2,4 2,8 ac s

Tyre size

Front

205/45 R16 205/40 R17 185/55 R15 M&S

2,8 2,9 2,8

2,2 2,0 2,2 2,4

2,6 2,4 2,6 2,8

3,0 2,8 3,0 3,2

Full load bar

Rear

Front

Rear

2,6 2,7 2,6

3,0 3,1 3,0

3,4 3,4 3,4

Diesel engine 1.4l/51 kW Diesel engine 1.4l/59 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

165/70 R14 185/60 R14 195/55 R15 205/45 R16

2,4

2,2

2,6

3,0

2,1 2,4

1,9 2,2

2,3 2,6

2,7 3,0

56 4. Descriptions of work:

in t his d o cu m en

Half load bar

Rear

r te o iva r rp fo ng

Petrol engine 1.8l/110 kW

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

2,4 2,2 2,4 2,6

Front

Prote cted by

185/60 R14 195/55 R15 205/45 R16 205/40 R17

Rear

AG.

Front

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Tyre size

Full load bar

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

Half load bar

c o p yri gh t.

C op yi

Petrol engine 1.6l/77 kW

pe rm itte d

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Front

ht rig py Co t.

Tyre size

Full load bar

Polo 2002 ➤ Maintenance - Edition 02.2018 Diesel engine 1.4l/51 kW Diesel engine 1.4l/59 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

205/40 R17

2,5

2,3

2,7

3,1

Diesel engine 1.4l/59 kW Blue Motion Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

165/70 R14

2,9

2,7

2,9

3,0

Diesel engine 1.9l/74 kW Half load bar Tyre size

Front

185/60 R14 195/55 R15 205/45 R16 205/40 R17

2,5 2,3 2,5 2,7 ss

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

165/70 R14 185/60 R14 195/55 R15 205/45 R16 205/40 R17

Rear

2,3 2,7 2,1 2,5 2,3AG. Volkswagen A 2,7 G do agen es n ksw 2,5 l 2,9 ot g o yV

3,1 2,9 3,1 3,3

ua ran tee

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Full load bar

Front

Rear

Front

2,3

2,1

2,5

2,0 2,3 2,5

1,9 2,1 2,3

2,2 2,5 2,7

Rear 2,9 2,6 2,9 3,1

Front

Rear

Front

2,6

2,4

2,8

2,5 2,6

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2,7 2,8

3,0 3,0

Rear

ht rig py Co t.

195/55 R15 205/45 R16 205/40 R17 185/55 R15 M&S

Full load bar

in t his d o cu m en

Tyre size

r te o iva r rp fo ng

Diesel engine 1.9l/96 kW

Half load bar

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

Tyre size

Front

Half load bar

pe rm itte d

un le

Rear

ility ab y li an pt ce

Diesel engine 1.9l/47 kW

Full load bar

3,2 3,4 3,4

4. Descriptions of work:

57

Polo 2002 ➤ Maintenance - Edition 02.2018 Spare wheel (all engine types) Half load bar Tyre size

Full load bar

Front

Temporary spare wheel Spare wheel -stand‐ ard tyre-

Rear

Front

Rear

4,2 Keep to the highest pressure required for the vehicle.

Polo GTI Cup Edition Petrol engine 1.8l/132 kW Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

205/45 R16 205/40 R17

2,8 3,1

2,6 2,9

3,0 3,3

3,4 3,4

Spare wheel (all engine types) Half load bar un le pe rm itte d

Keep to the highest pressure required for the vehicle.

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

4.11

4,2

ility ab y li an pt ce

Temporary spare wheel Spare wheel -stand‐ ard tyre-

Front

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

Tyre size

AG. Volkswagen AG d agen oes ksw no l o V Full load t guar by d an e bar tee ris ho t o u a Rear Front Rear r ac ss

Brake system and shock absorbers: in‐ specting for leaks and damage

Check following components for leaks and damage: ♦ Brake master cylinder

♦ Brake servo (for anti-lock brake system: hydraulic unit)

♦ Shock absorbers (during inspection only)

♦ Presence of dust caps on brake fluid bleeder valves

– Check brake hoses and lines for chafing.

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

58 4. Descriptions of work:

AG.

– Check brake hoses for porosity or brittleness.

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Prote cted by c o p yri gh t.

C op yi

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

ht rig py Co t.

– Ensure that brake hoses are not twisted.

in t his d o cu m en

♦ Brake caliper

r te o iva r rp fo ng

♦ Brake pressure regulator or brake pressure reducer and

Polo 2002 ➤ Maintenance - Edition 02.2018 WARNING

Faults found must always be rectified (repair measure).

4.12

Brakes, front and rear: checking thick‐ ness of brake pads and condition of brake discs

This chapter provides information on the following subjects: Front disc brake pads: checking thickness ⇒ page 59 Rear disc brake pads: checking thickness ⇒ page 60 Rear drum brake pads: Checking thickness ⇒ page 61 Brake discs: checking condition ⇒ page 62 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

♦ Electric hand torch and mirror Carry out following procedure: The adapter to loosen and tighten the anti-theft wheel bolts can be found in the vehicle tool kit.

4.12.1

Front brake pads:

– For better evaluation of remaining pad thickness, use a test mirror and, if necessary, remove the wheel on the side where the brake pad wear indicator is installed.

– Mark position of wheel relative to brake disc.

– Unbolt wheel bolts and remove wheel.

do c um en

r te o iva r rp fo g n

– Pull off wheel bolt caps if necessary.

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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♦ Torque wrench - V.A.G 1332-

4. Descriptions of work:

59

ht rig py Co t.

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AG.

Prote cted by c o p yri gh t.

C op yi

Polo 2002 ➤ Maintenance - Edition 02.2018 – Measure thickness of inner and outer pads. a - Pad thickness “without” backplate Wear dimension: 2 mm The brake pads have reached their wear limit at a pad thickness of 2 mm (without backplate) and must be renewed (repair meas‐ ure). Inform customer!

Note

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n AG. Volkswagen AG do es n wage s k l ot g o discs as well for When replacing brake pads, always check bbrake yV ua d ran wear! Checking and if necessary replacing ir se the brake discs is a tee o h t or repair measure. u ac a ss pe rm itte d

– Check brake disc for wear: Procedure

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

Running gear → Brake systems ⇒ Rep. gr. 46 → Brake mecha‐ nism → Repairing front brake

For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information.

– Install wheel in marked position.

– Tighten wheel bolts diagonally and alternately, specified tor‐ que ⇒ page 85 . r te o iva r rp fo ng

– Fit wheel bolt covers if necessary .

Rear brake pads:

AG.

Prote cted by

60 4. Descriptions of work:

agen lksw Vo by

c o p yri gh t .

C op yi

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

ht rig py Co t.

4.12.2

in t his d o cu m en

– Place adapter in vehicle tool kit after completing work.

Polo 2002 ➤ Maintenance - Edition 02.2018 – Inspect outer pad to determine thickness.

AG. – Illuminate inner pad with an electric hand torch andswmirror. agen

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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

Wear dimension: 2 mm

Volkswagen AG does not gu ara nte eo ra c ility ab y li an pt ce

k Vol – Inspect inner pad to determine thickness. sed by ri ho ut a - Inner and outer pad thickness without backplate a ss

Note

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

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!

When replacing brake pads, always check brake discs as well for wear! Checking and if necessary replacing the brake discs is a repair measure.

– Check brake disc for wear: Procedure

Running gear → Brake systems ⇒ Rep. gr. 46 → Brake mecha‐ nism → Repairing rear brake

r fo ng

AG.

Rear drum brake pads: checking

agen lksw Vo by

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4.12.3

ht rig py Co t.

For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information.

do c um en

Note

– Remove cap -1-.

4. Descriptions of work:

61

Polo 2002 ➤ Maintenance - Edition 02.2018 – Using an electric hand torch, check thickness -a- of drum brake pad without backplate by looking through the inspection hole -2-. ♦ Wear dimension: 2.5 mm – Also ensure that brake pads are not smeared with brake fluid or grease.

Note

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!

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara ⇒ Brake systems; Rep.isgr. ed 46 ; Repairing rear brake (drum brake) nte r o eo h ut ra Running gear → Brake systems → Rep. Gr. 46 → Repairing rear a c s s brake (drum brake)

Procedure

Prote cted by c o py rig ht .

C op yi

Brake discs: checking condition

agen lksw Vo by

4.12.4

ht rig py Co t.

r fo ng

– Replace cap -1- after checking.

Check all brake discs for the following damage pattern: AG.

♦ Cracks ♦ Scoring ♦ Rust (no surface rust) ♦ Degree of wear at the ridge along the circumference Note

Inform customer if brake disc damage is similar to these damage patterns. Renewing the brake discs is a repair measure.

62 4. Descriptions of work:

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

For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information.

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

un le

ility ab y li an pt ce

Note

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

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Note

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

pe rm itte d

Electric windows: Carry out initialisation (activation)

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4.13

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e Polo 2002 ➤ nte is r o eo h Maintenance - Edition 02.2018 ut ra a c ss

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.

DANGER!

It is very important to inform the customer!

Prote cted by c o py rig ht .

C op yi

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– Close all doors completely.

ht rig py Co t.

Carry out the following procedure to initialise the electric windows:

do c um en

r te o iva r rp fo g n

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!

AG.

– 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.

4.14

Vehicle system test: Carry out test

– Connect vehicle diagnostic tester ⇒ page 28 .

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

– Then perform vehicle identification on vehicle diagnostic test‐ er .

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.

Note ♦ At this point it is useful to change to operating mode Guided

Functions to carry out further operations with the vehicle di‐ agnostic tester and to prevent a second vehicle identification on the vehicle diagnostic tester .

♦ To do this, press button “operating mode” and then button

“guided functions”.

♦ For further procedure see respective work descriptions. (Re‐

set SID etc.)

♦ To return to the Guided Fault Finding, press the “mode” button

and then “Guided Fault Finding”.

4. Descriptions of work:

63

Polo 2002 ➤ Maintenance - Edition 02.2018 Caution

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

Static faults 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.

Sporadic faults If only sporadic faults or notes are stored in the event memory and the customer has no complaints regarding the electronic ve‐ hicle system, erase event memory.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e Now complete guided fault finding using “GoTo” button andris nte o eo h then “End”. ut ra a c s s

– Press continue button > again to go to the test plan.

–

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All event memories are read again.

4.15

Bonnet: greasing arrester

Special tools and workshop equipment required ♦ Universal oil spray G 000 115 A2 Note

Vehicle must be at least at room temperature.

– Lubricate bonnet arrester with universal oil spray G 000 115 A2 at points marked with -arrows-.

Note ♦ Only applicable for Chinese and Russian market. ♦ Applicable for petrol engines only.

– Fill additive G17 into regular fuel tank during each service.

64 4. Descriptions of work:

AG.

Adding multi-purpose additive G17

agen lksw Vo by

4.16

Prote cted by c o py rig ht .

C op yi

– Remove any excess lubricant using a lint-free cloth.

ht rig py Co t.

r fo ng

– Operate moving parts several times so that universal oil is able to penetrate.

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

The vehicle system test is completed.

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

Now it is shown on display that all sporadic faults have been cleared, the diagnosis log is sent “online” automatically.

Polo 2002 ➤ Maintenance - Edition 02.2018 Note ♦ The additive is only effective if the fuel tank is full. ♦ If the additive is added to a partly filled fuel tank, the customer

must be requested to fill the tank completely as soon as pos‐ wagen AG. Volkswagen AG doe s no olks sible. t gu yV

Boots: inspecting

or ac

pe rm itte d

Carry out following procedure:

ara nte e

ility ab y li an pt ce

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4.17

b ed ris o th au ss

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

4.18

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

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

Checking expiry date of first-aid kit r te o iva r rp fo ng

Interior and exterior body: inspecting for corrosion with doors and flaps open

AG.

Prote cted by

Test locations

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c o p yri gh t .

C op yi

4.19

ht rig py Co t.

Inform customer if date has been exceeded.

in t his d o cu m en

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

♦ Sliding roof frame ♦ Inner and outer door frame ♦ Area around trim strips ♦ Windscreen roof edge ♦ Outer and inner A-pillar ♦ Bonnet ♦ Wheel arches ♦ Inner and outer tailgate

4.20

Poly V-belt: Checking tension, adjusting if necessary

Procedure: »Power unit« ⇒ Power unit; Rep. gr. 13 ; Dismantling and as‐ sembling engine; Removing and installing poly V-belt; Belt pulley without tensioning roller »Dismantling and assembling engine; Removing and installing poly V-belt; Belt pulley without tensioning roller«

4.21

Poly V-belt: checking condition

Carry out following procedure:

4. Descriptions of work:

65

Polo 2002 ➤ Maintenance - Edition 02.2018 – Raise vehicle.

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

– Raise vehicle and 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.

4.22

Checking number plate on vehicle bumper (Polo Cross) Note

♦ For reasons of design, no number plate panel must be fitted

on the rear bumper.

♦ If a number plate panel is still fitted, the legally prescribeden AG. Volkswagen AG wag lighting for the number plate cannot not guaranteed. olks

does not gu ara nte eo ra c

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ility ab y li an pt ce

4.23

Fuel filter: Renewing (diesel engine)

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

Note

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

♦

yV db This can seriously impair the safety of vehicle ir seand invalidates ho the type approval of the vehicle. ut a ss

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

ry, clean hoses immediately.

♦ Observe environmental regulations for disposal.

Carry out following procedure: Removing

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C op yi

66 4. Descriptions of work:

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There are two versions of fuel filters. The procedure is basically the same.

Polo 2002 ➤ Maintenance - Edition 02.2018 – Pull off retaining clip -3- and remove regulating valve -4- with fuel lines connected.

– Pull off fuel hoses -1- and -2-.

– Release retaining lugs -arrows-.

– For version two also remove retaining clips -1- and release filter on retaining lugs.

– Remove fuel filter upwards.

Installing – Fill new filter with clean Diesel. This allows the engine to start quicker.

– Fit new O-ring to seal regulating valve.

– Insert filter.

– Secure clips -arrows-.

– Install regulating valve -4- with lines connected.

– Fit retaining clips -3-.

– Install fuel hoses -1- and -2- and secure with hose clips.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is Fuel through-flow direction is marked on the connections by ar‐ r o eo h rows (do not interchange connections). ut ra a c s s

Note

Fuel filter: Draining water (diesel en‐ gine)

Only applicable for diesel engines with distributor injection pump Note

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

ry, clean hoses immediately.

♦ Observe environmental regulations for disposal.

do c um en

ht rig py Co t.

r te o iva r rp fo g n

Carry out following procedure:

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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ility ab y li an pt ce

4.24

4. Descriptions of work:

67

agen lksw Vo by

AG.

Prote cted by c o py rig ht .

C op yi

Polo 2002 ➤ Maintenance - Edition 02.2018 – Pull off retaining clip -3- and remove regulating valve -4- with fuel lines connected.

– 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.

– Fit new O-ring to seal regulating valve.

ility ab y li an pt ce

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AG.

Prote cted by

c o p yri gh t .

C op yi

68 4. Descriptions of work:

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

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

pe rm itte d

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–

ht rig py Co t.

–

n AG. Volkswagen AG do es n wage s k l ot g o Install regulating valve -4- and fit retaining clipy V-3-. ua b ran ed s i tee r Check fuel system for leaks (visual check). o h t or u ac a ss

Polo 2002 ➤ Maintenance - Edition 02.2018

4.25

Cooling system: checking frost protec‐ tion and coolant level Note

♦ The water used for mixing has a major influence on the effec‐

tiveness of the coolant. Because the water quality differs from country to country and even from region to region, the quality of the water to be used in the cooling system has been speci‐ fied by Volkswagen. Distilled water fulfils all requirements.

Therefore, only ever use distilled water when mixing coolant for topping up or renewing coolant.

♦ Use only coolant additives which conform with the ⇒ Elec‐

tronic parts catalogue (ETKA) . Other coolant additives may reduce corrosion protection substantially. The resulting dam‐ age could lead to loss of coolant and subsequent severe damage to the engine.

♦ Mixed in the proper proportions, coolant inhibits frost and cor‐

rosion damage as well as scaling. Coolant additives also raise the boiling point of the coolant. Therefore, the cooling system . Volkswagen AG n AGadditive. must be filled all year round with a coolant doe wage

s no t gu ara nte s i r reliability under heavy loads, particularly in countries with trop‐ o eo h ut ra ical climates. a c s s

ks Vol

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

un le

pe rm itte d

rent anti-freeze value.

♦ Frost protection must be guaranteed down to -25°C as a min‐

♦ Do not reduce the coolant concentration by adding water even

in warmer seasons and in warmer countries. Frost protection must be guaranteed down to at least -25°C.

♦ Read off anti-freeze figures for respective replenished coolant

additive.

♦ The temperature read off the refractometer - T10007A- corre‐ r te o iva r rp fo ng

sponds to the »ice flocculation point«. Flakes of ice may start forming in the coolant at this temperature.

♦ Never reuse old coolant. ♦ Use only a water/coolant additive mixture as a slip agent for Prote cted by c o p yri gh t.

C op yi

Frost protection: checking, replenishing coolant additive if necessary

agen lksw Vo by

AG.

4.25.1

ht rig py Co t.

coolant hoses.

in t his d o cu m en

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

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

imum and, in countries with arctic conditions, down to approx.

-36°C. Increasing the frost protection is permissible only if cli‐ matic conditions require stronger frost protection. It may, how‐ ever, be increased only to a maximum of -48°C. Otherwise, the cooling effect will be impaired.

ility ab y li an pt ce

♦ Use ONLY the refractometer - T10007A- for determining cur‐

Special tools and workshop equipment required

4. Descriptions of work:

69

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Refractometer - T10007 A-

Note

Read precise value for the following tests at light/dark boundary.

Using a pipette, place a drop of water on the glass to improve the readability of the light/dark boundary. The bright/dark boundary can be clearly recognised on the “WATERLINE”.

– Check concentration of coolant additive using refractometer T10007 A- (refer to operating instructions).

The scale -1- of the refractometer is calibrated for coolant addi‐ tives G12; G12 Plus, G12 Plus Plus and G11.

The scale -2- is only calibrated for coolant additive G13.

– If frost protection is insufficient, drain coolant and add coolant additive ⇒ page 70 .

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

wage ♦ If the currently used coolant additive cannot be determined olks

precisely, use the scale -2- for coolant additive G13.d by V e ris

a ss

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ho ♦ Observe environmental regulations for disposal. ut

4.25.2

Coolant level: checking, replenishing coolant if necessary

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

70 4. Descriptions of work:

ht rig py Co t.

r fo ng

– Check coolant level on expansion tank with engine cold.

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

– Check coolant additive concentration after road test again.

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Delivery inspection: Coolant level at max. marking. ♦ Inspection service: Coolant level between min. and max. marking.

– If coolant is too low, add required amount according to mixture ratio.

Note

Mixing ratio:

Use only distilled water for mixing coolant additives. The use of distilled water ensures optimum protection against corro‐ sion.

Coolant additive portion

-25 °C -36 °C

approx. 40% approx. 50 %

Distilled water approx. 60 % approx. 50 %

Air filter: Cleaning housing and renew‐ ing filter element

ht rig py Co t.

4.26

r te o iva r rp fo ng

Frost protection to

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

Caution

in t his d o cu m en

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

pe rm itte d

4.25.3

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

ility ab y li an pt ce

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If fluid loss is greater than can be expected through normal use, determine source and rectify (repair measure).

c o p yri gh t.

C op yi

Air filter: Clean housing and renew filter element, engine codes BUD and BTS ⇒ page 71 agen lksw Vo by

Air filter: Clean housing and renew filter element, 1.4 l injection engines ⇒ page 72 .

AG.

Prote cted by

Air filter: Clean housing and renew filter element, engine codes: AWY, AZQ, BMD, BME and 4-cylinder FSI engines ⇒ page 73 .

Air filter: Clean housing and renew filter element, diesel engines, 1.8 l 5-valve engines and engines with engine codes: BZG and BBM ⇒ page 73 .

4.26.1

Air filter: Clean housing and renew filter element, engine codes BUD and BTS

Carry out following procedure:

4. Descriptions of work:

71

Polo 2002 ➤ Maintenance - Edition 02.2018 Removing – Carefully pull off hose -1-.

– Loosen bolts of air filter housing upper part -2- and fold up‐ wards to remove the air filter -3-.

Note

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

– Clean air filter housing.

un le

Observe environmental regulations for disposal.

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

– Install air filter and air filter housing in reverse order.

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

4.26.2

Air filter: Cleaning housing and renew‐ ing filter element, 1.4 l injection engines

Carry out following procedure: Removing

The air filter element is integrated in the engine cover panel.

– Removing engine cover ⇒ page 81 .

Installing – Clean filter housing -2- and install new filter element -3-.

72 4. Descriptions of work:

AG.

Observe environmental regulations for disposal.

agen lksw Vo by

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Note

ht rig py Co t.

– Take out used filter element -3-.

do c um en

r fo ng

– Unscrew bolts -arrows- and remove air filter housing from en‐ gine cover.

Polo 2002 ➤ Maintenance - Edition 02.2018 – Insert filter housing and tighten bolts -arrows- to 3 Nm. – Install engine cover and air filter housing in reverse order.

4.26.3

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

A agen Air filter: Clean housing and renew filter ksw Vol y b element, engine codes: AWY, AZQ, ed ris o h ut engines BMD, BME and 4-cylinder FSI sa un le pe rm itte d

s

ility ab y li an pt ce

Carry out following procedure: Removing

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

The air filter element is integrated in the engine cover panel.

– Removing engine cover ⇒ page 81 .

4.26.4

AG.

– Install filter housing and tighten.

agen lksw Vo by

Prote cted by c o p yri gh t.

C op yi

– Clean filter housing and install new filter element.

ht rig py Co t.

Installing

do c um en

– Take out used filter element.

r te o iva r rp fo g n

– Unscrew bolts -arrows- and remove air filter housing from en‐ gine cover.

Air filter: Clean housing and renew filter element, diesel engines, 1.8 l 5-valve engines and engines with engine codes: BZG and BBM

Carry out following procedure:

4. Descriptions of work:

73

Polo 2002 ➤ Maintenance - Edition 02.2018 Removing – Unscrew securing bolts -arrows-, and raise upper part of filter housing.

– Take out used filter element -3-.

Note

Observe environmental regulations for disposal.

Installing – Clean filter housing -5- and install new filter element -3-.

ility ab y li an pt ce

Engine oil level: Check, replenish en‐ gine oil if necessary

Note the following:

r te o iva r rp fo ng

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

– Pull out dipstick, wipe with a clean cloth and push dipstick in again to limit stop. ht rig py Co t.

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AG.

Prote cted by c o py rig ht .

C op yi

74 4. Descriptions of work:

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

4.27

in t his d o cu m en

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

pe rm itte d

un le

–

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara to d upper part and tighten bolts -arrowsInsert filter housing e nte is r o 3 Nm. eo h ut ra a c s s

Polo 2002 ➤ Maintenance - Edition 02.2018 Note

Observe environmental regulations for disposal.

Note

Oil level must always be in area A for the delivery inspection.

– Pull dipstick out again and read oil level.

A - Do not top up oil.

B - Oil can be replenished up to areaen-A-.

AG. Volkswagen AG ag lksw

does n

ot g o C - Oil must be replenished. bOil y V level must then be at least in upper ua d ran third of measuring areaor-B-. ise te

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

Oil specification ⇒ page 9 “LongLife engine oil” sticker ⇒ page 26 .

Attach vehicle data sticker in service schedule ⇒ page 26 .

4.28

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

Engine oil: Drain or extract engine oil ⇒ page 75 .

Renew oil filter ⇒ page 77 .

Replenishing engine oil ⇒ page 80 .

4.28.1

Engine oil: draining or extracting

Special tools and workshop equipment required

ht rig py Co t.

r fo ng

♦ Used oil collection and extraction unit - V.A.G 1782-

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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ility ab y li an pt ce

a – If oil level is above ss -A- marking, drain or extract excess oil in order to avoid damage to catalytic converter.

4. Descriptions of work:

75

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Used oil collection and extraction unit - VAS 6622-

♦ Oil spill cloth - VAS 6204/1Engine oil: draining or extracting Carry out following procedure: 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 the engine oil is drained and not extracted with an oil ex‐

tractor, replace drain plug. This prevents leaks.

♦ Observe environmental regulations for disposal.

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

Or

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

k – Extract engine oil using used oil collection Vol and extraction unit by d e - VAS 6622- . ris

pe rm itte d

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

Note

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

– Let engine oil drain.

tho au s s

ility ab y li an pt ce

– Remove oil drain plug.

un le

Or

♦ There are two different oil drain plug versions. ♦ 1) On 3-cylinder petrol engines, an oil drain plug with hexagon

socket and removable seal is used. On this version, only re‐ new the seal ⇒ seal→ Electronic parts catalogue (ETKA) .

♦ 2) On all other engines, an oil drain plug with hexagon head

and integrated seal is used. On this version, always renew the oil drain plug with integrated seal ⇒ plug with seal → Electronic parts catalogue (ETKA) .

– On 3-cylinder petrol engines, clean oil drain plug and fit new seal.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

76 4. Descriptions of work:

ht rig py Co t.

– Tighten oil drain plug with seal hand-tight first and then to 30 Nm.

do c um en

r te o iva r rp fo g n

♦ Observe environmental regulations for disposal.

Polo 2002 ➤ Maintenance - Edition 02.2018 WARNING

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

– Replenish engine oil, specification ⇒ page 9 .

Engine oil capacity: »Power unit« ⇒ Power unit; Rep. gr. 17 ; Lubrication; oil capacities »Lubrication; oil capacities« or ⇒ Main‐ tenance table .

4.28.2

Renewing oil filter

Renewing oil filter, 1.2 l petrol engines ⇒ page 77 .

Renewing oil filter, 1.4 l FSI engines ⇒ page 77 .

Renewing oil filter, 1.4 l injection engines ⇒ page 78 .

Renewing oil filter, 1.8 l injection engines ⇒ page 78 .

Renewing oil filter, diesel engines ⇒ page 79 .

Note ♦ Prevent engine oil from dripping onto components in engine

compartment.

♦ Oil new O-rings before installing. ♦ Observe environmental regulations for disposal.

Renewing oil filter, 1.2 l petrol engines – Remove engine cover panel, if necessary ⇒ page 81 .

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e Unscrew cover cap -5- with 36 mm socket insert and remove nte is r o eo h cover with oil filter insert. ut ra a c s s

Carry out following procedure: –

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ility ab y li an pt ce

– Pull used oil filter element -1- off sealing cap. pe rm itte d

– Renew O-ring -4- for cap.

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

– Renew O-rings -2- and -3- only if damaged.

– Insert new filter element.

Note

Observe environmental regulations for disposal.

– Clean engine sealing surface.

– Oil rubber seal lightly on new filter.

– Cover cap torque setting: 25 Nm. Renewing oil filter, 1.4 l FSI engine r te o iva r rp fo ng

Carry out following procedure:

in t his d o cu m en

– Remove engine cover panel ⇒ page 81 .

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4. Descriptions of work:

77

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AG.

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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 th ra Unscrew cover cap -1- with 36 mm socket insert sand au remove c s cover with oil filter insert -4- and valve -5-.

Polo 2002 ➤ Maintenance - Edition 02.2018

ility ab y li an pt ce

un le

–

pe rm itte d

– Renew O-ring -2- of cover cap and O-ring -3- of valve.

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

Note

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

– Renew used oil filter element by new filter element.

Observe environmental regulations for disposal.

– Tighten cover cap -1-.

Cover cap torque setting: 25 Nm.

Note

♦ Observe environmental regulations for disposal.

♦ Prevent engine oil from dripping onto components in engine

– To remove the guide tube loosen bolts.

– Loosen oil filter -arrow- e.g. using combination spanner, AF 30 - VAS 5399- or ring spanner, 30x32 mm - VAS 5410- , and remove oil filter.

– Clean engine sealing surface.

Installing – Oil rubber seal lightly on new filter.

– Screw in filter and tighten hand-tight.

– Place guide tube in position and tighten guide tube bolts to 10 Nm. Note

We recommend to use new bolts to ensure that the bolts can be loosened for the next oil change.

– Attach alternator wiring harness into guide tube again.

Oil filter: renewing, 1.8 l injection engines Special tools and workshop equipment required

78 4. Descriptions of work:

AG.

– Detach alternator wiring harness from guide tube, which is screwed on heat shield.

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compartment.

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♦ Oil new O-rings before installing.

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r te o iva r rp fo g n

Renewing oil filter, 1.4 l injection engine

Polo 2002 ➤ Maintenance - Edition 02.2018 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

– Loosen oil filter -arrow- from underneath using a strap spanner or oil filter tool - VAS 3417- .

Note

Observe environmental regulations for disposal.

– Clean oil cooler sealing surface.

– Tighten filter by hand.

AG.

– Remove engine cover panel ⇒ page 81 .

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Oil filter: renewing, diesel engines

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– Oil rubber seal lightly on new filter. This ensures best possible sealing when the filter is tightened.

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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♦ Oil filter tool - VAS 3417-

Note ♦ Observe environmental regulations for disposal. ♦ Oil new O-rings before installing.

Loosen cover cap -arrow-.

Note

Before draining or extracting, release sealing cap so that the en‐ gine oil can flow out of filter housing.

– Clean sealing surfaces on threaded cap and oil filter housing.

4. Descriptions of work:

79

Polo 2002 ➤ Maintenance - Edition 02.2018 Installing – Renew filter element -3-.swagen AG.

Volkswagen AG does not gu ara nte eo ra c ility ab y li an pt ce

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

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4.28.3

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

Replenishing engine oil

Oil specifications ⇒ page 9 Engine oil capacities: »Power unit« ⇒ Power unit; Rep. gr. 17 ; Lubrication; oil capacities »Lubrication; oil capacities« or ⇒ Main‐ tenance table .

General information Note

Observe environmental regulations for disposal.

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

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

– Pull dipstick out again and read oil level.

80 4. Descriptions of work:

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

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

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–

k Vol by 4-. dand Renew O-rings -2 e ris ho ut a ss

Polo 2002 ➤ Maintenance - Edition 02.2018 A - Do not top up oil.

AG. Volkswagen AG d B - Oil can be replenishedwup agento area -A-. oe

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Oil level must then be at least an upper ed tee ris area -B-. third of measuring o h

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4.29

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

Inspect as follows: – Check engine and components in engine compartment for leaks and damage.

– Check lines, hoses and connections of ♦ Cooling and heating system c o p yri gh t .

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for leaks, abrasions, porosity and brittleness. agen lksw Vo by

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Note

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♦ And brake system

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♦ Fuel system

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

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

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ss is above -A- marking, drain or extract excess oil inc – If oil level order to avoid damage to catalytic converter.

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

use, determine source and rectify (repair measure).

4.30

Removing and installing engine cover panel -top-

Removing and installing engine cover panel -top-, 1.4 l 59 kW diesel engine ⇒ page 82 .

Removing and installing engine cover panel -top-, 1.4 l petrol in‐ jection engines ⇒ page 82 .

Removing and installing engine cover panel -top-, 1.2 l petrol in‐ jection engines ⇒ page 82 .

Removing and installing engine cover panel -top-, 1.4 l FSI en‐ gines ⇒ page 82 .

Removing and installing engine cover panel -top-, engine code BMD ⇒ page 82 .

Removing and installing engine cover panel -top-, engine code BNV ⇒ page 83 .

Removing and installing engine cover panel -top-, 1.9 l diesel en‐ gines ⇒ page 83 .

Removing and installing engine cover panel -top-, 1.8 l 5-valve engines ⇒ page 84 .

4. Descriptions of work:

81

Polo 2002 ➤ Maintenance - Edition 02.2018 Removing and installing engine cover panel -top-, 1.4 l 59 kW diesel engine For this engine a two-part cover is used.

– Remove cover at positions marked (dotted circles).

Removing and installing engine cover panel -top-, 1.4 l petrol in‐ jection engines – Pull hose for oil separator or non-return valve off engine cover panel.

– Pull engine cover off mountings -arrows-.

– Installation is carried out in the reverse sequence of removal.

Removing and installing engine cover panel -top-, 1.2 l petrol in‐ jection engines

– Pull off cover at positions marked -arrows-.

– Installation is carried out in the reverse sequence of removal.

G. Volkswagen

A AG do agencover panel -top-, Removing and installing engine e1.4 s no l FSI en‐ lksw o t gu V gines by a d ise

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or – Pull off hoseuthfrom air filter housing to camshaft housing. ee or

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– Pull out oil dipstick.

– Pull off cover at positions marked -arrows-.

– Installation is carried out in the reverse sequence of removal.

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82 4. Descriptions of work:

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Removing and installing engine cover panel -top-, engine code BMD

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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

ac ility ab y li an pt ce

s – Pull connector off intake air temperature sender.

Polo 2002 ➤ Maintenance - Edition 02.2018 – Pull off cover at positions marked -arrows-.

Removing and installing engine cover -top-, engine code BNV – Pull out oil dipstick.

– Pull off cover at positions marked -arrows-.

– When installing, fit cover, and press it down until it is felt to engage. Reinsert oil dipstick.

Removing and installing engine cover panel -top-, 1.9 l diesel en‐ gines Version 1

– Pull cover upwards at positions marked -arrows- -A- and -Band pull out of guide forwards -C-.

– Installation is carried out in the reverse sequence of removal.

Version 2 Removing:

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2) Centre part -B-, not shaded in illustration.

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1) Outer part -A-, shaded in illustration.

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– Disengage engine cover panel carefully at individual securing points and raise as follows.

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-1-, -3-, -2-, -4-.

4. Descriptions of work:

83

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AG.

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c o p yri gh t .

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Polo 2002 ➤ Maintenance - Edition 02.2018 un le

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– Remove outer part -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

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– Disengage centre part -2- also carefully and remove.

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Installing:

– Disengage engine cover panel -1- at securing points -arrows B-, and raise it.

– Then, pull it out of bracket -arrow A-.

Installing: – First fit engine cover panel -1- at securing point -arrow A-.

– Then fit engine cover panel -1- at the other securing points -arrows B-, and press it on until it noticeably engages.

4.31

Removing and installing engine cover bottom- (noise insulation)

Procedure The procedure of removing the engine cover panel -bottom(noise insulation) can be found in Workshop Manual under:

84 4. Descriptions of work:

AG.

Removing:

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Removing and installing engine cover panel -top-, 1.8 l -5-valve engines

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– Then fit outer part -1- over retaining points -arrows- and press on, so that cover engages.

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– Fit engine cover panel onto securing points -arrows- and press on.

Polo 2002 ➤ Maintenance - Edition 02.2018 »General body repairs, exterior« ⇒ General body repairs, exte‐ rior; Rep. gr. 50 ; Noise insulation »Noise insulation« Note

For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information.

4.32

Road test: performing (driving behav‐ lkswagen AG. Volkswagen AG does n ot g o ua iour, noises, air conditioner etc.) sed by V ran i or

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Check the following during a road test:

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

– Engine: output, misfiring, idling speed, acceleration

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

– 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, dash panel insert display.

– ABS function: pulsing must be felt at the brake pedal during ABS-regulated braking – Foot brake and handbrake: function, free travel and effective‐ ness, pulling to one side, juddering, squeal

– Air conditioner: Function. (At very low temperatures the func‐ tion of air conditioner must be checked in a workshop)

AG.

– Vehicle: pulling to one side when travelling straight-ahead (level road)

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– Multi-function indicator (MFI): functions

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– Radio: Reception, GALA, interference

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– Folding fabric sunroof: function

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– Tilting roof: function

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– Steering: function, steering free clearance, steering wheel centred when vehicle is travelling straight ahead

– Imbalance: wheels, drive shafts, propshaft – Wheel bearings: noises – Engine: hot starting behaviour

4.33

Wheel securing bolts: tightening to specified torque

Removing and installing wheel bolt caps Note

Depending on vehicle equipment, the wheel bolts can be covered by the following components: ♦ Wheel bolt caps ♦ Hub cap ♦ Wheel trim

4. Descriptions of work:

85

Polo 2002 ➤ Maintenance - Edition 02.2018 – 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.

Example, removing hub cap – Hook puller hook into one drilling of wheel hub trim and pull off in -direction of arrow-.

Installation instructions Note

♦

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♦

AG. Volkswagen AG d agen oes ksw not l o V and should be recon‐ gu The cover caps protect the wheel bolts y b ara d e nte nected after the wheel securingorisbolts have been retightened. eo h t u ra a lug of the wheel hub trim locates Ensure that on some rims the c s s

♦ After completing work, place adapter and puller hooks with

vehicle tool kit.

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– 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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can be found in the vehicle tool kit.

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

♦ 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.

♦ The adapter code number to loosen and tighten the anti-theft

wheel bolts is stamped on the front side of the adapter.

Special tools and workshop equipment required

86 4. Descriptions of work:

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Note

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Loosening or tightening anti-theft wheel bolts

AG. Volkswagen AG d agen oes ksw not l o V gu Polo 2002 ➤ by ara d e nte is r Maintenance Edition 02.2018 o e h t or ac au s s

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

– Slide the wheel bolt wrench onto adapter onto stop.

– Retighten the wheel securing bolts to correct torque setting.

Retightening wheel securing bolts r fo ng

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♦ Torque wrench - V.A.G 1332-

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Special tools and workshop equipment required

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♦ Adapter set for wheel bolts - T10101-

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Note

Ensure that wheel bolts are tightened diagonally and alternately.

Specified torque: 120 Nm

4.34

Radio/radio navigation system: entering PIN of anti-theft coding and storing local radio stations to station buttons

The anti-theft coding electronically prevents unauthorized per‐ sons from operating the unit after it has been removed from vehicle. The anti-theft codes are also called radio codes or se‐ curity codes. Security code means that each unit with an anti-theft coding is programmed with its own code number. This security code is not active when leaving the factory. The security code is found on the unit card, if fitted. If the unit card is not fitted, the security code can be read using vehicle diagnostic tester of a central database.

4. Descriptions of work:

87

Polo 2002 ➤ Maintenance - Edition 02.2018 Note

If an incorrect code number is entered when releasing the elec‐ tronic lock, the whole procedure can be repeated once. If an incorrect code number is entered again, the unit is locked for about one hour. That means, it cannot be used. After one hour, during which time the unit must remain switched on, the display extinguishes. The electronic lock can be released as described above. The cycle two attempts, one hour lock applies again.

Procedure Vehicle electrics → Communication ⇒ Rep. gr. 91 → e.g. radio system "RCD 500" → Electronic anti-theft coding → Deactivating electronic anti-theft coding.

For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information.

4.35

Radio code: reading using vehicle diag‐ nostic tester

Authorization prerequisites for vehicle diagnostic tester • •

The vehicle diagnostic tester is connected via the Central Partner Network (CPN) with the central database (Carport, Fazit).

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Note

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♦ The radio codes can be read in the central database and can

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

be displayed on vehicle diagnostic tester .

♦ For radio activation the codes must be entered via radio but‐

tons, as previously ⇒ page 87 .

Procedure

– Connect vehicle diagnostic tester ⇒ page 28 .

– Switch on ignition.

– Confirm vehicle identification.

– Select one after another: ♦ “Radio system” ♦ “Reading radio code”

– Read code according to the information of “GUIDED FUNC‐ TIONS”.

88 4. Descriptions of work:

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♦ Engine code

AG.

♦ Model year

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♦ Model

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♦ Brand

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– Select one after another:

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– Confirm with > button.

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– On the screen, touch »GUIDED FUNCTIONS« field or button.

Polo 2002 ➤ Maintenance - Edition 02.2018 – Finish code reading as follows: – Press »GoTo« button on display.

– Press »End« button on display.

– Press »End« button in End menu.

– Switch off ignition and separate diagnosis connections.

4.36

Tyre repair set: checking

The tyre repair set is located in the spare wheel well -arrow-.

The tyre repair set consists of the compressor and a filler bottle with tyre sealant.

Caution

♦ The tyre sealant must not be more than 4 years old. ♦ If the bottle was opened e.g. in connection with a "flat tyre", it must also be renewed.

Note

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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♦ The tyre sealant in the bottle has a limited shelf life. pe rm itte d

♦ Therefore the expiry date is indicated on the bottle -arrow-. ♦ Residual tyre sealant or bottles which are filled and the expiry

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

date has been exceeded, must be disposed of.

♦ Old tyre sealant and/or remnants must not be mixed or dis‐

posed of with other fluids.

– Check the expiry date and enter this in maintenance tables.

– Renew tyre sealant if the expiry date has been reached.

•

Observe relevant disposal regulations.

4.37

Tyre Pressure Loss Indicator: perform‐ ing basic setting r te o iva r rp fo g n

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– Adjust the prescribed tyre pressure on each tyre.

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– After changing the tyre pressures or after changing one or more wheels, the Tyre Pressure Loss Indicator must be set to basic setting.

4. Descriptions of work:

89

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AG.

Prote cted by c o p yri gh t.

C op yi

Polo 2002 ➤ Maintenance - Edition 02.2018 – With ignition switched on, press and hold SET button for Tyre Pressure Loss Indicator until a confirmation tone is heard.

Press the button for Tyre Pressure Loss Indicator to confirm the new tyre pressure.

The basic setting has been performed.

4.38

Manual gearbox/final drive: Checking oil level, replenishing oil if necessary

Procedure: »Power transmission« ⇒ Power transmission; Rep. gr. 34 ; Checking gear oil »Checking gear oil«.

4.39

Window wiper and washer system and headlight washer system: Checking function

Checking anti-freeze concentration ⇒ page 90 .

Window wiper and washer system: Check spray jet settings ⇒ page 92 . agen Headlight washer system: check spray jet settings ⇒ pageo94 lksw.

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yV db ise r tho Wiper blades: checking setting angle ⇒ page 94s au. s

Checking wiper blade park position ⇒ page 94 .

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Note

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4.39.1

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

When during a functional check it is determined that the wiper blades »judder« or make noises, check the setting angle of the wiper blades ⇒ page 94 .

Anti-freeze concentration in window wiper and washer system: Checking and replenishing fluid if necessary

Checking anti-freeze concentration:

Special tools and workshop equipment required

r te o iva r rp fo ng

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90 4. Descriptions of work:

in t his d o cu m en

Read precise value for the following tests at light/dark boundary.

Using a pipette, place a drop of water on the glass to improve the

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♦ Refractometer - T10007 A-

Polo 2002 ➤ Maintenance - Edition 02.2018 readability of the light/dark boundary. The bright/dark boundary can be clearly recognised on the “WATERLINE”.

– Check concentration of anti-freeze additive using refractome‐ n AG. Volkswagen AG do ter - T10007 A- . e wage

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y The scale -4- of the refractometer is calibrated d b for Windscreen ise r Clear - G 052 164- . ho

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

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Mixing ratio

Water

In summer -16 °C -35 °C -40 °C

1 part 1 part 1 part 2 parts

4 parts 2 parts 1 part 1 part

AG.

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Starting immediately, use only “Genuine Volkswagen Wind‐ screen Clear” year-round when replenishing window wiper and washer system.

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

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Replenishing fluid:

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Windscreen Clear G 052 164

in t his d o cu m en

Frost protection to

Note ♦ Genuine Volkswagen Windscreen Clear protects the spray

jets, fluid reservoir and hoses from freezing.

♦ Use Genuine Volkswagen Windscreen Clear “G 052 164” also

in the warmer periods of the year. The powerful cleanser re‐ moves wax and oil residue from the glass.

♦ Frost protection in the washer system must be guaranteed to

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

4. Descriptions of work:

91

Polo 2002 ➤ Maintenance - Edition 02.2018

4.39.2

Window wiper and washer system: Checking spray jet settings

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

move spray jet, and rinse water opposite to direction of spray »Vehicle electrics, electrical system« ⇒ Vehicle electrics, electrical system; Rep. gr. 92 ; Windscreen washer system »Windscreen washer system«.

♦ 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 wagen A olksspray jets, otherwise the water passages the jet be G. V Ain G dwill agen oes ksw damaged! not l o V

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

– Turn eccentric on spray jet -in direction of arrow- using a screwdriver, to adjust spray direction upwards.

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92 4. Descriptions of work:

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

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The spray jets are preset. However, small differences in height may be corrected.

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Preset spray jets forsswindscreen washer system

Polo 2002 ➤ Maintenance - Edition 02.2018 Or – Adjust spray jet at adjuster -1- by hand upwards or down‐ wards.

Spray jet for rear window washer system

Special tools and workshop equipment required

pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com

Spray jet must spray to centre of wiped area.

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Note

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– If necessary, adjust the spray jet using adjusting tool - T10127or adjusting tool - T40187- .

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– Check jet setting.

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♦ or adjusting tool - T40187-

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♦ Adjusting tool - T10127-

Make sure that the spray is not directed into the rear window wiper cover.

4. Descriptions of work:

93

Polo 2002 ➤ Maintenance - Edition 02.2018

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Caution

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Headlight washer system: check jet set‐ ting pe rm itte d

4.39.3

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

rrectness of i t to the co nform spec 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

Only control function of spray jets but do not adjust them.

Spray pattern of right headlight (adjustment of left headlight is a mirror image)

r te o iva r rp fo g n

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The headlights are washed if the windscreen wiper lever is hold in “Wipe position” for at least 1.5 seconds.

The spray jet should spray on the headlight lens, as shown in illustrations.

If spray pattern deviates from specifications, carry out repair measures.

4.39.4

Checking wiper blade park position

Windscreen »Vehicle electrics, electrical system« ⇒ Vehicle electrics, elec‐ trical system; Rep. gr. 92 ; Removing and installing windscreen wiper system, wiper blade park position »Removing and installing windscreen wiper system, adjusting wiper blade park position« Rear window »Vehicle electrics, electrical system« ⇒ Vehicle electrics, elec‐ trical system; Rep. gr. 92 ; Removing and installing rear window wiper system, wiper blade park position »Removing and installing rear window wiper system, adjusting wiper blade park position«

4.39.5

Wiper blades: Check setting angle

Note ♦ With the introduction of the new hingeless wiper the setting

angle check has been discontinued.

♦ The setting angle of the hingeless wiper arm is always the

same and cannot be changed or adjusted.

94 4. Descriptions of work:

AG.

– Operate windscreen washer system.

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– Switch on dipped headlight.

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Washer spray jet: checking settings

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From 2006►

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Up to ►2005

Polo 2002 ➤ Maintenance - Edition 02.2018 Special tools and workshop equipment required ♦ Wiper setting tool - VAS 3358B-

– Set wiper arms to rest position.

– Remove wiper blade.

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

– Check setting angle.

Setting angle (specifications) for RHD vehicles AG. Volkswagen AG d agen oes ksw not l o V +5° gu by ara d e nte s i r +5.5° ho eo ut ra a c s -5° s ±2°

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Driver side Passenger side Rear window wiper Tolerance

LHD vehicles -5° -5.5° -5° ±2°

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

If required, proceed as follows to adjust setting angle according to specification: – Fit 24 mm open jaw spanner -1- on setting device and adjust wiper arm -2- to specification -arrows-.

– Release wiper arm -2- from setting device and then resecure with locking screw -3-.

– Check setting against table. If necessary, repeat setting and checking procedure until specification is achieved.

– Remove setting device, and install wiper blade.

Wiper blade protection: removing

AG.

There are 3 different versions of wiper blade protection:

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Prote cted by c o p yri gh t.

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Note

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4.40

4. Descriptions of work:

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– Make sure that wiper system operates without juddering.

95

Polo 2002 ➤ Maintenance - Edition 02.2018 Version 1: blade protector with 2 securing clips ♦ Identification, blade protector with two securing clips -arrows 1 + 2-.

♦ Identification, the blade protector -arrow- is slid on the wiper blade.

Wiper blade protection, version 2: removing ⇒ page 97

Version 3: transport wiper blade

♦ Identification, the transport wiper blade is fitted without wind deflector, it must be replaced by the standard wiper blade. r fo ng

– Switch ignition on and off briefly with bonnet closed.

– When engine is switched off move wiper lever down to touchwipe function within 10 seconds.

The wipers move in service position.

– Lift the wiper arm away from windscreen.

Caution

When doing this, do not touch the wiper blade to prevent dam‐ age.

96 4. Descriptions of work:

AG.

Wiper blade protection, version 1: re‐ moving

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Prote cted by c o py rig ht .

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4.40.1

ht rig py Co t.

Changing wiper blade protection, version 3 -transport wiper blade- ⇒ page 98

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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

Version 2: blade protector to slide on

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Wiper blade protection, version 1: removing ⇒ page 96

Polo 2002 ➤ Maintenance - Edition 02.2018

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– Remove upper securing clip upwards and lower securing clip downwards -arrows-.

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– Pull blade protector off wiper blade from bottom to top, as shown in illustration.

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

– Carefully place wiper arm back onto windscreen.

– Switch ignition on and briefly operate the wiper lever to move the wipers back to park position. Switch ignition off again.

– Switch ignition on and off briefly with bonnet closed.

– Lift the wiper arm away from windscreen.

AG.

Caution

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Prote cted by c o p yri gh t.

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The wipers move in service position.

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– When engine is switched off move wiper lever down to touchwipe function within 10 seconds.

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Wiper blade protection, version 2, re‐ moving r te o iva r rp fo ng

4.40.2

When doing this, do not touch the wiper blade to prevent dam‐ age.

– Pull blade protector off wiper blade upwards, as shown in il‐ lustration.

– Carefully place wiper arm back onto windscreen.

– Switch ignition on and briefly operate the wiper lever to move the wipers back to park position. Switch ignition off again.

4. Descriptions of work:

97

Polo 2002 ➤ Maintenance - Edition 02.2018

4.40.3

Wiper blade protection, version 3 -trans‐ port wiper blade: changing

– Switch ignition on and off briefly with bonnet closed.

– When engine is switched off move wiper lever down to touchwipe function within 10 seconds.

The wipers move in service position.

– Lift the wiper arm away from windscreen.

– Depending on version, turn wiper blade with lip upwards and pull off, or release wiper blade at joint -3- by pushing locking device -1- into mounting -2- and pull wiper blade out.

– Slide standard wiper blade into mounting and ensure that it audibly engages, or turn wiper blade with lip down onto stop.

Caution

When doing this, do not touch the wiper blade to prevent dam‐ age.

– Carefully place wiper arm back onto windscreen.

– Switch ignition on and briefly operate the wiper lever to move the wipers back to park position. Switch ignition off again.

4.41

Headlight adjustment: Check, adjust . Volkswagen AG headlights if necessary gen AG does swa k Vol

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ting line ⇒ page 100 . pe rm itte d

Adjust headlights ⇒ page 101 . es, in part or in w l purpos hole ercia , is n m ot com

Fog lights and other additional lights: Adjust ⇒ page 102 .

Test requirements

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

4.41.1

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not gu ara nte i r o eo h ut ra Checking headlight adjustment using test screen without 15° set‐ a c s s

Test conditions ⇒ page 98sed by

Special tools and workshop equipment required

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AG.

Prote cted by c o py rig ht .

C op yi

98 4. Descriptions of work:

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♦ Or

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♦ Headlight adjustment unit - VAS 5046-

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Headlight adjustment unit - VAS 5047♦ Headlight adjustment unit - VAS 5208A♦ Headlight adjustment unit - VAS 5209A♦ Headlight adjustment unit - VAS 5209BThe following test and adjustment instructions are applicable in all countries. However, national guidelines and regulations of the respective country are to be followed.

Conditions for testing and adjustment: • •

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ran The vehicle me‐ ise must be rolled forward or backward several tee or h t or tres or front and rear springs must be bounced fully several u ac a ss so that springs settle. times

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Vehicle and headlight adjuster must be on a level surface. → Operating instructions for headlight adjusters VAS 5046, VAS 5047, VAS 5208A, VAS 5209A, VAS 5209B.

•

Vehicle and headlight adjuster must be aligned.

•

Inclination must be set.

•

Reflectors and bulbs OK.

•

Vehicle must be loaded.

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

Loading: with one person or 75 kg on the driver seat and the ve‐ hicle otherwise unloaded (unladen weight).

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

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If the fuel tank is not at least 90 % full, then load as follows:

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Fuel gauge table

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Fuel gauge reading

Additional weight in kg

To 1/4 To 1/2 To 3/4 Full

30 20 10 0

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– Read level of fuel in fuel tank on fuel gauge. Determine addi‐ tional weight from following table and place weight in luggage compartment. ht rig py Co t.

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•

Tyre pressure OK.

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

Note ♦ For this purpose, a container filled with water or gravel can be

used, for example (a 5-litre fuel canister filled with water weighs approx. 5 kg).

♦ Write the weight in kg on the container and secure it against

being opened again in order to prevent misuse.

♦ In order to avoid soiling vehicle, place a mat or covering of

some kind in the luggage compartment.

4. Descriptions of work:

99

Polo 2002 ➤ Maintenance - Edition 02.2018 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 1.0 % is equivalent to 10 cm.

For vehicles in the North American market, an inclination of 0.7 % is to be set.

Inclination of 2.0 % applies for fog lights.

If the vehicle is equipped with separate dipped and main beam, adjust main beam additionally. When adjusting main beam en‐ sure that the adjustment unit is set to 0%.

– Check headlight height adjustment by setting the maximum level and monitoring the headlights' light.

– If fitted, then set the headlight range control thumb wheel to position 0 .

Note ♦ For certain export markets halogen headlights with manually

regulated headlight range control are not offered.

♦ For NAR vehicles the side adjustment of headlight is not per‐

mitted, therefore the adjustment screw is secured against turning. Adjustment is only allowed once when the headlight is to be exchanged. When the side adjustment screw has been adjusted once, it must be secured with a cap ⇒ Electronic parts catalogue (ETKA) . In this case, push securing cap into opening of side adjustment until it is securely seated.

4.41.2

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

Checking headlight adjustment (using test screen without 15° setting line) un le pe rm itte d

Check the following:

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Headlights:

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– Whether, with the dipped beam switched on, the horizontal bright/dark boundary contacts the dividing line -1- of the test area and – Whether the breaking point -2- between the horizontal part of the bright/dark boundary on the left and the rising part on the right lies on the vertical line of the central point -3-. The bright core of the light beam must be to the right of the vertical line.

Note

♦ To simplify the determination of the breaking point -2-, cover

and uncover left (from driver perspective) half of the headlight a few times. Then check dipped beam again. the main beam must lie on the centre mark -3-.

♦ If the vehicle is equipped with separate dipped and main

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AG.

100 4. Descriptions of work:

Prote cted by c o py rig ht .

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Fog lights:

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beam, adjust main beam additionally. When adjusting main beam ensure that the adjustment unit is set to 0%.

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r te o iva r rp fo g n

♦ After correct adjustment of dipped beams, the centre point of

Polo 2002 ➤ Maintenance - Edition 02.2018 – Check whether the upper light-dark border touches the setting line and runs horizontally over the entire width of the test screen.

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

4.41.3

Adjusting headlights

Note

Check that both headlights move evenly when manually operated headlight range control is operated.

Adjusting right headlight:

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olks The adjustment bolts for the left headlight are a mirror image. yV b ed

ris unit.

– Set corresponding inclination on headlight adjustment ho

t au

•

For vehicles for the North American market, an inclination of 0.7 % always applies.

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

Note

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The inclination for headlights with halogen bulbs ss is “1.0 %”

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•

Percentage given is based on a projection distance of 10 metres.

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AG.

4. Descriptions of work:

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ht rig py Co t.

Prote cted by c o p yri gh t.

C op yi

Up to ►2005

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Right headlights (the left headlight adjustment screws are a mirror image):

101

Polo 2002 ➤ Maintenance - Edition 02.2018 From 2006► -1- Lateral adjustment -2- Height adjustment – First turn height adjustment bolt of bright/dark boundary -2-.

– Then check lateral adjustment, if necessary correct with ad‐ justment screw -1-.

4.41.4

Fog lights and other auxiliary lights: ad‐ justing

Fog light (right) Location of adjustment screw on left-hand fog light is a mirror im‐ age.

– Set corresponding inclination on headlight adjustment unit.

•

The inclination for fog lights is “2.0 %” Note

Percentage given is based on a projection distance of 10 metres.

Up to ►2005 – To reduce the headlight range turn adjustment screw to the right. There is no provision for lateral adjustment.

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

From 2006►

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran Location of adjustment screw on left-hand headlight is a mirrorrised tee o h image. t or u ac a ss

– Unscrew bolt -1-, tightened to the air intake grille on the right side in direction of travel.

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c o p yri gh t .

C op yi

102 4. Descriptions of work:

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– Unclip the air intake grille -2-.

Polo 2002 ➤ Maintenance - Edition 02.2018 – To adjust the headlight range turn screw -arrow-.

– Retighten air intake grille after adjustment.

– On the left side the air intake grille is not bolted, otherwise it is the same procedure.

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

4.42

Sunroof: checking function, cleaning and greasing guide rails

Carry out following procedure: – Check function of sunroof.

or ac

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

Service interval display: resetting

Reset service interval display for vehicles with time or distance dependent service or LongLife service Note

♦ If vehicles with LongLife service (PR number QG1) are not

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using engine oil conforming to VW standard 503 00 (petrol engine), VW standard 506 00 (TDI) or VW standard 506 01 (TDI unit injector), the service interval display must be recoded to non-flexible. ⇒ page 106

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

4.43

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♦ Vehicles with LongLife service (PR number QG1), which have

an oil change service at approx. 15,000 km or 12 months the service interval display must be recoded to non-flexible. This ensures that these vehicles resume the normal LongLife serv‐ ice rhythm. Recoding service interval display to non-flexible: ⇒ page 106 agen lksw Vo by

AG.

Prote cted by

The service interval display can be reset using one of two meth‐ ods: ♦ With adjustment button for distance display on dash panel in‐ sert ⇒ page 104 Or ♦ With diagnostic tester ⇒ page 105

4. Descriptions of work:

103

Polo 2002 ➤ Maintenance - Edition 02.2018 Note

It is also possible to reset the service interval display manually. If the SID is reset manually, it must be taken into account that the vehicle is coded to non-flexible intervals, i.e. every 15,000 km or 12 months. This also modifies the adaptation channel for oil qual‐ ity.

4.43.1

Resetting service interval display with adjustment buttons for distance display and clock on dash panel insert

The service interval display must be reset (adapted) during ♦ every inspection service !

Note ♦ For vehicles with LongLife service (PR number QG1 ) at de‐

livery inspection, the service interval display must not be reset using the distance display and clock adjustment buttons. Rea‐ son: When the service interval display is reset using the ad‐ justment buttons for distance and clock on dash panel insert, the dash panel insert is automatically coded to non-flexible, i.e. to “time or distance dependent” service.

♦ If vehicles with “LongLife service” (PR number QG1) are filled

♦ Vehicles with LongLife service (PR number QG1), which have

an oil change service at approx. 15,000 km or 12 months the service interval display must be recoded to non-flexible. Rea‐ son: This ensures that these vehicles resume the normal LongLife service rhythm.

Reset the display as follows: – Switch off ignition.

– Press and hold button -1- next to speedometer.

r fo ng

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AG.

Prote cted by

c o p yri gh t .

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104 4. Descriptions of work:

ht rig py Co t.

– Switch on ignition.

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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with an engine oil conforming to VW standard 503 00 (petrol . Volkswagen AG gen AG does swa engine), VW standard 506 00 (TDI) or 506 01 (TDI unitolkinjector) not gu y V must b during inspection service, the service interval display ara d e nte ris NOT be reset using the distance display andhclock adjustment o eo t u ra buttons on dash panel insert. Reason: When the service in‐ c sa s terval display is reset using the adjustment buttons for dis‐ tance and clock on dash panel insert, the dash panel insert is automatically coded to non-flexible, i.e. to “time or distance dependent” service.

Polo 2002 ➤ Maintenance - Edition 02.2018 In display -1- 1) or -2- 2) of dash panel insert (depending on vehicle equipment) in display unit -1- the note “Service IN” appears or “SERVICE SINCE” or in display unit -2- a “workshop symbol” or a “clock” is displayed. An overdue service is identified additionally by a “minus sign”.

1) 1 Display unit in centre of dash panel insert 2) 2 Display unit in speedometer

– Release button -1-.

–

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u Turn a adjusting knob -1- next to speedometer to right.r ac s s

pe rm itte d

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The service displayed is being reset and the display in the dis‐ tance display or centre display changes to the normal state.

4.43.2

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

Resetting service interval display using diagnostic tester

– Connect vehicle diagnostic tester ⇒ page 28 .

r te o iva r rp fo g n

do c um en

– Touch the field or button on the screen for »GUIDED FUNC‐ TIONS«.

If the display is not as shown in the procedure: ⇒ Operating in‐ structions for diagnostic tester c o p yri gh t.

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– Confirm with > button.

AG.

Prote cted by

♦ Brand

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– Select one after another:

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

– Switch off ignition.

♦ Model ♦ Model year ♦ Engine code – Confirm vehicle identification.

– Select one after another:

4. Descriptions of work:

105

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ “Dash panel insert” -ARROW-. ♦ “Reset service interval display”.

– Carry out adaption according to the information of “GUIDED FUNCTIONS”.

Ending adaption Indicated on display: – Press GoTo button on display -arrow-.

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

– Press End button in End menu.

– Switch off ignition and separate diagnosis connections.

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– Switch on ignition.

Service interval display: recoding

– Connect vehicle diagnostic tester ⇒ page 28 .

– On the screen, touch “GUIDED FUNCTIONS” field or button.

Note

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

– Select one after another: ♦ Brand ♦ Model year Prote cted by c o py rig ht .

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– Confirm vehicle identification.

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♦ Engine code

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If the vehicle identification has been performed correctly, confirm with > button.

AG.

106 4. Descriptions of work:

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r te o iva r rp fo g n

♦ Model

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

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4.44

Polo 2002 ➤ Maintenance - Edition 02.2018 – Select one after another: ♦ “Dash panel insert” -ARROW-. ♦ “Adapting service interval extension”.

– Carry out adaption according to the information of “GUIDED FUNCTIONS”.

Ending adaption

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

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

– Press End button in End menu.

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– Switch off ignition and separate diagnosis connections.

Carry out following procedure:

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Track rod ends: checking clearance, firm seating and boots

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

4.45

– With the vehicle raised (wheels hanging free), check play by moving track rods -arrow- and wheels. Clearance: zero clear‐ ance – Check attachment.

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AG.

4. Descriptions of work:

in t his d o cu m en

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– Check if boots are not damaged and are seated correctly.

107

Prote cted by c o p yri gh t.

C op yi

Polo 2002 ➤ Maintenance - Edition 02.2018

4.46

Dust and pollen filter: renew filter ele‐ ment

Procedure Heating, ventilation, air conditioning system ⇒ Rep. gr. 80 → Repairing heating system → Removing and installing dust and pollen filter.

Note

For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information.

4.47

Door arrester: grease.

Perform the following procedure: – Lubricate door arrester at positions -1-, -2-, -3- and -4- with universal oil spray - G 000 115 A2- .

Ensure universal oil penetrates by moving door several times over all detents.

– Wipe off excess universal oil with a cloth.

do c um en

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

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108 4. Descriptions of work:

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–

n AG. Volkswagen AG do es n wage s k l ot g o Then, lubricate door arrester rollers y Vwith lubricating paste - G ua b d ran 000 150- at positions marked with ir se an -arrow-. tee o h t or u ac a ss

Polo 2002 ➤ Maintenance - Edition 02.2018

4.48

Transportation device: Remove block‐ ing pieces from front axle springs

Blocking pieces are fitted to front axle springs for all vehicle ver‐ sions. These vehicles are identified by a warning tag on the mirror -arrow-.

Note

The blocking pieces prevent the springs compressing and possi‐ ble damage to the vehicle when being driven onto a vehicle transporter or railway wagon.

Caution

The blocking pieces must be removed without reservation be‐ fore delivering the vehicle. A “Warning” notice, attached to the interior rear view mirror, specifically reminds of this.

Carry out following procedure: Note

There is no requirement to remove the wheels.

– Relieve weight on springs by raising vehicle with a hoist.

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

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– Slide suspension strut protective sleeve -arrow- upwards.

4. Descriptions of work:

109

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Polo 2002 ➤ Maintenance - Edition 02.2018 – Push blocking piece -arrow- off piston rod.

– Slide suspension strut protective sleeve downwards onto sus‐ pension strut.

4.49

Recoding dash panel insert

•

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with time and distance dependent service (visible on data sticker: “QG2”, “QG0”); in countries listed in chapter “Countries where diesel has a high sulphur content” (ask your importer which countries have diesel with a high sulphur content).

– Connect vehicle diagnostic tester ⇒ page 28 .

– Press button »Vehicle self-diagnosis«.

– Now select “17-Dash panel insert”.

– Now select diagnostic function “07-Coding control unit”.

The actual four or five-digit code can be found on the upper right of screen next to “Coding”.

– Enter new code “xx0x” or “xxx0x” in display zone, only change 2nd digit from right, “1” to “0”. r fo ng

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– Press lower left button arrow .

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– Now select “10-Adaption”.

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The control unit is now coded to “QG0”.

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– For channel 43 enter 43 in display zone and press button Q at lower right.

– A horizontal bar is shown on display on which a vertical slider can be moved backwards and forwards. However it is quicker to use the number block. It is not possible to enter exactly 7500 km, because the system only accepts steps of 1000 km.

Enter 8 for oil service interval of 7500 km. Select “Save” and then “Accept” to accept the value.

– The coding is now completed, end vehicle self-diagnosis using buttons GoTo and “End”

110 4. Descriptions of work:

do c um en

– For entry press button Q on lower right of display and confirm.

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

•

with LongLife service (visible on data sticker: “QG1”);

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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AG. Volkswagen AG d agen oes ksw not l o Note gu yV b ara d e nte is r o eo h Recoding to non-flexible intervals only valid for vehicles: ut ra a c s s

Polo 2002 ➤ Maintenance - Edition 02.2018

4.50

Clock: setting to correct time

Carry out adjustment as follows: Setting hours: – Turn setting knob -1- (on lower left next to speedometer) anticlockwise.

By turning the setting knob shortly, the clock will be altered by one swagen AG G. Volkthe gen Aknob hour. By turning and holding the setting alteration doeswill be a w ks not Vol continuous. gu by a ed ris ho t au

Setting minutes:

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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 adjustment knob to the right at the moment when the seconds indicator of accurate clock shows a full minute.

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Underseal: inspecting for damage to un‐ derseal, underbody cladding, routing of lines and plugs

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4.51

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ss -1- clockwise.

– Turn setting knob

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During inspection, also check floor pan, wheel housings and sills.

AG.

Always ensure that all lines are secured in their mountings, all plugs are available and that there is no visible damage on the underbody.

Always ensure that there are no cracks, detachments and corro‐ sion of underbody protection on the sealing caps -arrows-.

Note

Faults found must always be rectified (repair measure). This in‐ hibits corrosion and rusting through.

4.52

Toothed belt and tensioning roller: Re‐ new Note

Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life and cannot be covered by goodwill or warranty processing.

4. Descriptions of work:

111

Polo 2002 ➤ Maintenance - Edition 02.2018 Toothed belt and camshaft drive tensioning roller: renew.

– »Power unit« ⇒ Power unit; Rep. gr. 15 ; Cylinder head, valve gear; removing and installing toothed belt »Cylinder head, valve gear; removing and installing toothed belt«.

4.53

Camshaft drive toothed belt: Renewing (4-cylinder 5-valve petrol engine)

»Power unit« ⇒ Power unit; Rep. gr. 15 ; Cylinder head, removing and installing toothed belt »Cylinder head, removing and installing toothed belt«.

4.54

Camshaft drive toothed belt: Check (4cylinder petrol engine) not for engine code AXU

Toothed belt: checking condition – Open clips for upper toothed belt guard and remove cover.

– By turning crankshaft one full turn, check toothed belt condi‐ tion for:

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Layer separation (toothed belt body, tensile cords) is r o eo h ut ra a c Toothed belt body breakup s s

♦ Cracks, cross sectional breaks

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♦ Frayed cord strands

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♦

♦ Surface cracks (synthetic coating)

Note

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♦ Traces of oil and grease

If faults are found, always renew toothed belt. This can avoid breakdowns and malfunctions. The replacement of a toothed belt is a repair measure.

When checking condition, especially watch for following damage: B - Side contact C - Fraying

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Renewing spark plugs, engine codes BUD, BTS ⇒ page 114 Renewing spark plugs, engine codes AUA and AUB ⇒ page 114 .

Renewing spark plugs, engine codes AWY, BBY, BBZ, AXU, AZQ, BMD, BME, BKY, BUD, BTS, BZG ⇒ page 115 .

Renewing spark plugs, 1.8 l 5-valve engines ⇒ page 116 Special tools and workshop equipment required

112 4. Descriptions of work:

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Renewing spark plugs

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4.55

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D - Cracks (in teeth base)

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A - Cracks (coating)

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Spark plug socket - VAS 3122B-

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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♦ Puller - T40039-

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

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♦ Assembly tool - T10118-

4. Descriptions of work:

113

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Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Puller - T10094 A-

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Spark plugs: renewing, engine codes BUD, BTS

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

4.55.1

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♦ »Power unit« ⇒ Power unit; Rep. gr. 28 ; Test data, spark plugs »Test data, spark plugs«

– Carefully pull off hose -2-.

– Unscrew the four bolts -1- and remove cover.

– Installation is carried out in the reverse sequence of removal.

– Remove engine cover panel. ⇒ page 81

– Take ignition cables -2- out of ignition cable guide -3- and pull ignition cable guide slightly upwards.

– Pull off spark plug connectors and place ignition cables with ignition cable guide to side.

114 4. Descriptions of work:

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– Take off oil sealing cap -1-.

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Carry out following procedure:

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Spark plugs: renewing, engine codes AUA and AUB

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4.55.2

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Specified torque for bolts: 10 Nm

Polo 2002 ➤ Maintenance - Edition 02.2018 – Unscrew spark plugs using spark plug socket - VAS 3122B- .

– Screw in new spark plugs using spark plug socket and exten‐ sion - VAS 3122B- .

Note ♦ Spark plug designation and specified Gtorque, »Power unit« ⇒ . Volkswage

n AG d A agen spark plugs »Test Power unit; Rep. gr. 28 ; Test data, oesdata, not lksw o V gu spark plugs«. by a

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– Fit spark plug connectors.

– Fit oil sealing cap -1-.

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– Press ignition cables -2- into ignition cable guide.

– Install engine cover panel. ⇒ page 81

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– Remove engine cover panel ⇒ page 81 .

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– Carefully pull off hose -2-.

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Only valid for BUD and BTS:

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Renewing spark plugs, engine codes AWY, BBY, BBZ, AXU, AZQ, BMD, BME, BKY, BUD, BTS, BZG

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4.55.3

– Unscrew the four bolts -1- and remove cover.

Valid for all:

4. Descriptions of work:

115

Polo 2002 ➤ Maintenance - Edition 02.2018 – Fit puller - T10094 A- on ignition coil with output stage -arrow-.

– Slightly pull out ignition coil with output stage.

– Fit assembly tool - T10118- as shown.

– Release connection locking device carefully and pull off con‐ nector.

– Pull out ignition coil with output stage.

– Unscrew spark plugs using spark plug socket - VAS 3122B- .

– Screw in new spark plugs using spark plug socket and exten‐ sion - VAS 3122B- .

Note ♦ Spark plug designation and specified torque »Power unit« ⇒

Power unit; Rep. gr. 28 ; Test data, spark plugs »Test data, spark plugs«.

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– Place puller - T10094 A- on ignition scoil with output stage. s

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– Push connector onto ignition coil with output stage until it en‐ gages audibly.

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– Push ignition coil with output stage in -direction of arrow- into cylinder head.

– Install engine cover panel. ⇒ page 81 Only valid for BUD and BTS:

– Fit cover and tighten bolts of cover to 10 Nm.

♦ To pull off spark plugs, fit puller - T40039- on top, thick rib Prote cted by c o p yri gh t.

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-arrow- of ignition coils with final output stages.

116 4. Descriptions of work:

AG.

Removing and installing engine cover panel -top- ⇒ page 81 .

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♦ If the lower ribs are used, they could be damaged.

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Note

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Removing:

Renewing spark plugs, 1.8 l 5-valve en‐ gines

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4.55.4

Polo 2002 ➤ Maintenance - Edition 02.2018 – Remove bolts -arrows- from vacuum reservoir -A- and place vacuum reservoir to side with lines connected.

The spark plugs are located below the ignition coils with output stages -2-.

Note

Note installation position of ignition coils with output stages.

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– Press connectors in direction of ignition coils with output stages, press onto catch by hand and pull connectors -arrows- off.

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– Pull all ignition coils out of cylinder head approx. 30 mm in direction of arrow using puller - T40039- .

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–

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Remove the two ibolts e nte s r o eo h ut ra a c s s

4. Descriptions of work:

117

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Polo 2002 ➤ Maintenance - Edition 02.2018 – Unscrew spark plugs using spark plug socket - 3122 B- .

Note ♦ Spark plug designation and specified torque »Power unit« ⇒

Power unit; Rep. gr. 28 ; Test data, spark plugs »Test data, spark plugs«.

♦ Observe environmental regulations for disposal.

Installing AG. Volkswagen AG d – Screw in new spark plugs using spark plug socketswand agenexten‐ oes k not l o sion - 3122 B- and tighten to correct torque setting.

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–

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– Align ignition coils with output stages in respective recesses of cylinder head cover.

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– Fit all connectors onto ignition coils -arrows-.

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118 4. Descriptions of work:

AG.

– Installing engine cover, ⇒ page 81 .

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– Install vacuum reservoir -A- and tighten bolts to 5 Nm.

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– Secure cable guides with bolts -1-.

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– Press ignition coils with output stages on spark plugs until stop by hand. They must be felt to engage.

Polo 2002 ➤ Maintenance - Edition 02.2018

4.56

Diesel particulate filter: check.

Note

When checking the diesel particulate filter the ash mass limit val‐ ue is read.

– Connect vehicle diagnostic tester ⇒ page 28 .

– Switch on ignition.

– On the screen, touch »GUIDED FUNCTIONS« field or button.

If the display is not as shown in the procedure: ⇒ Operating in‐ structions for vehicle diagnostic tester – Confirm with > button.

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

– Select one after another: ♦ Brand

♦ Engine code

– Confirm vehicle identification.

– Select vehicle system “Engine”.

– Select “Checking ash mass of diesel particulate filter”.

Follow instructions on display.

– End test.

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– Switch off ignition and separate diagnosis connections.

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♦ Model year

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♦ Model

4. Descriptions of work:

119

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Polo 2002 ➤ Maintenance - Edition 02.2018

Exhaust emissions test pe rm itte d

Note

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5

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♦ Please observe the country specific legal regulations.

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♦ The exhaust emissions test described below has been created

according to the legal regulations valid in Germany.

Exhaust emissions test for diesel engines ⇒ page 129 Exhaust emissions test for petrol engines ⇒ page 120

5.1

Exhaust emissions test for petrol en‐ gines

Exhaust emissions test for petrol engines without OBD ⇒ page 122 Exhaust emissions test for petrol engines with OBD r te o iva r rp fo ng

♦ Exhaust gas testing station L - VAS 7320 A-

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♦ 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.

•

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 data: ♦ Registration number ♦ Key numbers ♦ Vehicle identification number

120 5. Exhaust emissions test

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board diagnosis” OBD.

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♦ The following description refers to vehicles fitted with “On‐

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Special tools and workshop equipment required

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Fuel type ♦ Mileage The following vehicle data can be found in the vehicle registration n AG. Volkswagen A G do es n wage certificate part 1: o olks

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♦ Registration number: “e.g. WOB-HH 1234”

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♦ Emission key number “field 14.1 (code for field 14)” ss 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

♦ Vehicle manufacturer: “field 2”, “field 2.1 (code for field 2)” ♦ Vehicle identification number “field E”

Specified data input for EET

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

♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for field D.2)” 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 exhaust gas testing station r fo ng

specific vehicle via the network to the respective mask.

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Manual specified data input for EET:

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♦ The ELSA web service automatically transmits the data for the

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L which is used for the exhaust emissions test must be inte‐ grated in the workshop network.

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: 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”.

9-

Lambda probe value

Specified data input for EET as bar code:

5. Exhaust emissions test

121

Polo 2002 ➤ Maintenance - Edition 02.2018 – 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 – Follow instructions from exhaust gas testing station .

Exhaust emissions test for petrol engines without OBD Note ♦ All test conditions and data required for emissions test ⇒ Ex‐

haust emissions test binder

♦ 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 (check only).

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 event memory.

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The following description refers to vehicles without OBD with regulated catalytic converter.

Special tools and workshop equipment required

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122 5. Exhaust emissions test

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♦ Adapter for older vehicles - VAS 5051/2-

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♦ Emissions testing station - VAS 6300-

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Note

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a injection system, the ignition system wiring (including high r ac ss voltage wiring) should be connected and disconnected only with ignition switched off.

Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ Engine speed adapter - VAS 5087/ A♦ Exhaust emissions test binder Note ♦ It is only possible to carry out an exhaust emissions test when

all units of the exhaust emissions station - VAS 6300- are con‐ nected properly and combined with each other according to the operating instructions.

♦ All work to be performed is displayed by the exhaust emissions

station - VAS 6300- .

Test requirements: •

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.

•

en A Automatic gearbox: selector lever in position “P” orag“N”. lksw

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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-.

An overview is displayed to select the respective EET type.

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– Select “EET petrol” -arrow-.

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5. Exhaust emissions test

123

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Polo 2002 ➤ Maintenance - Edition 02.2018 The display for warm-up phase appears.

– Continue exhaust emissions test according to instructions on display.

– If the EET specification selection is displayed, select respec‐ tive “EET specification selection” -arrow-. ♦ When exhaust emissions test is performed for the first time, either select “Standard values”, ♦ Or “Last vehicle” when an exhaust emissions test is to be car‐ ried out again.

– Select “Continue” on display see -item 1-.

Vehicle data input:

♦ 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

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124 5. Exhaust emissions test

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log book is now called the vehicle registration certificate part 2.

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The vehicle data input menu is displayed.

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Polo 2002 ➤ Maintenance - Edition 02.2018 ♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ♦ -2- Vehicle type: “e.g. Golf” ♦ -3- Key number for 1: “e.g. 11” ♦ -4- Key number for 2: “e.g. 0603” (vehicle registration docu‐ ment) ♦ -4- Key number for 2.1 (code to 2): “e.g. 0603” (vehicle regis‐ tration certificate part 1) ♦ -5- Key number for 3: “e.g. 358” (vehicle registration docu‐ ment) ♦ -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” . Volkswagen AG gen AG a lksw

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♦ Further functions can be called up using GoTo button.

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Note

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– Enter mileage (km) sat s a -item 9- “e.g. 32000”.

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♦ The test can be terminated using GoTo button.

Specified data input for EET: Note

♦ If specifications are not available as bar code, they are to be

entered manually.

♦ All test conditions and data required for exhaust emissions Manual specified data input for EET: ht rig py Co t.

– Perform manual data input according to instructions on dis‐ play.

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test, see EET data sheet for respective engine.

5. Exhaust emissions test

125

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Polo 2002 ➤ Maintenance - Edition 02.2018 – 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 has been entered properly, press »Continue« -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.

All data required are shown on display.

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126 5. Exhaust emissions test

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– Press ► -arrow- to proceed.

Polo 2002 ➤ Maintenance - Edition 02.2018 Visual inspection: – Follow instructions on display.

– Perform visual check.

– If visual check is OK, press “OK” button -arrow-.

Note

When the "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.

♦ For these engines, the engine speed adapter -VAS 5087/- can AG. Volkswagen

be used.

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– Switch ignition on.

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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: It is automatically switched to warm-up phase of catalytic con‐ verter.

– Follow instructions on display. r te o iva r rp fo ng

Measurement starts when the engine speed has reached the re‐ quired level.

– Maintain engine speed in required engine speed range. ht rig py Co t.

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The remaining time to perform the warm-up phase is displayed -arrow A-.

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– Insert emission probe in exhaust tail pipe.

5. Exhaust emissions test

127

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Polo 2002 ➤ Maintenance - Edition 02.2018 Warm-up phase: It is automatically switched to display for measuring agen AG tem‐ n AG. Volkswengine does wage perature. no olks

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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 ♦ Measured values are reset using ← button, and the test can agen lksw Vo by

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be repeated.

– Maintain engine speed in required engine speed range.

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The remaining time to perform measurement is displayed -arrow A-.

Measuring idling speed and CO content: It is automatically switched to display for measuring the idling speed and CO content.

Measurement starts when the engine speed has reached the re‐ quired level.

The remaining time to perform measurement is displayed -arrow A-.

Regulating probe test: It is automatically switched to display for regulating probe test.

Measurement starts when the engine speed has reached the re‐ quired level.

– Maintain engine speed in required engine speed range.

The remaining time to perform measurement is displayed -arrow A-.

128 5. Exhaust emissions test

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emissions test has failed.

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ed – Follow instructions on display. ris

Polo 2002 ➤ Maintenance - Edition 02.2018 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”, see -arrow C-.

After confirming, the two “TEST CERTIFICATES” are printed out automatically.

– If a further test certificate is required, press -arrow A- “Print” button.

– Follow instructions on display.

– Take emission probe out of exhaust tail pipe.

– Then press ► -arrow B-.

The exhaust emissions test is completed, a new exhaust emis‐ sions test can be performed.

5.2

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Exhaust emissions test for diesel engines without OBD with diesel tho au s tester V.A.G 1743 ⇒ page 129 s pe rm itte d

Exhaust emissions test for diesel engines without OBD with emis‐ sions testing station VAS 6300 ⇒ page 136

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5.2.1

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Exhaust emissions test for diesel engines with OBD ⇒ page 145

Exhaust emissions test for diesel en‐ gines without OBD with diesel tester V.A.G 1743

The test sequence is designed for the test with test unit combi‐ nation for the emissions test.

Special tools and workshop equipment required

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♦ Diesel tester - V.A.G 1743-

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Polo 2002 ➤ Maintenance - Edition 02.2018

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Note ♦ All test conditions and data required for exhaust emissions

test: ⇒ Data sheets for exhaust emissions test

♦ If possible, the test should be completed outdoors following a

road test. If this is not possible for various reasons (weather, excessive noise in residential areas), then the test can be car‐ ried out in a workshop.

♦ To reduce noise levels, the bonnet should be closed on first

catch during tests.

Carrying out visual check of components that affect pollution – Performing visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

130 5. Exhaust emissions test

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♦ ⇒ Data sheets for exhaust emissions test

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♦ Data reader - V.A.G 1799-

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♦ Data reader - V.A.G 1798-

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♦ Engine speed adapter - VAS 6296-

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♦ or

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♦ Engine speed adapter - VAS 5087 A-

Polo 2002 ➤ Maintenance - Edition 02.2018 Test prerequisites •

Engine temperature at least 80 °C

•

No fault stored in event memory

Connecting test units Connect diesel tester - V.A.G 1743- according to operating in‐ structions.

Description, measuring process, function, setting up and opera‐ tion see ⇒ V.A.G 1743 operating instructions Note ♦ The engine speed adapter - VAS 5087 A- or the engine speed

adapter - VAS 6296- can be used instead of the TDC sender, for engines where the hole of the TDC sender cannot be reached or cannot be reached easily or is large.

♦ It is not possible to use the diesel tester pick-up clamp (for

cylinder 1).

– Connect engine speed adapter - VAS 5087 A- with ignition switched off as follows: Note ♦ Follow operating instructions for engine speed adapter - VAS

5087 A- !

♦ Strictly follow the safety precautions in the operating instruc‐

tions!

– Connect adapter cable - VAS 5087/3- from output connector of engine speed adapter - VAS 5087 A- to pick-up clamp input . Volkswagen AG gen AG does of diesel tester - V.A.G 1743- . swa olk yV

b – Set rotary switch to respective number of cylinders for engine, ed ris o e.g. “4” for 4-cylinder engine. h t

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5. Exhaust emissions test

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s – Connect a cable from adapter - VAS 5087/1- to engine speed adapter - VAS 5087 A- (socket VAS 5087/1).

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Polo 2002 ➤ Maintenance - Edition 02.2018 – Using the other wires from adapter - VAS 5087/1- make a connection to the vehicle battery, by connecting: ♦ Red clamp on positive ♦ Black clamp on negative.

Note ♦ When using the engine speed adapter - VAS 5087 A- press

button “Start”. The red signal lamp must flash for approx.

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 ⇒ Op‐

erating instructions for VAS 5087

Test sequence – Start engine and run it at idling speed.

– Press F2 button for “EET diesel” on data reader.

If this message appears on the display: Please insert vehicle identity card!!

Manual input with -> button

– Enter vehicle identification data as follows, using data reader keyboard: ♦ Registration number ♦ Vehicle manufacturer = “NO. 2” ♦ Key number = “to NO. 2” ♦ Vehicle type = “NO. 3” ♦ Key number = “to NO. 3” (the first 3 digits) ♦ For vehicle identification number = “NO. 4” ♦ Engine code un le

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♦ Mileage

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Check input with -> button Continue with Q button

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– Confirm entry of vehicle identification data by pressing Q but‐ ton.

If this message appears on the display: Read bar code Manual input with the -> button

– Enter specifications using bar code reader of data reader, to do this slide bar code reader over respective bar code of data sheet in “Exhaust emissions test” binder.

Or

– Carry out entry by hand following instructions on data reader display using → button.

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132 5. Exhaust emissions test

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– Confirm vehicle data entered or read using Q button.

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Check input with the -> button Continue with the Q button

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If this message appears on the display:

Polo 2002 ➤ Maintenance - Edition 02.2018 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 measur‐ ing sensor and push dipstick in until stop.

– Continue test sequence by pressing the Q button.

If this message appears on the display: Idling speed -> Speed ACT. xxxx rpm SPEC. xxxx rpm

– Press → button.

Idling speed not within specified range: Note

The idling speed and maximum speed can be checked but not adjusted.

– If the values are not within specified range, a repair must be made.

– 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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– Depress accelerator pedal fully and hold for specified Vol

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If this message appears on the display:

Rev limit -> Speed ACT. xxxx rpm SPEC. xxxx...xxxx rpm

– Release accelerator pedal.

– Check actual values. To do this, switch the actual display to the next display by pressing the → button.

Rev limit not within specified range:

– If the values are not within specified range, a repair must be made.

– Continue test sequence by pressing the Q button.

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Idling speed 1st measurement 15 sec Speed ACT. xxxx rpm SPEC. xxx...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 perform repair measures.

5. Exhaust emissions test

133

Polo 2002 ➤ Maintenance - Edition 02.2018 – The data reader accepts the actual values within 15 seconds.

If this message appears on the display: Data transfer to diesel tester Depress accelerator quickly

– Depress accelerator pedal fully and hold.

If this message appears on the 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 2nd measurement 15 sec Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm

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– Release accelerator pedal.

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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.

If this message appears on the 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.

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If this message appears on the 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 values within 15 seconds.

If this message appears on the display: Data transfer to diesel tester Depress accelerator quickly

– Depress accelerator pedal fully and hold.

134 5. Exhaust emissions test

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– Depress accelerator pedal fully and hold.

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Data transfer to diesel tester Depress accelerator quickly

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If this message appears on the display:

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The data reader accepts the actual values within 15 seconds.

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The data reader accepts the actual values within 15 seconds.

Polo 2002 ➤ Maintenance - Edition 02.2018 If this message appears on the display: 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: Average opacity figure -> ACT. x.xx rpm SPEC. x...x.xx rpm

– Press → button.

If the following is indicated on display: Opacity band width -> ACT. x.xx rpm SPEC. x...x.xx rpm

– Press → button.

If the following is indicated on display: Test OK Continue with Q button Repeat test with F1 button

– Press Q button.

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♦ If this message appears on the display:

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♦ Press F1 button and repeat test or carry out repair measures.

Enter remarks with -> button Continue with the Q button

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If this message appears on the display:

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Test n.OK Continue with Q button Repeat test with F1 button

– Enter remarks if necessary after pressing the → button.

– Press Q button.

If this message appears on the display: Select tester / manual input F3 F1 XXXXX F2 XXXXX

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– End test by pressing the F2 button.

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– Press → button.

5. Exhaust emissions test

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– Press Q button, wait for log print-out.

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– Select tester or enter name using F1 to F3 buttons.

135

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Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐ CAUTIONS” in the operating instructions for VAS 6300. es, in part or in w l purpos hole ercia , is n m ot com

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5.2.2

Note

The following description refers to vehicles not fitted with “On‐ board diagnosis”, OBD. Special tools and workshop equipment required

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Note ♦ It is only possible to carry out an exhaust emissions test when

all units of the exhaust emissions station - VAS 6300- are con‐ nected properly and combined with each other according to the operating instructions.

♦ All work to be performed is displayed by the exhaust emissions

station - VAS 6300- .

Test requirements: •

All test conditions and data required for exhaust emissions test are found on EET data sheet for the respective engine.

•

For bar code reading of specified data for EET, the EET data sheet must be printed out.

•

Automatic gearbox: selector lever in position “P” or “N”.

•

Manual gearbox: gear lever in neutral

•

Parking brake applied

– Perform exhaust emissions test according to instructions on display.

136 5. Exhaust emissions test

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♦ OBD adapter cable - VAS 5052/16-

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♦ Emissions testing station - VAS 6300-

Polo 2002 ➤ Maintenance - Edition 02.2018 Initial screen: – Select button “Exhaust emissions test” -arrow-.

An overview is displayed to select the respective EET type.

– Select “EET diesel” -arrow-.

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The display for warm-up phase appears.

5. Exhaust emissions test

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Polo 2002 ➤ Maintenance - Edition 02.2018 – Continue exhaust emissions test according to instructions on display.

olkswagen AG en AG. V does not gu ara nte is r o eo h When exhaust emissions testauist performed for the first time, ra c s either select “Standard values”, s

ag select respec‐ – If the EET specification selection is displayed, ksw Vol y tive “EET specification selection” -arrow-. b ed

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♦ Or “Last vehicle” when an exhaust emissions test is to be car‐ ried out again.

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– Select “Continue” -item 1- on display.

Vehicle data input:

The vehicle data input menu is displayed.

Note

♦ For new models the document previously known as the vehicle

registration document is now called the vehicle registration certificate part 1.

♦ For new models the document previously known as the vehicle r te o iva r rp fo ng

♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW”

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♦ -4- Key number for 2: “e.g. 0603” (vehicle registration docu‐ ment)

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♦ -4- Key number for 2.1 (code to 2): “e.g. 0603” (vehicle regis‐ tration certificate part 1) ♦ -5- Key number for 3: “e.g. 358” (vehicle registration docu‐ ment) ♦ -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 mileage (km) at -item 9- “e.g. 32000”.

Note ♦ Further functions can be called up using GoTo button. ♦ The test can be interrupted using GoTo button.

138 5. Exhaust emissions test

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♦ -3- Key number for 1: “e.g. 11”

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♦ -2- Vehicle type: “e.g. Golf”

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log book is now called the vehicle registration certificate part 2.

Polo 2002 ➤ Maintenance - Edition 02.2018 – Select “diesel below 3.5t” or “diesel above 3.5t” -arrow-.

Specified data input for EET: There are different ways to enter the specified ndata: AG. Volkswagen A

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♦ 1. By manual input ♦

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♦ 3. Through ELSA web service

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♦ To use the ELSA web service, the vehicle diagnostic tester ,

which is used for the exhaust emissions test, must be integra‐ ted 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

– Perform manual data input according to instructions on dis‐ play.

1-

Speed for conditioning

2-

Number of throttle bursts for conditioning

3-

Engine oil temperature (min. value)

4-

Select engine oil temperature measurement procedure

5-

Idling speed

6-

Governed speed

7-

Governed speed measuring period (1 second)

8-

Opacity figure (average)

9-

Select probe type (No. of probe)

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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.

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Note

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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

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Polo 2002 ➤ Maintenance - Edition 02.2018 All required data is shown on display -1-.

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Visual inspection:

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– Press → button -arrow- to continue procedure.

– Follow instructions on display.

– Perform visual check.

– If visual check is OK, press “OK” button -arrow-.

Note

When the "not OK" button is pressed, a check will be carried out.

•

Ignition is switched off.

The visual check is displayed with the request to connect the di‐ agnostic connector -arrow A-

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140 5. Exhaust emissions test

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– Follow instructions on display -arrow A- and -arrow B-.

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Connecting diagnostic connector:

Polo 2002 ➤ Maintenance - Edition 02.2018 – Connect diagnosis cable connector to EOBD connection.

Conditioning: – Start engine.

In the conditioning phase the engine and, if necessary, the emis‐ sion control systems are brought to operating temperature by throttle bursts and are prepared for the exhaust emissions test.

– Follow instructions on display.

– Maintain engine speed in required engine speed range.

If no conditioning is necessary, press → button -arrow- for the next measurement.

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Measuring engine temperature:

5. Exhaust emissions test

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Polo 2002 ➤ Maintenance - Edition 02.2018 It is automatically switched to display for measuring engine tem‐ n AG. Volkswagen AG do perature. e wage

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– Follow instructions on display. un le pe rm itte d

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reached 80 °C.

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♦ Do not insert emission probe into exhaust tail pipe. ♦ 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 the end of the exhaust emissions test, the measured value is marked by a # 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”.

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Measuring idling speed:

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– Bring engine to required temperature.

It is automatically switched to display for measuring the idling speed.

– 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:

142 5. Exhaust emissions test

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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!

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Caution

Polo 2002 ➤ Maintenance - Edition 02.2018 It is automatically switched to display for measuring rev limit.

Measurement starts when the engine speed has reached the re‐ quired level. n AG. Volkswagen A

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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.

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.

– When the air quality check is carried out, insert emission probe into exhaust tail pipe Free acceleration: r fo ng

It is automatically switched to display for “Free acceleration”.

During “Free acceleration” the engine is revved up to rev limit without load as quickly as possible.

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Free acceleration - phase 1:

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The “Free acceleration” test consists of at least four throttle bursts.

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o perform measurement is displayed The remaining timeuthto a s -arrow-. s

– 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:

5. Exhaust emissions test

143

Polo 2002 ➤ Maintenance - Edition 02.2018 – 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 speed.

The test results and information on the latest “Free acceleration” are shown on display -arrow A-. If the measured values are not OK, here you can obtain information why the “Free acceleration” has failed.

Note ♦ If the field is coloured white the measured value is within tol‐

erance.

♦ If the field is coloured 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”.

Many “Free accelerations” can be carried out until:

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th ♦ All values are OK, with the exception of range au of acceleration, and the test is continued by pressing the →ssbutton -arrow C-.

(In this case, the operator assesses if the value is OK).

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♦ 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.

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.

– Then confirm with “Yes” -arrow C-.

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144 5. Exhaust emissions test

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The exhaust emissions test log is shown on the display and can be printed out as often as required in the menu “Print preview” using “Print” button -arrow A-.

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– When the exhaust emissions test is classed as passed, select “EET sticker issued” and date in drop-down menu -arrow B-.

Polo 2002 ➤ Maintenance - Edition 02.2018 – Press “Close” -arrow B- to close the “Print preview” menu.

– Follow instructions on display.

– Take emission probe out of exhaust tail pipe.

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–

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The exhaust emissions test is completed, a new exhaust emis‐ sions test can be performed.

Exhaust emissions test for diesel en‐ gines with OBD

♦ Exhaust gas testing station L - VAS 7320 A-

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board diagnosis” OBD.

♦ The OBD monitors all components and part systems influenc‐

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ing the exhaust emissions quality.

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Special tools and workshop equipment required

♦ 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 .

Test requirements •

All test conditions and data required for exhaust emissions test are found on EET data sheet for the respective engine.

•

For bar code reading of specified data for EET, the EET data sheet must be printed out.

•

Automatic gearbox: selector lever in position “P” or “N”.

•

Manual gearbox: gear lever in neutral

•

Parking brake applied

•

12V battery fully charged (if battery charge is too low, raise idling speed if necessary).

5. Exhaust emissions test

145

Polo 2002 ➤ Maintenance - Edition 02.2018 – Perform exhaust emissions test according to instructions on display.

Vehicle data input – Enter the following data: ♦ Registration number ♦ Key numbers ♦ Vehicle identification number ♦ Fuel type

♦ Registration number: “e.g. WOB-HH 1234”

♦ Emission key No. “field 14.1 (code for field 14)”

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♦ Vehicle identification number “field E”

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♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)” ♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for field D.2)” ♦ Nominal speed “field P4” Specified data input for EET

♦ 2. By bar code input from EET data sheet ♦ 3. Through ELSA web service

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♦ If there is no ESP to deactivate the engine speed limiter, the

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 (ex‐ ception: nominal speed can only be entered manually).

Manual specified data input for EET:

146 5. Exhaust emissions test

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♦ To use the ELSA web service, the exhaust gas testing station

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rev limit can be measured using the engine speed limited by the control unit. To do this, all the EET specifications must be entered manually.

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♦ 1. By manual input

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There are different ways to enter the specified data:

Polo 2002 ➤ Maintenance - Edition 02.2018 Note ♦ For the relevant test requirements and all the necessary data

for the exhaust emissions test, refer to the ⇒ Data sheets for exhaust emissions test of the respective engine.

♦ The nominal speed is located in field P4 of the registration

certificate part 1 or field 7 of the vehicle document and must always be entered manually.

♦ If the engine speed limiter cannot be deactivated, enter the

value 2500 ± 200 rpm in the box for rev limit and 2500 in the box for engine speed for conditioning.

– Perform manual data input according to instructions on dis‐ play.

– Enter displayed values on EET data sheet in column “Testagen AG. Volkswagen AG d oes ksw not values for exhaust emissions test” on display as follows: Vol g 2-

by ed ris o h ut Number of throttle bursts for conditioningss a

3-

Engine oil temperature (min. value)

4-

Select engine oil temperature measurement procedure

5-

Idling speed

6-

Governed speed

7-

Nominal speed (registration certification part 1, vehicle document)

8-

Governed speed measuring period (1 second)

9-

Type plate value ⇒ page 147

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Speed for conditioning

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1-

12 - Measured period portion

♦ When performing the exhaust emissions test, the respective

engineer must always use the vehicle-specific exhaust emis‐ sions limit value indicated on the type plate.

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specified by the manufacturer and indicated in ELSA must be used.

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♦ If no value is indicated on the type plate, the opacity figure

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11 - Select measuring mode

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10 - Select probe type (No. of probe)

♦ If no value is indicated on the type plate and no opacity figure

has been specified by the manufacturer, the statutory opacity figures (2.5 m -1 or 1.5 m -1, depending on date of initial reg‐ istration) must be used.

♦ For all Euro-6-vehicles an opacity figure of max. 0.5 m -1 ap‐

plies.

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.

The nominal speed can only be entered manually.

5. Exhaust emissions test

147

Polo 2002 ➤ Maintenance - Edition 02.2018 If the opacity figure on the EET data sheet is different from the value indicated on the type plate, enter the type plate value man‐ ually.

Inspection – Inspect all exhaust emissions relevant components.

– Check if exhaust system is fitted and complete and check for leaks and damage.

Procedure – Follow instructions from exhaust gas testing station .

Evaluation Note

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148 5. Exhaust emissions test

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If the exhaust emissions test was performed at governed speed, the log note “governed speed <90 % of the nominal speed (idle speed control)” is entered in the log.

Polo 2002 ➤ Maintenance - Edition 02.2018 n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o Explanation h t or u a a ss (anti-lock brake system); the ABS is a regulating system in the brakecsystem, that pre‐

Glossary

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QG1

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PM QG0

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OBD-II Unit injector PR No.

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OBD

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MIL

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CN DIN Part no.

EN EOBD FAME FSI TFSI TSI

vents the wheels from locking up while 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 Standards Authority) Abbreviation for part number European standard European On-Board Diagnosis Fatty acid methyl ester Fuel Stratified Injection Turbo fuel stratified injection From model year 2008 the designation TFSI is replaced by TSI. Therefore the desig‐ nation TSI is given to TSI turbocharger and TSI twincharger.

TSI turbocharger: charging only with turbocharger TSI twincharger: charging with turbocharger and compressor (Malfunction indicator light); American designation for exhaust emissions warning lamp K83 (Onboard diagnosis); the OBD monitors all components influencing the exhaust emis‐ sions quality.

American onboard diagnosis Unit injector for diesel engines Abbreviation for production control number. Identifies among other things optional equipment and country-specific deviations (Particulate matter); soot particulate value for diesel engine emissions Vehicles “not” factory-fitted with components for LongLife service. For maintenance, the intervals based on time and distance (non-flexible intervals) apply.

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

ATF ATF level CO

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♦ Engine oil level sensor ♦ Brake lining wear indicator QG2

The LongLife service is not factory-activated. This means vehicles have a fixed service interval display (time and mileage dependent service intervals): These vehicles are fitted with the following components: ♦ Non-flexible service interval display in dash panel insert ♦ Engine oil level sensor ♦ Brake lining wear indicator

Readiness code RON SAE SD

8-digit binary code which indicates if all exhaust relevant diagnoses have been per‐ formed by the engine management.

Research octane number: measurement unit of the knock resistance of petrol (Society of Automotive Engineers); association which creates proposals/guidelines for implementing legal requirements (e.g. standards).

Naturally aspirated diesel engine

6. Glossary

149

Polo 2002 ➤ Maintenance - Edition 02.2018 Explanation

SDI TDI DP ULEV ESI Common rail

Naturally aspirated diesel engine - direct injection. Volkswag en AG gen AG does Turbo diesel engine - direct injectionVolkswa not gu y ara db e Distributor injection pump nte is r o eo h ra Ultra low emission vehicle s aut c s Extended service interval Refers to a common high-pressure injection line (rail), which supplies all cylinders of the relevant cylinder bank with fuel.

The diesel 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.

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TPMS, TPLI

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Broad-band probe

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Step-type probe

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Diesel particulate filter LongLife service

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