matinanceSM - 28 VW Polo

Service
Maintenance
Polo 2002 ➤
Edition 02.2018
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Service Department. Technical Information

Service
Maintenance
Heading
1. Engine list
2. Service work
3. General information
4. Descriptions of work:
5. Exhaust emissions test
6. Glossary
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg P0050352920

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Contents
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1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Information on LongLife service and time or distance dependent service . . . . . . . . . . . . . . 5
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2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.3 ole,
Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2.4 Oil change service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.5 Interval service 2008► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Inspection ►2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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2.7 Inspection service 2008► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Time or distance dependent additional work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.9 Service intervals with market-specific deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
inform
3.1 Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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3.2 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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3.3 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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3.4 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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3.7 Countries where diesel has a high sulphur content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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3.8 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.9 RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.10 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.11 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Descriptions of work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1 Removable towing bracket: checking and cleaning if necessary . . . . . . . . . . . . . . . . . . . . 37
4.2 Swivel joints and suspension link mountings: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3 Automatic gearbox: checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4 Automatic gearbox: changing ATF (09G gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 41
4.6 Battery: Checking using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . 42
4.7 Brake and clutch system: Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.8 Brake fluid level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.9 Front passenger airbag: checking key switch and “On/Off function” . . . . . . . . . . . . . . . . . . 48
4.10 Tyres: checking condition, wear pattern, tread depth, tyre pressure and age . . . . . . . . . . 49
4.11 Brake system and shock absorbers: inspecting for leaks and damage . . . . . . . . . . . . . . . . 58
4.12 Brakes, front and rear: checking thickness of brake pads and condition of brake discs . . 59
4.13 Electric windows: Carry out initialisation (activation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.14 Vehicle system test: Carry out test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.15 Bonnet: greasing arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.16 Adding multi-purpose additive G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.17 Boots: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.18 Checking expiry date of first-aid kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.19 Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . . 65
4.20 Poly V-belt: Checking tension, adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.21 Poly V-belt: checking condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.22 Checking number plate on vehicle bumper (Polo Cross) . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.23 Fuel filter: Renewing (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.24 Fuel filter: Draining water (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.25 Cooling system: checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 69
4.26 Air filter: Cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.27 Engine oil level: Check, replenish engine oil if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.28 Engine oil: Draining or extracting and replenishing; renewing oil filter . . . . . . . . . . . . . . . . 75
Contents i
Polo 2002 ➤
Maintenance - Edition 02.2018
4.29 Engine and components in engine compartment: inspecting for leaks and damage (from
above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.30 Removing and installing engine cover panel -top- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.31 Removing and installing engine cover -bottom- (noise insulation) . . . . . . . . . . . . . . . . . . . . 84
4.32 Road test: performing (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 85
4.33 Wheel securing bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.34 Radio/radio navigation system: entering PIN of anti-theft coding and storing local radio
stations to station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.35 Radio code: reading using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.36 Tyre repair set: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.37 Tyre Pressure Loss Indicator: performing basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.38 Manual gearbox/final drive: Checking oil level, replenishing oil if necessary . . . . . . . . . . . . 90
4.39 Window wiper and washer system and headlight washer system: Checking function . . . . 90
4.40 Wiper blade protection: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.41 Headlight adjustment: Check, adjust headlights if necessary . . . . . . . . . . . . . . . . . . . . . . 98
4.42 Sunroof: checking function, cleaning and greasing guide rails . . . . . . . . . . . . . . . . . . . . . . 103
4.43 Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.44 Service interval display: recoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.45 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 107
4.46 Dust and pollen filter: renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.47 Door arrester: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.48 Transportation device: Remove blocking pieces from front axle springs . . . . . . . . . . . . . . 109
4.49 Recoding dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.50 Clock: setting to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.51 Underseal: inspecting for damage to underseal, underbody cladding, routing of lines and
plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.52 Toothed belt and tensioning roller: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.53 Camshaft drive toothed belt: Renewing (4-cylinder 5-valve petrol engine) . . . . . . . . . . . . 112
4.54 Camshaft drive toothed belt: Checkn(4-cylinder . Volkswage petrol
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4.55 Renewing spark plugs . . .Vo. lk.s.w.a . . . . . . . . . . . . . . . .oe. s.n.ot. . . . . . . . . . . . . . . . . . . . . . . . . . 112
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4.56 Diesel particulate filter:isecheck.
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5 Exhaust emissionsauttest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . . 120
5.1 Exhaust emissions ss test for petrol engines . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . 120
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5.2 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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ii Contents
Polo 2002 ➤
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
Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine
Engine code AUA AUB AWY AXU
Displace‐ I 1,4 1,4 1,2 1,4
ment
No. of cylinders/valves per 4/4 4/4 3/2 4/4
cylinder
Power kW at rpm 55/5000 74/6000 40/4750 63/5000
Torque Nm at rpm 126/3800 128/4400 106/3000 130/3750
Bore ∅ mm 76,5 76,5 76,5 76,5
Stroke mm 75,6 75,6 86,9 75,6
Compression ratio 10,5 10,5 10,8 10,5
Injection/ignition Magneti Marelli Magneti Marelli Simos 3 PD Motronic MED
4MV 4MV manifold inj. 7.5.11
manifold inj. olksw
manifold inj. FSI
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RON min. olks
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Engine code AZQ BBM BBU BBY

Displace‐ I 1,2 1,2 1,8 1,4
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Power kW at rpm 47/5400 44/5200 132/5800 55/5000
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Torque Nm at rpm 112/3000 108/3000 235/1950 to 5000 126/3800

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Bore ∅ mm 76,5 76,5 81,0 76,5

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manifold inj. manifold inj. manifold inj. 4MV
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1. Engine list 1
Polo 2002 ➤

Engine code AZQ BBM BBU BBY
Displace‐ I 1,2 1,2 1,8 1,4
ment
Camshaft drive Chain Chain Toothed belt Toothed belt
put

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Engine code BBZ BJX BKY BMD
Displace‐ I 1,4 1,8 1,4 1,2
ment
cylinder
Power kW at rpm 74/6000 110/5500 55/5000 40/4750
Torque Nm at rpm 128/4400 220/2000 126/3800 108/3000
Bore ∅ mm 76,5 81,0 76,5 76,5
Stroke mm 75,6 86,4 75,6 86,9
Injection/ignition Magneti Marelli Motronic ME 7.5 Magneti Marelli Simos 9.1
4MV G. Volkswagemanifold inj. 4TV manifold inj.
manifold
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RON min. yV
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Camshaft drive tho Toothed belt Toothed belt or Toothed belt Chain
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Engine code BME BTS BUD BZG
Displace‐ I 1,2 1,6 1,4 1,2
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Power kW at rpm 47/5400 77/5600 59/5000 51/5400

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Torque Nm at rpm 112/3000 153/3800 132/3800 112/3000

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Bore ∅ mm 76,5 76,5 76,5 76,5

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Stroke mm 86,9 86,9 75,6 86,9

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Injection/ignition Simos 9.1 Motronic ME 7.5.20 Magneti Marelli Simos 9.1
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RON min. 95 unleaded1) 951 951 95 unleaded1)
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Camshaft drive Chain Chain Toothed belt Chain
2 1. Engine list
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Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine
Engine code AMF ASY ASZ ATD
rrectness of i
Displace‐ I 1,4 1,9 1,9 1,9
ment
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cylinder
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Power kW at rpm 55/4000 47/4000 96/4000 74/4000
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Torque Nm at rpm 195/2200 125/1600 to 2800 310/1900 240/1800 to
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Bore ∅ mm 79,5 79,5 79,5 79,5

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Stroke mm 95,5 86,4 95,5 86,4
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Injection/ignition TDI (SDI) TDI TDI
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Diesel particle filters No No No No

Camshaft drive Toothed belt Toothed belt Toothed belt Toothed belt

Engine code AXR BAY BLT BMS
Displace‐ I 1,9 1,4 1,9 1,4
ment
cylinder
Power kW at rpm 74/4000 55/4000 96/4000 59/4000
Torque Nm at rpm 240/1800 to 2400 195/2200 310/1900 195/2200
Bore ∅ mm 79,5 79,5 79,5 79,5
Stroke mm 95,5 95,5 95,5 95,5
Injection/ignition TDI TDI TDI TDI
unit injector unit injector unit injector unit injector
Diesel particle filters No No No Yes

Engine code BMT BNM BNV BWB
Displace‐ I 1,9 1,4 1,4 1,4
ment
cylinder
Power kW at rpm 74/4000 51/4000 59/4000 51/4000
1. Engine list 3
Polo 2002 ➤

Engine code BMT BNM BNV BWB
Displace‐ I 1,9 1,4 1,4 1,4
ment
Torque Nm at rpm 240/1800 155/2200 195/2200 155/1600 to
2800
Bore ∅ mm 79,5 79,5 79,5 79,5
Stroke mm 95,5 95,5 95,5 95,5
Injection/ignition TDI TDI TDI TDI
unit injector unit injector unit injector unit injector
Diesel particle filters Yes No No Yes
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4 1. Engine list
Polo 2002 ➤
2 Service work
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
Service intervals with market-specific deviations ⇒gepage
n AG. V24
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2.1 Information on LongLife service and ed
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Service identification ⇒ page 5
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2.1.1 Service identification
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– 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.
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⇒ page 8
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Vehicle IDs with the following PR number

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Note
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)
2. Service work 5
Polo 2002 ➤
Maintenance - Edition 02.2018 agen
AG. Volkswagen AG d
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For vehicles with LongLife service the service intervalrisedis deter‐
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number “QG0/QG2” the non-flexible service intervals are set by
t to the co
Volkswagen according to predetermined mileage or time values.
For normal operating conditions achieving these service intervals
is technically assured.
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Therefore the service intervals for time or distance dependent
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For vehicles
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♦ Which were delivered without extended servicing intervals

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Vehicles are “not” factory-fitted with components for LongLife
service. For maintenance the time or distance dependent inter‐
vals (non-flexible intervals) apply.
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
♦ 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
Polo 2002 ➤
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 agen
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Filter change intervals ⇒ page 10 d byV gu
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Toothed belt change intervals ⇒ page ut 10
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Spark plug change intervals ⇒ page 11
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♦ For combined kilometre and time display applies: whichever

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♦ Depending on conditions under which the vehicle is used

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⇒ page 34 and vehicle equipment, extra service work must

be performed in addition to the interval service, inspection
service or interval service inspection.
rrectness of i
♦ It is also possible, to perform additional work outside the serv‐

l purpos
ice intervals with regard to the entries in the service schedule

(or sticker: your next service).
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2. Service work
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Polo 2002 ➤
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.
POLO 2002►
SERVICE INTERVALS ►2007
from-to Engine/Engine code/ Service/intervals Indicated on
PR No./Remarks service interval display SID
(includes oil change)
Since in‐ Diesel in countries where sul‐ Oil change service YES
troduc‐ phur content in fuel is high every 7,500 km or 1 ayear
gen AG
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From in‐ Petrol and diesel: Oil change risservice
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troduc‐ QG0/QG2 or QG1 vehicles tho
every 15,000 km or 1
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every 30,000 km or 2 years

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30,000 km or 2 years
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From in‐ Diesel: QG1 Inspection service: LongLife YES

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troduc‐ flexible from 15,000 km to max.

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tion 50,000 km or 2 years

►2005
2006►20 Diesel: QG1 Inspection service: LongLife YES
rrectne
07 flexible from 15,000 km to max.

30,000 km or 2 years
ss o
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POLO 2002►
atio
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SERVICE INTERVALS 2008►

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tion ⇒ page 32 p by
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8
AG.
2. Service work
Polo 2002 ➤
POLO 2002►
SERVICE INTERVALS 2008►
2008► Petrol and diesel: Oil change service YES
QG0/QG2 or QG1 vehicles every 15,000 km or 1 year
coded to non-flexible interval Interval service: YES
every 30,000 km or 2 years
Petrol and diesel: Interval service: YES
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: NO
all vehicles kswage after 3 years/max.
does
no 60,000 km,
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2.2.2 VW ENGINE OIL STANDARDS
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Caution
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Only engine oils approved by VW may be used, up-to-date in‐

formation ⇒ ServiceNet, Technical information, Inspection and
nf
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maintenance, Approved oils

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POLO 2002►
or
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VW ENGINE OIL STANDARDS

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With LongLife service (QG1) Without LongLife service (QG0, QG2)

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PETROL ENGINES
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3 and 4-cylinder engines 3 and 4-cylinder en‐ 501 01/502 00
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3 and 4-cylinder en‐ 502 00
AG.
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DIESEL ENGINES
Diesel engines without 507 001 alternative Diesel engines without 505 01
diesel particulate filter 3 diesel particulate filter
506 01
Diesel engines with diesel 507 001) Diesel engines with 507 001)
particulate filter diesel particulate filter
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 ➤
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 According to service interval display
service QG1
All other vehicles Every 15,000 km or 1 year
AIR FILTER
All engine types Every 60,000 km or 4 years
FUEL FILTER
All diesel engines 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
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2) Only applies to diesel engines: in some countries, th or
au diesel has a ac
s
high sulphur content. The high sulphur content leads to excessive
s
ce
le
wear of cylinders and it considerably reduces the cleanliness of

un
pt
an
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pistons. Therefore change engine oil every 7,500 km in countries

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diesel has a high sulphur content. ⇒ page 32

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2.2.4 TOOTHED BELT CHANGE INTERVALS

es, in part or in w
t to the co
• If the engine is fitted with toothed belt or timing chain can be

found in the engine list.
rrectness of i
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Note
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The camshaft drive with timing chain is maintenance-free!

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POLO 2002►
n in
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TOOTHED BELT CHANGE INTERVALS

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DIESEL ENGINES
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Engine type Engine code Model year Change interval Tensioning roll‐ Idler roller
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SDI ASY ►2002 yri
Every --- Every
p by
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120,000 km 120,000 km
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10 2. Service work
Polo 2002 ➤
POLO 2002►
TOOTHED BELT CHANGE INTERVALS
ASY 2003► Every --- ---
150,000 km
TDI - unit injec‐ AMF, BAY, ATD, AXR ►2003 Every 90,000 km Every ---
tor 90,000 km
ATD, AXR, ASZ, BLT 2004► Every Every ---
120,000 km 240,000 km
AMF, BAY, BNM, BNV, 2004 -2006 Every Every ---
BMS, BWB 120,000 km 240,000 km
AMF, BAY, BNM, BNV, 2007► Every 300,000 km ---
BMS, BWB, BMT 150,000 km
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 Spark plug change intervals

• Spark plug designation and specified torque: Power unit ⇒
Rep. gr. 28 → Repairing ignition system → Test data. n AG. Volkswagen AG do
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For technical reasons it is possible that several cross references
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cedure manually in the information.

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POLO 2002►
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Spark plug change intervals

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Engine type Engine code Change intervals

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Petrol engines All engine codes EVERY 60,000 km

• Mileage more than 60,000 km in 4 years
rrectne
EVERY 4 years
• Mileage less than 60,000 km in 4 years
ss o
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atio
2.3 Delivery inspection

om
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Scope of work Page

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– Battery: Check battery terminals by hand for tightness ⇒ page 41

um
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– Battery: Check with battery tester and printer VAS 5097A or VAS 6161 ⇒ page 42
t.
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(always see workshop manual) C py
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– Service interval display: Reset ⇒ page 103
p by
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• Only applies to stock vehicles and vehicles in storage
2. Service work 11
Polo 2002 ➤
Scope of work Page

– Radio code: Read using vehicle diagnostic tester ⇒ page 88
• Only valid for vehicles with radio units from RCD 200
– Radio/radio navigation system: Enter PIN of anti-theft coding and store ⇒ page 87
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 110
• In countries with sulphur content in diesel fuel

olkswagen AG
• Your importer will inform you which countries have diesel with a high ssul‐
agen
AG. V does
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phur content. by
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– All switches, electrical consumers, gauges and other controls:
au
t Check func‐
h eo
ra
tion ss c
ce
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– Clock: setting to correct time un ⇒ page 111
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– Front passenger airbag: Check key switch and “On/Off function” ⇒ page 48
rm
ab
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– Turn switch to “ON”
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– Electric windows: Carry out initialisation (activation) ⇒ page 63
hole
spec
– Check vehicle interior for cleanliness: Front and rear seats, interior trim,
es, in part or in w
carpets/mats, windows
t to the co
– Seat and carpet protective coverings: remove.
– Fit all equipment which has been packed inside vehicle (if fitted): Mats,
rrectness of i
wiper arms, spoilers, roof aerial, wheel trims/hub caps, valve extensions
l purpos
– Edge protection on doors (plastic film): remove.

– Check number plate on rear bumper of vehicle. ⇒ page 66
nform
ercia
• On the Polo Cross no number plate panel must be fitted.

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tion in
– Check vehicle exterior for cleanliness: Paintwork, decorative parts, win‐
r
te o
thi
dows, wiper blades
s
iva
do
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– Wiper blade protection: removing ⇒ page 95

rp
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– Wheel bolts: tightening to specified torque ⇒ page 85

n
t.
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– Tyre pressure of all 4 wheels and spare wheel: Set to correct pressures (in ⇒ page 49
t. C rig
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the factory the tyres are inflated to 3.5 bar) yri
p by
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by lksw
– Tyre pressure loss indicator: performing basic setting cted
⇒ page 89
agen
Prote AG.
– Transportation devices: removing blocking pieces from springs on front ⇒ page 109
axle
– Vehicle from below; engine (components in engine compartment), brake ⇒ page 81
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 ⇒ page 111
– Windscreen wipe/wash and headlight washer system: Check function and ⇒ page 90
spray jet settings; replenish fluid -G 052 164- to maximum
– Engine oil level: Check, top-up with engine oil if necessary; observe oil ⇒ page 74
specifications!
– Engine and components in engine compartment: visual check for leaks and ⇒ page 81
damage (from above)
– Coolant level: Check it is at maximum ⇒ page 69
– Brake fluid level: Check level is at maximum ⇒ page 47
– Number and function of keys: Check, wipe off grease if necessary
12 2. Service work
Polo 2002 ➤
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 agen

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service “QG0/QG2” ⇒ page 6 pt

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♦ Inform the customer if faults are found during service and re‐ ab
ility
pair measures are necessary.
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⇒ page 32
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– Ask the customer if he requires: Cop
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• Replenish Windscreen Clear G 052 164 (cleanser and anti- Prote
cted AG.
agen
freeze).
– 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
Polo 2002 ➤ lkswage es n
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Maintenance - Edition 02.2018 byV ua
d ran
ir se tee
tho
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The sequence of the individual service positions
ss
a has been tested ac
and optimised and should therefore be adhered to in order to pre‐
ce
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vent unnecessary work interruptions
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Oil change service – scope of work Page
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– Engine oil: Drain or extract, renew oil filter ⇒ page 75
wit
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– Fuel filter: drain water ⇒ page 67
hole
spec
es, in part or in w
• Only diesel engines with DP
t to the co
• Vehicles with diesel engine using biodiesel according to EN 14214
rrectness of i
– Front and rear brake pads/linings: Check thickness ⇒ page 59
l purpos
– Engine oil: Replenish, observe oil specification ⇒ page 75

nf
ercia
– Service interval display: Recode to non-flexible intervals ⇒ page 106
orm
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atio
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• Only vehicles with PR number QG1

o
n in
or c
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– “Your next service” sticker: Enter a cross at the position for oil change ⇒ page 26
t
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service or inspection service (next service due) and enter date/odom‐
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rp
cu
eter reading; if necessary, enter a cross at the position for supplemen‐
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tary information (e.g. renew toothed belt) and changing brake fluid and
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enter date/odometer reading; attach sticker to driver side door pillar (B- C py
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2.5 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‐
14 2. Service work
Polo 2002 ➤
Caution

G. Volkswage
• The high sulphur content leads lksw
agto
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A
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n AG d
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♦ Therefore change
ss engine oil every 7,500 km in countries
a ra
c
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e
nl
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⇒ page 32
erm
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– Ask the customer if he requires:
hole
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• New wiper blades
es, in part or in w
t to the co
• Replenish Windscreen Clear G 052 164 (cleanser and anti-
freeze).
rrectness of i
l purpos

nf
ercia
orm
The sequence of the individual service positions has been tested
m
atio
m

o
n in
c

or
thi
te
sd
iva
Interval service – scope of work Page

o
r
rp
cu
o
m
f
– Battery: Check with battery tester and printer VAS 5097A or VAS 6161 ⇒ page 42
en
ng
t.
yi
(always see workshop manual)
Co
Cop py
ht. rig
– Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre rig ht
py by
____
co Vo
by lksw
cted agen
Prote
– Tyre pressure of all 4 wheels and spare wheel: Correct ⇒ page 49
AG.
– Spare wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 49
depth: _______ mm
– Tyre repair set: Check if bottle is damaged or used; check and enter ⇒ page 89
use-by date of tyre sealant __________
• If part of equipment
– Tyre pressure loss indicator: performing basic setting ⇒ page 89
– Rear right wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 49
depth: _______ mm
– Rear left wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 49
depth: _______ mm
– Front left wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 49
depth: _______ mm
– Front right wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 49
depth: _______ mm
– Engine oil: Drain or extract, renew oil filter ⇒ page 75
– Brake system: inspect for leaks and damage. ⇒ page 58
– Engine oil: Replenish, observe oil specification ⇒ page 75
– Brake fluid level (dependent upon brake pad/lining wear): check. ⇒ page 47
2. Service work 15
Polo 2002 ➤
Interval service – scope of work Page

– “Next service” sticker: Enter a cross at the position for next service due, ⇒ page 26
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 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.
Note agen
AG. Volkswagen AG d
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Inform the customer if faultsrisare
ed found during service and repair arante
measures are necessary.utho eo
ra
s a c
s
ce
e
nl
pt
du
Caution
an
itte
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erm
ab
ility

ot p
wit
, is n

h re
hole
spec

es, in part or in w

t to the co
tons.
rrectness of i

l purpos

⇒ page 32
nform
mercia
at

om
ion
c
in t

or
his
ate

do
priv
freeze).
um
for
en
ng
t.
yi
Co
op py
t. C rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
(noise insulation) ⇒ page 84 Prote AG.
The sequence of the individual service positions has been tested

Scope of work Page
Electrics
– Battery: Check with battery tester and printer VAS 5097A or VAS 6161 (al‐ ⇒ page 42
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
Polo 2002 ➤
Scope of work Page

– 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 agen
AG. Volkswagen AG d
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– Vehicle system test: Carry out test ed by
V gu
ara ⇒ page 63
ris nte
– Service interval display: Reset tho e or⇒ page 103
au ac
Vehicle exterior ss
ce
e
nl
pt
– Sunroof: Check function, clean guide rails and lubricate with special grease ⇒ page 103
du
an
itte
-G 000 450 02-
y li
erm
ab
– Window wiper and washer system and headlight washer system: Check ⇒ page 90
ility
ot p
function, spray jet settings and for damage
wit
, is n
h re
– Door arrester: grease. ⇒ page 108
hole
spec
Tyres
es, in part or in w
t to the co
– 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
rrectness of i
– Spare wheel: Check condition and wear pattern of tyre; enter tread depth: ⇒ page 49
l purpos
_______ mm
– Tyre repair set: Check if bottle is damaged or used; check and enter use- ⇒ page 89
nf
ercia
by date of tyre sealant __________
orm
m
atio
m
o
n in
or c
thi
e

t
sd
iva
o
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rp
cu
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m
f
en
ng
t.
yi Co
op
C py
t. rig
gh
depth: _______ mm
ht
pyri by
Vo
o
by c lksw
– Rear left wheel: Check condition and wear pattern of tyre; enter tread depth: cted ⇒ page 49
agen
Prote AG.
_______ mm
– Front left wheel: Check condition and wear pattern of tyre; enter tread depth: ⇒ page 49
_______ mm
depth: _______ mm
Underside of vehicle
– Engine oil: Drain or extract; renew oil filter ⇒ page 75
– Engine and components in engine compartment: inspect for leaks and dam‐ ⇒ page 81
age (from below).
– Poly V-belt: checking condition ⇒ page 65
– Gearbox, final drive and drive shaft boots: inspect for leaks and damage. ⇒ page 65
– Manual gearbox/final drive: checking oil level ⇒ page 90
– Swivel joints: Visual check of swivel joint boots for leaks and damage ⇒ page 39
– Brake system: inspect for leaks and damage. ⇒ page 58
– Track rod ends: checking clearance, firm seating and boots ⇒ page 107
– Exhaust system: inspect for leaks, firm seating and damage.
– Underseal: inspecting for damage to underseal, underbody cladding, rout‐ ⇒ page 111
ing of lines and plugs
Engine compartment
– Engine oil: Replenish ⇒ page 75
2. Service work 17
Polo 2002 ➤
AG. Volkswagen AG d
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agen oes
n
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ran edb
Scope of work tee
tho
ris Page
or
a au
– Engine and components
ss in engine compartment: visual check for leaks cand ⇒ page 81
damage (from above)
ce
e
nl
pt
du
an
– Window wiper and washer system: Replenish fluid -G 052 164- (only if cus‐ ⇒ page 90
itte
y li
erm
tomer requires)
ab
ility
ot p
– Cooling system: Checking frost protection and coolant level ⇒ page 69
wit
, is n
h re
Specification -25°C (in countries with arctic climate -35°C)/actual value (meas‐
hole
spec
ured value): ____°C
es, in part or in w
t to the co
– Fuel filter: Drain water ⇒ page 67
♦ Only diesel engines with DP
♦ At 30,000 km, 90,000 km, 150,000 km etc.
rrectness of i
♦ Only for vehicles using diesel fuel according to EN 590
l purpos
– Poly V-belt: Check condition ⇒ page 65
nf
ercia
o
– Poly V-belt: Check tension, adjust if necessary ⇒ page 65
rm
m
atio
m
– Brake fluid level (dependent upon brake pad/lining wear): check. ⇒ page 47
o
n in
or c
Final checks
thi
te
sd
a
– Headlights: Check adjustment ⇒ page 98

iv
o
r
rp
cu
o
m
– “Next service” sticker: Enter a cross at the position for next service due, oil ⇒ page 26
f
en
ng
t.
change service or interval service according to flexible service interval dis‐
yi Co
op py
play or month/year/km and enter date/odometer reading as necessary; . C rig
ht ht
enter a cross at the position for supplementary information (e.g. renew
rig by
opy Vo
toothed belt) and changing brake fluid and enter date/odometer reading; by c lksw
cted agen
attach sticker to driver side door pillar (B-pillar).
Prote AG.
2.7 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‐
Caution

tons.
⇒ page 32

18 2. Service work
Polo 2002 ➤

freeze).
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
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
Vehicle exterior AG. Volkswagen AG d
agen oes
olksw not
V
– Window wiper and washer system d by and headlight washer system: gu
aCheck
ran ⇒ page 90
function, spray jet settings rise for damage
and tee
ho
ut or
– Sunroof: Check function, ss clean guide rails and lubricate with special grease
a ac
⇒ page 103
-G 000 450 02-
ce
le
un
pt
an
d
– Door arrester: grease. ⇒ page 108

itte
y li
erm
ab
Tyres
ility
ot p
– Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre
wit
is n
____
h re
ole,
spec
– Tyre pressure of all 4 wheels and spare wheel: Check ⇒ page 49
– Spare wheel: Check condition and wear pattern of tyre; enter tread depth: t to the co ⇒ page 49
_______ mm
– Tyre repair set: Check if bottle is damaged or used; check and enter use- ⇒ page 89
rrectne
by date of tyre sealant __________

s
s o
cial p
f in

form
mer
atio
m
depth: _______ mm
o
n
c
i
or
n thi
– Rear left wheel: Check condition and wear pattern of tyre; enter tread depth: ⇒ page 49
te
sd
a
_______ mm
iv
o
pr
cum
r
fo
– Front left wheel: Check condition and wear pattern of tyre; enter tread depth: ⇒ page 49
en
ng
t.
_______ mm
yi Co
Cop py
t. rig
gh ht
yri by
depth: _______ mm cop Vo
by lksw
cted agen
Underside of vehicle Prote AG.
– Automatic gearbox: Check ATF level, replenish if necessary ⇒ page 40

– Engine and components in engine compartment: inspect for leaks and dam‐ ⇒ page 81
age (from below).
– Poly V-belt: checking condition ⇒ page 65
– Poly V-belt: Check tension, adjust if necessary ⇒ page 65
– Gearbox, final drive and drive shaft boots: inspect for leaks and damage. ⇒ page 65
– Manual gearbox/final drive: Check oil level, replenish if necessary ⇒ page 90
– Swivel joints: Visual check of swivel joint boots for leaks and damage ⇒ page 39
– Track rod ends: checking clearance, firm seating and boots ⇒ page 107
2. Service work 19
Polo 2002 ➤
Scope of work Page

– Exhaust system: inspect for leaks, firm seating and damage.
– Underseal: inspecting for damage to underseal, underbody cladding, rout‐ ⇒ page 111
ing of lines and plugs
Engine compartment
– Engine and components in engine compartment: visual check for leaks and ⇒ page 81
damage (from above)
– Window wiper and washer system: Replenish fluid -G 052 164- (only if cus‐ ⇒ page 90
tomer requires)
– Cooling system: checking frost protection and coolant level ⇒ 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 ⇒ page 98
– “Next service” sticker: Enter a cross at the position for next service due, oil ⇒ page 26
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).
AG. Volkswagen AG d
agen oes
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2.8 Time or distance dependent additional d byV
ol not
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ara
work ise nte
or eo
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aut ra
s c
Depending on conditions under which the vehicle is used s
ce
e
⇒ page 34 and vehicle equipment, extra servicing work must be

nl
pt
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an
performed in addition to the oil change service, interval service or
itte
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inspection service.
erm
ab
ility
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It is also possible, to perform additional work outside the service
wit
, is n
intervals with regard to the entries in the service schedule (or
h re
sticker: your next service).
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ As of model year 2008 a new maintenance concept will be
introduced which changes the accounting procedures for cer‐
l purpos
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
nform
ercia
inspection services.
m
at
om
♦ From model year 2008 this is no longer valid. These opera‐

ion
c
tions are carried out as separate charge, which can be recog‐

in t
or
his
e
nised in the maintenance table, signified by the red mark. This

at
do
riv
is also valid when changing the brake fluid, renewing the

p
cum
or
toothed belt, tensioning roller and when performing the ex‐

f
en
g
haust emissions test.

n
t.
yi Co
Cop py
♦ All service operations are integrated as previously in the repair
ht. rig
rig ht
operation for an inspection service.
py by
co Vo
by lksw
cted agen
Prote AG.
Every 30,000 km
Additional work Page
– Dust and pollen filter: cleaning housing and renewing filter element ⇒ page 108
• Only valid for vehicles driving more than 30,000 km in 2 years
20 2. Service work
Polo 2002 ➤

– 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
– 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
– Air filter: Clean housing and renew

wagefilter element
es ⇒ page 71
ks not
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by
• Only valid for vehiclesrisdriving
ed more than 60,000 km in 4 yearsarant
ee
utho or
a ac
– Automatic gearbox:
ss Check ATF level ⇒ page 40
ce
le
un
pt
• Not valid for 09G gearbox
an
d
itte
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erm
– Automatic gearbox: Change ATF ab ⇒ page 40

ility
ot p
wit
is n
• Only applies to vehicles from model year 2009 h re

ole,
spec
• Applies only to 09G gearboxes in countries with hot climates, China and USA
t to the co
rrectne
Every 90,000 km
ss o
cial p
– Camshaft drive toothed belt: renew. ⇒ page 111

inform
mer
• Only valid for vehicles with diesel engine ►2003 with engine codes AMF, BAY, ATD,
atio
m
AXR
o
n
c
i
or
• Generally it is not necessary to renew the toothed belt before the actual change
thi
te
sd
a
interval is reached. Especially cracks on the belt side are not relevant for service life
iv
o
pr
cum
r
fo
en
ng
– Camshaft drive tensioning roller: Renew ⇒ page 111

t.
yi Co
Cop py
t.
• Only valid for vehicles with diesel engine ►2003 with engine codes AMF, BAY, ATD,
rig
gh ht
yri by
AXR cop Vo
by lksw
cted agen
Prote
AG.
2. Service work 21
Polo 2002 ➤
At 90,000 km, then every 30,000 km thereafter

– 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
• Only valid for vehicles with diesel engine ►2002 with engine code ASY
Volkswagen AG
– Camshaft drive relay roller:
swa Renew
gen AG
.
does ⇒ page 111
olk not
y V gu
• Only valid for vehicles d b with diesel engine ►2002 with engine ara
rise nte code ASY
tho eo
• Generally itssis
au not necessary to renew the toothed belt beforer athe c actual
change
ce
e
nl
pt
du
an
itte

y li
erm
ab
ility
ot p
• Only valid for vehicles with diesel engine 2004► with engine codes ATD, AXR, ASZ,
wit
, is n
BLT
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
• Only valid for vehicles with diesel engine model year 2004 - 2006 with engine codes
AMF, BAY, BNM, BNV, BMS, BWB
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi

te
sd
iva
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cu

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f
en
ng
t.
yi
– Diesel particulate filter: check. ⇒ page 119
Co
Cop py
t. rig
gh ht
• Only valid for RHD vehicles pyri by
Vo
o
by c lksw
cted agen
• Only valid for vehicles with diesel engines and factory-fitted diesel particulate filter
Prote AG.
⇒ page 1
Every 150,000 km
• Only valid for vehicles with diesel engine 2003► with engine code ASY
22 2. Service work
Polo 2002 ➤

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

– 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
• Only valid for vehicles with 1.8 l 5V petrol engine
Every 240,000 km AG. Volkswagen AG d

agen oes
lksw not
Additional work d by
Vo gu
ara Page
ise nte
– Camshaft drive tensioning
ut
hor
roller: Renew eo ⇒ page 111
a ra
ss c
• Only valid for vehicles with diesel engine 2004► with engine codes ATD, AXR, ASZ,
ce
le
un
pt
BLT
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re

ole,
spec
• Only valid for vehicles with diesel engine model year 2004 - 2006 with engine codes
t to the co
AMF, BAY, BNM, BNV, BMS, BWB

rrectne
ss o
cial p
f in
Every 300,000 km
form
mer
atio

om
n
c
i
or

thi
te
sd
iva
o
r
• Only valid for vehicles with diesel engine model year 2007► with engine codes AMF,
p
cum
r
fo
BAY, BNM, BNV, BMS, BWB, BMT

en
ng
t.
yi Co
op
• Generally it is not necessary to renew the toothed belt before the actual change C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Service work 23
Polo 2002 ➤
Every 12 months
– Exhaust emissions test (EET): Perform ⇒ page 120
• For vehicles used for commercial passenger transport, e.g. taxis

• Applies only to Germany
Every 2 years
– Brake and clutch system: Change brake fluid ⇒ page 42
• Only applies to vehicles ►2007
– Dust and pollen filter: cleaning housing and renewing filter element ⇒ page 108
. Volkswagen AG
gen AG
wayears does
• Only valid for vehicles driving less than 30,000 kmVoin lks2 not
gu
by ara
ed
ris nte
tho eo
au ra
ss c
ce
3 years after initial registration and then every 2 years
e
nl
pt
du
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itte
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erm
ab
ility
ot p
– Brake and clutch system: Change brake fluid ⇒ page 42
wit
, is n
h re
• Only applies to vehicles 2008►
hole
spec
es, in part or in w
– Exhaust emissions test (EET): Perform ⇒ page 120
t to the co
rrectness of i
l purpos
Every 4 years
nf
ercia

rm
m
atio
m
– Air filter: Clean housing and renew filter element ⇒ page 71

o
n in
or c
thi
• For vehicles driving less than 60,000 km in 4 years

te
sd
iva
o
r
rp
cu
– Spark plugs: Renew ⇒ page 112

o
m
f
en
ng
t.
yi Co
op
• For vehicles driving less than 60,000 km in 4 years C py
t. rig
gh ht
yri by
• Spark plug designation: “Power unit” ⇒ Rep. gr. 28 “Test data, spark plugs” cop Vo
by lksw
cted agen
Prote AG.
2.9 Service intervals with market-specific

deviations
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
Polo 2002 ➤
Russian market from model year 2010

Interval Description of
work
Interval service (QG0/QG2) Every 15,000 km → Mainte‐
(appears on service interval display) or 1 year1) nance tables
Inspection service Every 30,000 km → Mainte‐
(does not appears on service interval display) or 2 years 1) nance tables
– Adding multi-purpose additive G17 At every service ⇒ page 64
• Applies only to petrol engines
– Dust and pollen filter (cabin filter): renew. Every 15,000 km ⇒ page 108
or 1 year1)
– Spark plugs: renew Every 30,000 km ⇒ page 112
or 2 years 1)
– Fuel filter: Renew Every 30,000 km ⇒ page 66
– Air filter element: check; renew as needed and clean housing. Every 30,000 km ⇒ page 71
or 2 years 1)
lkswage es n
1) o ot g
Whichever occurs first. d byV ua
ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Service work 25
Polo 2002 ➤
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 AG. Volkswagen AG d
agen oes
ksw
Attach hotline sticker. ⇒ page 27 by
Vol not
gu
ara
ed
is nte
3.1.1 Attaching “Your next service” sticker or eo
h
aut ra
ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
ility
The sticker “Your first service” has been discontinued, therefore
ot p
sticker “Your next service” must be used for the delivery inspec‐
wit
, is n
h re
tion.
hole
spec
es, in part or in w
– Your “next service dates” sticker: Enter a cross in position for t to the co
next oil change service or inspection service (next service due)
and enter date/odometer reading
rrectness of i
Service intervals ⇒ page 8

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
26 3. General information
Polo 2002 ➤
– Attach sticker to driver side door pillar (B-pillar) -arrow-.
3.1.2 Attaching “data sticker” in customer

service schedule
– Attach the lower of the two data stickers -arrow- in the service
schedule.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
aut ra
ss c ce
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un
pt
an
d
itte
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erm
ab
ility
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3.1.3 Attaching hotline sticker

wit
is n
h re
ole,
– Attach hotline sticker to the inside of glove box cover as

spec
shown.
t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
3.2 Entries in service schedule

i
o
pr
cum
r
fo
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If a component is changed which has a change interval prescribed
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• Therefore it is very important, every time a component is
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changed, to document this in the service schedule.
• This also applies to components which were changed before
the regular change interval.
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 agen
AG. Volkswagen AG d
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3.3 Connecting vehicle diagnostic tester d ara
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♦ Vehicle diagnostic, testing and information system - VAS 5051
pt
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♦ Vehicle diagnostic tester - VAS 5051B-
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♦ Diagnostic cable - VAS 5051/6A-
♦ Vehicle diagnostic and service information system - VAS

5052- or successor
Polo 2002 ➤
♦ Diagnostic cable - VAS 5052/3-
Note
Ensure that the selected vehicle diagnostic

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with the respective diagnostic cable.
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♦ During a road test, you must always secure testing and
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measuring equipment on the back seat.
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♦ Only a passenger may operate these devices while the
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– Carry out following procedure:
– Connect diagnosis cable connector to diagnostic connection. rrectness of i
– Switch on vehicle diagnostic tester .

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– Switch on ignition.
Now follow information given on screen to start desired functions.
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3.4 Raising vehicle with lifting platform or

trolley jack
Safety notes ⇒ page 30
Lifting points for lifting platform or trolley jack ⇒ page 30
Polo 2002 ➤
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: en AG. V
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On no account should vehicle be lifted at the sump, gearbox or

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on front or rear axle as this may cause serious damage.
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Lifting points for trolley jack
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On side member at positions marked by an indentation.
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Lifting platform:
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Before driving onto a lifting platform, ensure that there is sufficient
clearance between low-lying vehicle components and lifting plat‐
form. rrectness of i
Caution
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Under no circumstances must the vehicle be raised at front on

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vertical reinforcement of side member.

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Lifting points for Polo GTI Cup Edition

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Front: Remove sill cover if necessary by pulling down in

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Rear: Remove sill cover if necessary.
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Polo 2002 ➤
On alignment point, covered by a black rubber plug. This need

not be removed.
Lifting points for all other
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Front: On alignment point, covered by a black rubber plug. This
es, in part or in w
need not be removed.
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Rear: On vertical reinforcement of side member.

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Or at the alignment points, covered by black rubber plugs. This is
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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 Z 2 D (Y) 000 001

Manufacturer Filler char‐ Mo Filler char‐ From mod‐ Production loca‐ Serial number
code acters del acters el year tion
2002
Polo 2002 ➤
3.6 Vehicle data sticker

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The vehicle data sticker -1- is located in rear of vehicle on the lefty Volks ot g
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in spare wheel recess. The vehicle data sticker is also foundisein d b ran
the service schedule for the customer. uthor tee
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The sticker contains the following data of the vehicle
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1 - Vehicle identification number (chassis number)
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2 - Vehicle type, engine output, gearbox
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3 - Engine and gearbox code letters, paint number, interior equip‐

ment
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4 - Optional equipment, PR numbers
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The sticker in service schedule includes the same data. The leg‐ pyri by
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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 Ghana Cuba Saudi Arabia
Egypt Guatemala Kuwait Senegal
Algeria Honduras Laos Zimbabwe
Angola Indonesia Lebanon Sri Lanka and the Mal‐
dives
Argentina Iraq Libya Sudan
Armenia Iran Madagascar Surinam
Bangladesh Jamaica Mali Syria
Bolivia Jordan Mauritius Tajikistan
Polo 2002 ➤
Brazil Cambodia Mongolia Tanzania

Brunei Cameroon Myanmar (Burma) Trinidad and Tobago
Dominican Republic Kazakhstan Nigeria Tunisia
Ecuador Qatar Pakistan Uruguay
Ivory Coast Kenya Paraguay Uzbekistan
El Salvador Kyrgyz Republic Peru Venezuela
Gabon Columbia Russian Federation Vietnam
China Republic of Congo Pacific islands, driving on
left
3.8 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)

For Polo diesel engines without dieselwage particulate filterdup
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♦ When RME fuel is used and your vehicle is not suitable for
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this, the fuel system can be damaged.

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

spec
es, in part or in w
♦ When biodiesel is used which does not conform to the re‐

t to the co
quired standard, the fuel filter can become blocked.

rrectness of i
RME fuel must conform to EN 14214 (FAME).

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♦ RME means “Rapeseed Methyl Ester”.

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♦ EN means “Euro standard”.

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♦ FAME means “Fatty Acid Methyl Ester”.

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Characteristics of RME fuel

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♦ Performance can slightly be lower when using biodiesel.

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♦ Fuel consumption can slightly be higher when using biodiesel.

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AG. Volkswagen AG d
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Maintenance - Edition 02.2018d by gu
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♦ When using biodiesel observe the changed intervals for drain‐
erm
ab
ing and changing the fuel filter ⇒ page 16 .
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♦ If it is planned not to use the vehicle for approx. two weeks, it
h re
is recommended to fill the tank with conventional diesel be‐
hole
spec
forehand and drive approx. 50 km, to prevent damage to the
es, in part or in w
fuel injection system.
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3.10 Severe operating conditions
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If the vehicle is used under severe operating conditions some jobs
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will have to be performed before the next service due or at shorter

service intervals.
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Severe operating conditions

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• Regular short trips or stop and go operation in urban traffic
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• Using diesel with elevated sulphur content

• Regular operation in areas with high levels of dust
3.11 Type plate

– The type plate -2- is located on the left suspension turret.
Polo 2002 ➤
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4. Descriptions of work: 35
AG. Volkswagen AG d
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Polo 2002 ➤ ed b ara
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Maintenance - Edition
ut
h 02.2018
o eo
ra
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s
4 Descriptions of work:
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Removable towing bracket: checking and cleaning if necessary
rm
ab
⇒ page 37 pe
ility
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Swivel joints and axle mountings: inspecting ⇒ page 39
h re
hole
spec
Automatic gearbox: checking ATF level ⇒ page 40
es, in part or in w
t to the co
Automatic gearbox: changing ATF (09G gearbox) ⇒ page 40
Battery: checking battery terminal clamps for secure seating
⇒ page 41
rrectness of i
Battery: check using battery tester with printer VAS 5097A or VAS
l purpos
6161 ⇒ page 42
Brake and clutch system: changing brake fluid ⇒ page 42
nform
ercia
Brake fluid level: checking ⇒ page 47

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com
tion in
Tyres: checking condition, wear pattern, tread depth, tyre pres‐
r
te o
thi
sure and age ⇒ page 49
s
iva
do
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Brake system and shock absorbers: inspecting for leaks and

rp
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damage ⇒ page 58
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Brakes, front and rear: checking thickness of brake pads and
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condition of brake discs ⇒ page 59 rig ht
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Diesel particulate filter: checking ⇒ page 119
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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:
Polo 2002 ➤
Removing and installing engine compartment cover -bottom-

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 AG. Volkswagen AG d
agen oes
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Radio code: reading using vehicle diagnostic tester ⇒ page by V 88
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Tyre Pressure Loss Indicator: performing basic setting
uthor eo
⇒ page 89 ss a ra
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Tyre repair set: checking ⇒ page 89
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Manual gearbox/final drive: Check oil level, replenish oil if nec‐
erm
ab
essary ⇒ page 90
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Window wiper and washer system and headlight washer system:
h re
checking function ⇒ page 90
hole
spec
es, in part or in w
Wiper blade protection: removing ⇒ page 95
t to the co
Headlight adjustment: Check, adjust headlights if necessary
⇒ page 98
rrectness of i
Sunroof: checking function, cleaning and lubricating guide rails
⇒ page 103
l purpos
Service interval display: resetting ⇒ page 103
nf
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Service interval display: recoding ⇒ page 106
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m
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Track rod ends: checking clearance, security and boots

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⇒ page 107
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Dust and pollen filter: Renew filter element ⇒ page 108

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Door arrester: lubricating ⇒ page 108
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Transportation device: Remove blocking pieces from front axle C py
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springs ⇒ page 109
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Dash panel insert: Recode ⇒ page 110 Prote
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agen
Clock: setting to correct time ⇒ page 111

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.
lkswage es n
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Polo 2002 ➤ byV ua
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Maintenance - Edition 02.2018 tho tee
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Check procedure
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– Detach cover -1-.
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– Pull off protective cap -1- from ball head mounting -2-.
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– Insert ball head into mounting.
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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.
Note
If a repair has to be performed, it has only to be in agreement with

the customer. A repair must be charged separately.
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.
Polo 2002 ➤
n AG. Volkswagen AGMaintenance - Edition 02.2018
lkswage does
not
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– Check contact surfaces -arrows- of ball by
ed head for corrosion.
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– If contact surfaces are corroded,s aeliminate corrosion with a tri‐
ut ra
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angular scraper and clean the treated areas with silicone
s
ce
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remover.
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– Apply a thin coat of lubricating paste G 000 650 or G 000 150
erm
ab
on cleaned surfaces.
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– Check again ball head seat in mounting ⇒ page 38 .
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t to the co
rrectness of i
– After checking, fit protective cap -1- into ball head mounting
-2-.
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Note
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at
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If protective cap is damaged or not available, a new protective
ion
c
cap must be fitted to protect ball head mounting against corrosion.
in t
or
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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.
Polo 2002 ➤
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

Afghanistan Egypt Algeria
Angola Equatorial Guinea Ethiopia
Australia Bahrain (AGCC) Benin (Dahomey)
Botswana AGBrunei
. Volkswagen AG Burkina Faso (Upper Volta)
agen does
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Djibouti rise Dubai (AGCC) nte Ivory Coast
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Eritrea ss a Gabon c Gambia
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Ghana Guinea Guinea-Bissau

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India Indonesia / (Borneo) Iraq

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Iran Israel Japan

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Yemen (AGCC) Jordan Cameroon

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Qatar (AGCC) Kenya Congo

spec
Kuwait (AGCC) Lesotho Lebanon

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Liberia Libya Madagascar

Malawi Malaysia Mali
rrectne
Morocco Mauritania Mauritius

Mexico Mozambique Namibia
ss o
cial p
Niger Nigeria Oman (AGCC)

inform
Palestine Puerto Rico Rwanda

mer
atio
m
Zambia Saudi Arabia (AGCC) Senegal

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Sierra Leone Zimbabwe Singapore

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Somalia South Africa Sudan

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Swaziland Syria Tanzania

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Thailand Togo t. Cop py
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Tunisia Turkey Uganda
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West Sahara
(AGCC)
Central African Republic
Polo 2002 ➤
4.5 Battery: checking battery terminal

clamps for secure seating
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331- (5-50 Nm)
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A securely seated battery clamp ensures trouble free function and
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long service life of the battery.
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Carry out following procedure:
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– Press lug -arrow- together and open cover out forwards.
rrectne
If necessary:
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– Push retaining tab of positive terminal cover in
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– Check whether battery clamps are secure on battery terminals
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by moving battery positive cable and battery negative cable
back and forth.
WARNING
If the battery clamp is not seated securely on the positive ter‐

minal, first disconnect battery clamp from battery negative
terminal to prevent possible accidents.
If the battery clamp is not seated securely on positive terminal:
Polo 2002 ➤
– 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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♦ Battery terminals must not be greased. by Vo l ot g
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♦ The battery terminal clamps must only th be connected by hand
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without using force, to ensure thessbattery
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pt
du
an
♦ When the battery is reconnected, do not forget to check the
itte
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vehicle equipment (radio, clock, convenience electrics, elec‐
erm
ab
tric windows etc.) as per workshop manual and/or the operat‐
ility
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ing instructions.
wit
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spec
es, in part or in w
4.6 Battery: Checking using battery tester

t to the co
with printer VAS 5097A or VAS 6161

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

l purpos
»Checking battery«
4.7 Brake and clutch system: Changing

nform
ercia
brake fluid
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at
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WARNING
o
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♦ Never allow brake fluid to come into contact with fluids that
um
for
contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐

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eral oils will damage seals and rubber grommets of brake Cop py
system.
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♦ Brake fluid is poisonous. In addition, due to its corrosive
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nature, it must not come into contact with paint.
Prote 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.
♦ Rinse off spilled brake fluid using plenty of water.
♦ Observe relevant disposal regulations.
Polo 2002 ➤
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).

♦ Brake filling and bleeding equipment - VAS 5234-
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♦ Brake bleeding wrench - VAS 5519-
ot p
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
♦ Brake bleeding tool - VAS 6564-

i
or
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te
sd
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
Polo 2002 ➤
– Unscrew cap -1- from brake fluid reservoir.
AG. Volkswagen AG d
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– Extract as much brake fluid as possible using suction hose
ce
le
un
pt
from brake filling and bleeding equipment - VAS 5234- .
an
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erm
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ility
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Note
wit
is n
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ole,
The strainer in brake fluid reservoir must remain in place.
spec
t to the co
WARNING
rrectne
Do not reuse extracted brake fluid!
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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fo
– Screw adapter -1- onto brake fluid reservoir.
en
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op
Observe ⇒ operating instructions for -VAS 5234- ! C py
ht. rig
rig ht
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– Adjust correct pressure on brake filling and bleeding equip‐ copy Vo
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ment - VAS 5234- : Running gear, brake systems ⇒ Running cted agen
Prote AG.
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.
Polo 2002 ➤
– 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.
– Fit again cover cap on bleeder valve of front left brake caliper.
Repeat procedure on right-hand side of vehicle at front.
wage
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Vol t gu
– If necessary, remove both wheels on reared axle to reach the
by ara
bleed screw. thoris nte
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– Remove cover cap -1- from bleeder valve of rear left brake
erm
ab
caliper.
ility
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spec
es, in part or in w
t to the co
rrectness of i
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orm
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or c
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.
Polo 2002 ➤
– 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

are not directed to the correct chapter. In this case select the pro‐
AG. Volkswagen AG d
– Push bleeder hose onto bleeder valve -arrow- of clutch slave wage
n oes
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cylinder -1-. db
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ris
– Open valve and allow approx. 50 ml of brake fluid to flow
ut out.
ho eo
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– Close valve and depress clutch pedal 10 to 15 timessquickly
ce
le
in succession.
un
pt
an
d
itte
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– Open valve again and allow approx. 50 ml of brake fluid to flow
rm
ab
out.
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ility
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– Close valve, remove bleeder hose and depress clutch pedal
h re
several times.
hole
spec
es, in part or in w
– Install air filter housing accordingly in reverse order.
t to the co
Sequence and quantity of brake fluid
Sequence Brake fluid quantity rrectness of i

bleeder valves: which must flow out of bleeder valves:
l purpos
Brake caliper
nform
ercia
Front left 0.20 l

m
Front right 0.20 l

a
com
tion in
Wheel brake cylinder/brake caliper

r
te o
thi
Rear left 0.30 l

s
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Rear right 0.30 l

um
fo
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ng
t.
Clutch slave cylinder 0.10 l
yi Co
Cop py
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pyri by
Vo
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Total quantity: approx. 1.15 litres including the amount extracted Prote AG.
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.
Polo 2002 ➤
– Unscrew adapter from brake fluid reservoir.

– Check brake fluid level and correct if necessary. It must be
between position -1- and -2-.
AG. Volkswagen AG d
agen oes
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– Screw on cap -1- of brake fluid reservoir.
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– Reinstall rear wheels, if removed previously.
itte
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– Perform functional check during road test.
ility
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spec
es, in part or in w
t to the co
rrectness of i
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4.8 Brake fluid level: checking
nform
ercia
Operation and safety notes ⇒ page 42

m
at
om
io
Brake fluid specification ⇒ page 42
n
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or
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Procedure, brake fluid level (dependent upon lining/pad wear):

at
do
riv
check ⇒ page 47 .
p
cum
for
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4.8.1 Procedure, brake fluid level (dependent

n
t.
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op py
upon lining/pad wear): checking
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pyri by
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Brake fluid level at delivery inspection:
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Prote AG.
For delivery inspection fluid level must be at MAX. marking.
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:
Polo 2002 ➤
“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.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
– Using vehicle key, turn key switch to aposition
uth -2- “Airbag Off”. or
ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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spec
es, in part or in w
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rrectness of i
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nform
mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
Polo 2002 ➤
The “airbag deactivated warning lamp (K145)” in the dash panel
must also light up after self-test.
lkswage es n
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o
Activating front passenger
auth airbag (activated) or
ac
ss
– Using ignition key, turn key switch to position -1- “Airbag ON”.
ce
le
un
pt
an
d
itte
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rm
ab
“Airbag deactivated warning lamp (K145)” goes out after self-test.
pe
ility
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es, in part or in w
WARNING
t to the co
The front passenger airbag must only be deactivated if in ex‐
ceptional cases a child is transported in a rear-facing child seat
rrectness of i
on the front passenger seat.
l purpos
nform
ercia
4.10 Tyres: checking condition, wear pattern,

m
tread depth, tyre pressure and age

a
com
tion in
r
In this chapter you will obtain information on the following sub‐

te o
thi
jects:
s
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rp
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Checking condition ⇒ page 49

fo
en
ng
t.
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Checking tyre wear pattern ⇒ page 50 t. Cop py
rig
gh ht
Checking tyre tread depth (including spare wheel) ⇒ page 50 pyri by
Vo
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cted agen
Checking tyre pressure (including spare wheel) and correcting if Prote AG.
necessary ⇒ page 50
Note
For safety reasons, only tyres of same type and tread pattern
should be fitted on a vehicle!
4.10.1 Checking condition

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.
Polo 2002 ➤
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
AG. Volkswagen AG d
agen oes
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This figure may vary according to legislation in individual coun‐
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♦ by Vo gu
ara
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The minimum tread depth is reached when the tyres have
u
♦ ss a ra
c
worn down level with the 1.6 mm high tread wear indicators
ce
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nl
positioned at intervals around the tyre.

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

erm
ab
inform the customer.

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4.10.4 Tyre pressure (including spare wheel):

hole
spec
Checking, correcting if necessary

es, in part or in w
t to the co
WARNING
rrectness of i
♦ For safety reasons, only tyres of same type and tread pat‐
l purpos
tern should be fitted on a vehicle! Approved wheel and tyre

combinations, e.g. ⇒ Running gear; Rep. gr. 44 ; Polo as
nf
ercia
of model year 2002

orm
m
♦ On four-wheel drive vehicles, tyres of the same type and

atio
m
tread pattern must be used. Otherwise the centre differ‐

o
n in
or c
ential may be damaged.

thi
te
sd
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en
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t.
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op
♦ Tyre pressure gauge
C py
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pyri by
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Prote AG.
Polo 2002 ➤
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. agen
AG. Volkswagen AG d
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♦ The pressures ondthe
by sticker apply to cold tyres. Do not
V t gu reduce
ar
increased pressures
or
ise of warm tyres. an
tee
th or
au
♦ Adjust thesstyre pressure to suit the vehicle load. ac
ce
e
nl
♦ If no inflation pressure is shown for the spare wheel, then in‐
pt
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an
flate the spare wheel to the highest inflation pressure for the
itte
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vehicle.
ab
ility
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♦ Important information on recommended winter tyres can be
wit
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found in »Wheels and Tyres Guide« ⇒ Running gear; Rep.
h re
hole
gr. 44 ; Recommended winter tyres »General«.
spec
es, in part or in w
♦ If winter tyres are fitted, a sticker, visible for the customer and
t to the co
indicating the speed limit, must be applied in the interior of the
vehicle.
rrectness of i
♦ For winter tyres, the tyre pressure does not have be increased.
However, this only applies if the winter tyre used corresponds
l purpos
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
nform
ercia
recommendation of the tyre manufacturer.

m
at
om
Polo 9N1 to ►2004 ⇒ page 51

ion
c
in t
or
Polo “Fun” and “Cross” ⇒ page 53

his
ate
do
riv
Polo 9N3 from 2005► ⇒ page 54

p
cum
for
en
ng
Polo GTI Cup Edition ⇒ page 58

t.
yi Co
Cop py
ht. rig
rig ht
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o Vo
Note by c lksw
cted agen
Prote AG.
The mandatory tyre pressures for the respective model can be

found on a sticker attached to the inside of tank flap or to the B-
pillar.
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
Half load Full load
bar bar
Tyre size Front Rear Front Rear
155/80 R13 2,3 2,1 2,3 2,8
165/70 R14 2,0 1,9 2,2 2,6
185/60 R14
195/55 R15 1,9 1,9 2,1 2,5
205/45 R16 2,0 1,9 2,2 2,6
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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h
Polo 2002 ➤ aut ra
c
s
Maintenance - Edition 02.2018 s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
Half load Full load
ot p
bar bar
wit
, is n
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hole
spec
es, in part or in w
165/70 R14 2,2 2,0 2,4 2,8
t to the co
185/60 R14
195/55 R15 1,9 1,9 2,1 2,5
rrectness of i
205/45 R16 2,2 2,0 2,4 2,8
l purpos
nform
ercia

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om
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Half load Full load
in t
or
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bar bar
ate
do
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185/60 R14 2,2 2,0 2,4 2,8

n
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op py
195/55 R15 1,9 1,9 2,1 2,5
t. C rig
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205/45 R16 2,2 2,0 2,4 2,8
op Vo
by c lksw
cted agen
Prote AG.
Diesel engine 1.4l/55 kW

Half load Full load
bar bar
165/70 R14 2,3 2,1 2,6 3,0
185/60 R14
195/55 R15 2,0 1,9 2,2 2,6
205/45 R16 2,3 2,1 2,6 3,0

Half load Full load
bar bar
185/60 R14 2,4 2,2 2,7 3,1
195/55 R15 2,2 2,0 2,4 2,8
205/45 R16 2,4 2,2 2,7 3,1

Half load Full load
bar bar
165/70 R14 2,2 2,0 2,5 2,9
185/60 R14
195/55 R15 2,0 1,9 2,2 2,6
205/45 R16 2,2 2,0 2,5 2,9
Polo 2002 ➤

Half load Full load
bar bar
AG. Volkswagen AG d
agen oes
195/55 R15 2,4 y Volksw 2,2 not
gu 2,6 3,0
db ara
205/45 R16 2,6
orise 2,4 2,8
nte 3,2
th eo
s au ra
c
s
ce
le
un
pt
Spare wheel (all engine types)
an
d
itte
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erm
ab
Half load Full load
ility
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bar bar
wit
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ole,
spec
Temporary spare 4,2
wheel
t to the co
Spare wheel -stand‐ Keep to the highest pressure required for the vehicle.
ard tyre-
rrectness
Polo “Fun” and “Cross”
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
Half load Full load
iva
o
r
bar bar
p
cum
r
fo
en
ng

t.
yi Co
Cop py
215/40 R17 2,0 1,9 2,2 2,6
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Half load Full load
bar bar
215/40 R17 2,0 1,9 2,2 2,7

Half load Full load
bar bar
215/40 R17 2,1 1,9 2,3 2,7
185/60 R15 2,1 1,9 2,3 2,7
Polo 2002 ➤

Half load Full load
bar bar
215/40 R17 2,2 2,0 2,4 2,8

Half load Full load
bar bar
215/40 R17 2,3 2,1 2,5 2,9
lkswage es n
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Diesel engine 1.9l/74 kW utho
or
a ac
ss Half load Full load
ce
e
bar bar
nl
pt
du
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itte
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erm
ab
215/40 R17 2,4 2,2 2,6 3,0
ility
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, is n
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hole
spec
es, in part or in w
t to the co
Half load Full load
bar bar
rrectness of i
l purpos
Temporary spare 4,2

wheel
nform
ercia
ard tyre-
m
at
om
ion
c
in t
or
his
te
Polo 9N3 from 2005►

a
do
priv
cum
or

f
en
ng
t.
yi Co
. CHalf load
op py Full load
bar bar
t rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
155/80 R13 2,3 2,1 2,3 2,8

165/70 R14 2,0 1,9 2,2 2,6
185/60 R14
195/55 R15 1,9 1,9 2,1 2,5
205/45 R16 2,0 1,9 2,2 2,6
205/40 R17 2,1 1,9 2,3 2,7
Polo 2002 ➤

Half load Full load
bar bar

165/70 R14 2,1 1,9 2,3 2,7
185/60 R14
185/55 R15 2,1 1,9 2,2 2,6
195/50 R15 1,9 1,9 2,2 2,5
195/55 R15 1,9 1,9 2,1 2,5
205/45 R16 2,1 agen
AG. Volkswage1,9
n AG d
oes
2,3 2,7
lksw not
205/40 R17 b2,2
y Vo 2,0 gu
a 2,4 2,8
ed ran
ris tee
tho or
au ac
ss
ce
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nl
pt
du
an
itte
Half load Full load
y li
erm
ab
bar bar
ility
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wit
, is n
h re
hole
spec
165/70 R14 2,1 1,9 2,3 2,7
es, in part or in w
t to the co
185/60 R14
195/55 R15 1,9 1,9 2,1 2,5
rrectness of i
205/45 R16 2,1 1,9 2,3 2,7
205/40 R17 2,2 2,0 2,4 2,8
l purpos
nform
ercia

m
at
om
io

n
c
in t
or
Half load Full load

his
ate
bar bar
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
165/70 R14 gh
2,1 1,9 2,3 2,7
ht
pyri by
Vo
co
185/60 R14
by lksw
cted agen
Prote AG.
195/55 R15 1,9 1,9 2,1 2,5
205/45 R16 2,1 1,9 2,3 2,7
205/40 R17 2,2 2,0 2,4 2,8

Half load Full load
bar bar

165/70 R14 2,3 2,1 2,5 2,9
185/60 R14
195/55 R15 2,0 1,9 2,2 2,6
205/45 R16 2,3 2,1 2,5 2,9
Polo 2002 ➤

Half load Full load
bar bar

205/40 R17 2,4 2,2 2,6 3,0

Half load Full load
bar bar

AG. Volkswagen AG d
185/60 R14 2,2 2,0 agen
2,4 oes 2,8
olksw not
y V gu
b
195/55 R15 2,0 1,9 rise
d 2,2 2,6 arant
ee
ho
205/45 R16 2,2 2,0 s aut 2,4 2,8 or
ac
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
Half load Full load
wit
, is n
bar bar
h re
hole
spec
es, in part or in w
t to the co
185/60 R14 2,4 2,2 2,6 3,0
195/55 R15 2,2 2,0 2,4 2,8
rrectness of i
205/45 R16 2,4 2,2 2,6 3,0
l purpos
205/40 R17 2,6 2,4 2,8 3,2
nf
ercia
orm
m
atio
om
n in
c
Half load Full load

or
thi
e
bar bar
t
sd
iva
o
r
rp
cu
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f

en
ng
t.
yi Co
op
205/45 R16 2,8 2,6 3,0 3,4
C py
t. rig
gh ht
yri by
205/40 R17 2,9 2,7 3,1 3,4
cop Vo
by lksw
cted agen
185/55 R15 M&S 2,8 2,6 Prote 3,0 3,4
AG.

Half load Full load
bar bar

165/70 R14 2,4 2,2 2,6 3,0
185/60 R14
195/55 R15 2,1 1,9 2,3 2,7
205/45 R16 2,4 2,2 2,6 3,0
Polo 2002 ➤

Half load Full load
bar bar

205/40 R17 2,5 2,3 2,7 3,1
Diesel engine 1.4l/59 kW Blue Motion

Half load Full load
bar bar

165/70 R14 2,9 2,7 2,9 3,0

Half load Full load
bar bar

185/60 R14 2,5 2,3 2,7 3,1
195/55 R15 2,3 2,1 2,5 2,9
205/45 R16 2,5 2,3AG. Volkswagen A 2,7 3,1
agen G do
205/40 R17 2,7 yV
olksw 2,5 2,9
es n
ot g 3,3
b ua
ed ran
oris tee
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au ac
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nl
pt
du
Half load Full load

an
itte
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bar bar
erm
ab
ility
ot p
wit
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h re
hole
165/70 R14 2,3 2,1 2,5 2,9

spec
es, in part or in w
185/60 R14
t to the co
195/55 R15 2,0 1,9 2,2 2,6

205/45 R16 2,3 2,1 2,5 2,9
rrectness of i
205/40 R17 2,5 2,3 2,7 3,1

l purpos
nf
ercia

rm
m
atio
m
Half load Full load

o
n in
c
bar bar
or
thi
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ng
195/55 R15 2,6 2,4 2,8 3,2

t.
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op py
205/45 R16
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ht ht
rig by
py
205/40 R17 2,7 2,5 3,0 3,4
co Vo
by lksw
cted agen
Prote
185/55 R15 M&S 2,8 2,6 3,0 3,4
AG.
Polo 2002 ➤

Half load Full load
bar bar
Temporary spare 4,2
wheel
ard tyre-
Polo GTI Cup Edition

Half load Full load
bar bar

205/45 R16 2,8 2,6 3,0 3,4
205/40 R17 3,1 2,9 3,3 3,4
Spare wheel (all engine types) agen

AG. Volkswagen AG d
oes
olksw no
Half load d by
V Full load t guar
bar ris
e
bar an
tee
tho o
u
Tyre size Front Rear
ss
a Front Rear r ac
ce
e
Temporary spare 4,2

nl
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an
wheel
itte
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erm
ab
ility
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ard tyre-
wit
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h re
hole
spec
es, in part or in w
4.11 Brake system and shock absorbers: in‐
t to the co
specting for leaks and damage
rrectness of i
Check following components for leaks and damage:
l purpos
♦ Brake master cylinder

♦ Brake servo (for anti-lock brake system: hydraulic unit)
nf
ercia
♦ Brake pressure regulator or brake pressure reducer and

rm
m
atio
m
♦ Brake caliper
o
n in
or c
thi
♦ Shock absorbers (during inspection only)

te
sd
iva
o
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♦ Presence of dust caps on brake fluid bleeder valves

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– Ensure that brake hoses are not twisted.

t.
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Cop py
t. rig
– Additionally ensure that brake hoses do not touch any vehicle yri
gh by
ht
components when steering is at full lock.
op Vo
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cted agen
Prote
– Check brake hoses for porosity or brittleness.
AG.
– Check brake hoses and lines for chafing.

– Check brake connections and fastenings for correct seating,
leaks and corrosion.
Polo 2002 ➤
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
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
♦ Torque wrench - V.A.G 1332-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
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ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
♦ Electric hand torch and mirror

hole
spec

es, in part or in w
t to the co
The adapter to loosen and tighten the anti-theft wheel bolts can
be found in the vehicle tool kit.
rrectness of i
4.12.1 Front brake pads:

l purpos
– For better evaluation of remaining pad thickness, use a test

mirror and, if necessary, remove the wheel on the side where
nform
ercia
the brake pad wear indicator is installed.

m
– Pull off wheel bolt caps if necessary.

com
tion in
r
– Mark position of wheel relative to brake disc.

te o
thi
s
iva
do
– Unbolt wheel bolts and remove wheel.

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Polo 2002 ➤
– 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
kswage es n
When replacing brake pads, always check bbrake yV
o discs as well for
l ot g
ua
wear! Checking and if necessary replacing
ir se the brake discs is a
d ran
tee
repair measure. autho
or
ac
ss
ce
e
– Check brake disc for wear:

nl
pt
du
an
itte
y li
Procedure
erm
ab
ility
ot p
Running gear → Brake systems ⇒ Rep. gr. 46 → Brake mecha‐
wit
, is n
nism → Repairing front brake
h re
hole
spec
es, in part or in w
Note
t to the co
rrectness of i
l purpos
– Install wheel in marked position.
nf
ercia
o
– Tighten wheel bolts diagonally and alternately, specified tor‐
rm
m
que ⇒ page 85 .
atio
om
n in
c
– Place adapter in vehicle tool kit after completing work.

or
thi
te
sd
a
– Fit wheel bolt covers if necessary .

iv
o
r
rp
cu
o
m
f
en
ng
4.12.2 Rear brake pads:

t.
yi Co
Cop py
t. rig
gh
– Illuminate area behind hole in wheel using an electric hand
ht
pyri by
Vo
torch.
co lksw
by
cted agen
Prote AG.
Polo 2002 ➤
– Inspect outer pad to determine thickness.

Volkswagen AG
– Illuminate inner pad with an electric hand torch andswmirror.
agen
AG. does
k not
Vol gu
– Inspect inner pad to determine thickness. sed by ara
nte
ri
ho eo
a - Inner and outer pad thickness without backplate
aut ra
c
ss
Wear dimension: 2 mm
ce
e
nl
pt
du
an
itte
The brake pads have reached their wear limit at a pad thickness
y li
erm
ab
of 2 mm (without backplate) and must be renewed (repair meas‐
ility
ot p
ure). Inform customer!
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
When replacing brake pads, always check brake discs as well for
wear! Checking and if necessary replacing the brake discs is a
repair measure.
rrectness of i
l purpos
– Check brake disc for wear:

Procedure
nform
ercia
Running gear → Brake systems ⇒ Rep. gr. 46 → Brake mecha‐

m
at
om
nism → Repairing rear brake
ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng

t.
yi Co
op
C py
ht. rig
cedure manually in the information. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.12.3 Rear drum brake pads: checking

– Remove cap -1-.
Polo 2002 ➤
– 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
Procedure lksw
agen oes
not
o
yV gu
⇒ Brake systems; Rep.isgr.ed 46 ; Repairing rear brake (drum brake)
b ara
nte
or eo
h
Running gear → Brake
aut systems → Rep. Gr. 46 → Repairing rear ra
s c
brake (drum brake)
s
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Replace cap -1- after checking.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
. rig
4.12.4 Brake discs: checking condition
ht ht
rig by
copy Vo
by lksw
cted
Check all brake discs for the following damage pattern:
agen
Prote 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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
nte Polo 2002 ➤
o eo
aut
h
Maintenance
ra - Edition 02.2018
ss c
ce
le
4.13 Electric windows: Carry out initialisation
un
pt
an
d
itte
(activation)
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Note hole
spec
es, in part or in w
The automatic opening and closing features for the electric win‐
t to the co
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‐
rrectness of i
nected after initialisation.
l purpos
DANGER!
nform
mercia
After vehicle battery has been disconnected and reconnected
a
com
tio
the roll-back function of the electric window regulators is disa‐
n in
r
bled. Severe pinching injuries could result!

te o
thi
s
iva
do
It is very important to inform the customer!
r
rp
cum
fo
en
ng
t.
yi Co
op
Carry out the following procedure to initialise the electric windows:
C py
ht. rig
rig ht
py by
– Close all doors completely. co Vo
by lksw
cted agen
Prote 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”.
Polo 2002 ➤
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
– Press continue button > again to go to the test plan. lksw
agen oes
not
o
byV gu
– Now complete guided fault finding using “GoTo” button andris ed ara
nte
then “End”. ut
ho eo
ra
s a c
s
All event memories are read again.
ce
le
un
pt
an
Now it is shown on display that all sporadic faults have been
d
itte
y li
cleared, the diagnosis log is sent “online” automatically.
erm
ab
ility
ot p
The vehicle system test is completed.
wit
is n
h re
4.15 Bonnet: greasing arrester
ole,
spec
t to the co
♦ Universal oil spray G 000 115 A2
rrectne
Note
ss o
Vehicle must be at least at room temperature.
cial p
f inform
mer
– Lubricate bonnet arrester with universal oil spray G 000 115
atio
m
A2 at points marked with -arrows-.

o
n
c
i
or
n thi
e
– Operate moving parts several times so that universal oil is able

t
sd
va
to penetrate.
i
o
pr
cum
r
fo
– Remove any excess lubricant using a lint-free cloth.

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.16 Adding multi-purpose additive G17
Note
♦ Only applicable for Chinese and Russian market.

♦ Applicable for petrol engines only.
– Fill additive G17 into regular fuel tank during each service.
Polo 2002 ➤
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
sible. yV
olks s no
t gu
b ara
ed nte
oris e
4.17 Boots: inspecting ss
au
th or
ac
ce
e
nl
pt
du
an
itte
y li
– Check outer joint bellows -arrow- and inner joint bellows (not
erm
ab
shown in illustration) for leaks and damage.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
4.18 Checking expiry date of first-aid kit
m
atio
om
n in
c
With immediate effect, the expiry date of the first-aid kit must be
or
thi
e
checked at every inspection service.

t
sd
iva
o
r
rp
cu
Inform customer if date has been exceeded.
o
m
f
en
ng
t.
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4.19 Interior and exterior body: inspecting for
Co
Cop py
t. rig
corrosion with doors and flaps open
gh ht
pyri by
Vo
co lksw
by
cted
Test locations
agen
Prote AG.
♦ 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

Polo 2002 ➤
– 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
lighting for the number plate cannot not guaranteed.
olks
wag does
not
yV gu
db ara
♦ This can seriously impair the safety of vehicle ir seand invalidates nte
the type approval of the vehicle. aut
ho eo
ra
ss c
ce
e
nl
4.23 Fuel filter: Renewing (diesel engine)

pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ Ensure that no diesel fuel contacts coolant hoses. If necessa‐

spec
ry, clean hoses immediately.

es, in part or in w
t to the co
♦ Observe environmental regulations for disposal.

rrectness of i

l purpos
Removing
There are two versions of fuel filters. The procedure is basically
nform
ercia
the same.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2002 ➤
– 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.
Note AG. Volkswagen AG d

agen oes
o lksw not
byV gu
ara
d
Fuel through-flow direction
orise is marked on the connections by ar‐
nte
eo
rows (do not interchange
aut
h connections). ra
ss c
ce
le
un
pt
an
d
4.24 Fuel filter: Draining water (diesel en‐

itte
y li
rm
ab
gine)
pe
ility
ot
wit
, is n
Only applicable for diesel engines with distributor injection pump

h re
hole
spec
es, in part or in w
t to the co
Note
♦ Ensure that no diesel fuel contacts coolant hoses. If necessa‐

rrectness of i
ry, clean hoses immediately.

l purpos

nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Polo 2002 ➤
– 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.
wage es n
– Install regulating valve -4- and fit retaining clipy V-3-.
olks ot g
b ua
ed ran
– Check fuel system for leaks (visual check). horis tee
ut or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2002 ➤
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
must be filled all year round with a coolant
wage
n AGadditive.
. Volkswagen AG
doe s no ks
t gu Vol
♦ Because of its high boiling point,
ed
by the coolant improves engine ara
reliability under heavy loads,
horis particularly in countries with trop‐ nte
eo
ical climates. s aut ra
c
s
♦ Use ONLY the refractometer - T10007A- for determining cur‐
ce
e
nl
pt
du
rent anti-freeze value.
an
itte
y li
erm
ab
♦ Frost protection must be guaranteed down to -25°C as a min‐
ility
ot p
imum and, in countries with arctic conditions, down to approx.

wit
, is n
-36°C. Increasing the frost protection is permissible only if cli‐

h re
matic conditions require stronger frost protection. It may, how‐
hole
ever, be increased only to a maximum of -48°C. Otherwise, spec

es, in part or in w
the cooling effect will be impaired.

t to the co
♦ Do not reduce the coolant concentration by adding water even

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

l purpos
♦ Read off anti-freeze figures for respective replenished coolant

additive.
nf
ercia
♦ The temperature read off the refractometer - T10007A- corre‐

or
sponds to the »ice flocculation point«. Flakes of ice may start

m
m
atio
forming in the coolant at this temperature.

om
n in
or c
♦ Never reuse old coolant.

thi
te
sd
iva
♦ Use only a water/coolant additive mixture as a slip agent for

o
r
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cu
coolant hoses.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
4.25.1 Frost protection: checking, replenishing pyri by
Vo
o
by c lksw
coolant additive if necessary
cted agen
Prote AG.
Polo 2002 ➤
♦ 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
♦ If the currently used coolant additive cannot be determined
olks
wage es n
ot g
precisely, use the scale -2- for coolant additive G13.d by V ua
ran
e
ris tee
ut
ho or
a ac
ss
ce
le
– Check coolant additive concentration after road test again.

un
pt
an
d
itte
y li
erm
ab
4.25.2 Coolant level: checking, replenishing

ility
ot p
coolant if necessary
wit
is n
h re
ole,
– Check coolant level on expansion tank with engine cold.

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2002 ➤
♦ 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
If fluid loss is greater than can be expected through normal use,

determine source and rectify (repair measure).
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
4.25.3 Mixing ratio:
itte
y li
erm
ab
ility
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Caution
wit
, is n
h re
hole
spec
Use only distilled water for mixing coolant additives. The use
es, in part or in w
of distilled water ensures optimum protection against corro‐
t to the co
sion.
rrectness of i
Frost protection to Coolant additive Distilled water
l purpos
portion
-25 °C approx. 40% approx. 60 %
nf
ercia
-36 °C approx. 50 % approx. 50 %

orm
m
atio
om
n in
or c
thi
e
4.26 Air filter: Cleaning housing and renew‐

t
sd
iva
o
r
ing filter element

rp
cu
o
m
f
en
ng
t.
yi Co
Air filter: Clean housing and renew filter element, engine codes Cop py
BUD and BTS ⇒ page 71
t. rig
gh ht
pyri by
Vo
co
Air filter: Clean housing and renew filter element, 1.4 l injection
by lksw
cted agen
engines ⇒ page 72 .
Prote AG.
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
Polo 2002 ➤
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-.
AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
ara
ed
ris nte
Observe environmental regulations for disposal. ut
ho eo
ra
s a c
s
ce
e
– Clean air filter housing.
nl
pt
du
an
itte
– Install air filter and air filter housing in reverse order.
y li
erm
ab
ility
ot p
wit
4.26.2 Air filter: Cleaning housing and renew‐
, is n
h re
hole
ing filter element, 1.4 l injection engines
spec
es, in part or in w
t to the co
Removing
rrectness of i
The air filter element is integrated in the engine cover panel.
l purpos
– Removing engine cover ⇒ page 81 .

– Unscrew bolts -arrows- and remove air filter housing from en‐
nform
ercia
gine cover.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Take out used filter element -3-.
Note
Observe environmental regulations for disposal.
Installing
– Clean filter housing -2- and install new filter element -3-.
Polo 2002 ➤
– Insert filter housing and tighten bolts -arrows- to 3 Nm.

– Install engine cover and air filter housing in reverse order.
G. Volkswagen AG d
4.26.3 Air filter: Clean housing and renew filter ksw
agen
A
oes
not
Vol
element, engine codes: AWY, AZQ, by gu
ara
ed nte
ris
BMD, BME and 4-cylinder FSI ut engines
ho eo
ra
sa s c
ce
le
un
pt
an
d
itte
Removing
y li
rm
ab
pe
ility
The air filter element is integrated in the engine cover panel.
ot
wit
, is n
– Removing engine cover ⇒ page 81 .
h re
hole
spec
– Unscrew bolts -arrows- and remove air filter housing from en‐
es, in part or in w
gine cover.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Take out used filter element.
um
fo
en
ng
t.
Installing
yi Co
Cop py
t. rig
– Clean filter housing and install new filter element.
gh ht
pyri by
Vo
o
by c lksw
– Install filter housing and tighten. cted agen
Prote AG.
4.26.4 Air filter: Clean housing and renew filter

element, diesel engines, 1.8 l 5-valve
engines and engines with engine codes:
BZG and BBM
Polo 2002 ➤
Removing
– Unscrew securing bolts -arrows-, and raise upper part of filter
housing.
– Take out used filter element -3-.
Note
Installing
– Clean filter housing -5- and install new filter element -3-.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Insert filter housing ed upper part and tighten bolts -arrows-
b ara to
nte
is
3 Nm. hor eo
aut ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
4.27 Engine oil level: Check, replenish en‐

l purpos
gine oil if necessary

Note the following:
nf
ercia
orm
After shutting off engine, wait at least 3 minutes so that the oil can
m
atio
m
flow back into the sump.

o
n in
or c
– Pull out dipstick, wipe with a clean cloth and push dipstick in
thi
te
sd
a
again to limit stop.

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Polo 2002 ➤
Note
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 does
lksw n
C - Oil must be replenished. bOil
y V level must then be at least in upper
o ot g
ua
third of measuring areaor-B-.
ise
d ran
te
h eo
ut
– If oil level is above
ss -A- marking, drain or extract excess oil in
a ra
c
order to avoid damage to catalytic converter.
ce
le
un
pt
an
d
– If oil level is below marking -C-, replenish oil to marking -A-.

itte
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Oil specification ⇒ page 9
erm
ab
ility
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“LongLife engine oil” sticker ⇒ page 26 .
wit
is n
h re
Attach vehicle data sticker in service schedule ⇒ page 26 .
ole,
spec
t to the co
4.28 Engine oil: Draining or extracting and re‐
plenishing; renewing oil filter
rrectne
Engine oil: Drain or extract engine oil ⇒ page 75 .
Renew oil filter ⇒ page 77 .
ss o
cial p
Replenishing engine oil ⇒ page 80 .

inform
mer
4.28.1 Engine oil: draining or extracting

atio
om
n
c

or
n thi
te
sd
a
♦ Used oil collection and extraction unit - V.A.G 1782-

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2002 ➤
♦ Used oil collection and extraction unit - VAS 6622-
♦ Oil spill cloth - VAS 6204/1-

Engine oil: draining or extracting
Note
♦ For engines with standing oil filter, the oil filter must be re‐
newed before changing the engine oil. When removing the
filter element a valve is opened, the oil in the filter housing
automatically flows into crankcase.
♦ If the engine oil is drained and not extracted with an oil ex‐
tractor, replace drain plug. This prevents leaks.
– Extract engine oil using used oil collection and extraction unit
- V.A.G 1782- .
Or . Volkswagen AG
gen AG does
swa
– Extract engine oil using used oil collection
by
Vol and extraction unit
k not
gu
- VAS 6622- . ris
ed ara
nte
tho eo
Or s au ra
c
s
ce
le
– Remove oil drain plug.

un
pt
an
d
itte
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– Let engine oil drain.

rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
♦ There are two different oil drain plug versions.

es, in part or in w
t to the co
♦ 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) .
rrectness of i
♦ 2) On all other engines, an oil drain plug with hexagon head

l purpos
and integrated seal is used. On this version, always renew the

oil drain plug with integrated seal ⇒ plug with seal → Electronic
nform
ercia
parts catalogue (ETKA) .

m

a
com
tion in
r
te o
thi
– On 3-cylinder petrol engines, clean oil drain plug and fit new
s
iva
seal.
do
r
rp
cum
fo
– Tighten oil drain plug with seal hand-tight first and then to
en
ng
t.
yi
30 Nm.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2002 ➤
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.
Renewing oil filter, 1.2 l petrol engines

– Remove engine cover panel, if necessary ⇒ page 81 .
AG. Volkswagen AG d
Carry out following procedure: agen oes
olksw not
byV gu
– Unscrew cover cap -5- with 36 mm socket
rised insert and remove ara
nte
cover with oil filter insert. ut
ho eo
ra
s a c
s
– Pull used oil filter element -1- off sealing cap.
ce
e
nl
pt
du
an
– Renew O-ring -4- for cap.

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

ility
ot p
wit
– Insert new filter element.

, is n
h re
hole
spec
es, in part or in w
Note
t to the co

rrectness of i
– Clean engine sealing surface.

l purpos
– Oil rubber seal lightly on new filter.

nf
ercia
– Cover cap torque setting: 25 Nm.

orm
m
atio
Renewing oil filter, 1.4 l FSI engine

om
n in
c
– Remove engine cover panel ⇒ page 81 .

or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
77
cted agen
Prote AG.
AG. Volkswagen AG d
Polo 2002 ➤ ksw
agen oes
not
ol
Maintenance - Edition 02.2018 d byV gu
ara
ise nte
or eo
th
– Unscrew cover cap -1- with 36 mm socket insert sand
au remove ra
c
cover with oil filter insert -4- and valve -5-. s
ce
le
un
pt
– Renew O-ring -2- of cover cap and O-ring -3- of valve.
an
d
itte
y li
rm
ab
– Renew used oil filter element by new filter element.
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
– Tighten cover cap -1-.
rrectness of i
Cover cap torque setting: 25 Nm.
l purpos
Renewing oil filter, 1.4 l injection engine
nform
ercia
Note
m
a
com
tion in
r

te o
thi
s
iva
do
r
rp
cum
fo
♦ Prevent engine oil from dripping onto components in engine
en
ng
t.
yi Co
compartment. . Cop py
rig
ht ht
rig by
py
– Detach alternator wiring harness from guide tube, which is
co Vo
by lksw
cted
screwed on heat shield.
agen
Prote AG.
– 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
Polo 2002 ➤
♦ Oil filter tool - VAS 3417- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
– Loosen oil filter -arrow- from underneath using a strap spanner
or oil filter tool - VAS 3417- .
rrectnes
Note
s o
cial p
f inform
mer
atio
om
– Clean oil cooler sealing surface.
n
c
i
or
n thi
e
– Oil rubber seal lightly on new filter. This ensures best possible
t
sd
iva
o
sealing when the filter is tightened.
pr
cum
r
fo
en
ng
– Tighten filter by hand.

t.
yi Co
Cop py
Oil filter: renewing, diesel engines
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note

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.
Polo 2002 ➤
Installing
Volkswagen AG
– Renew filter element -3-.swagen AG. does
k not
Vol gu
– Renew O-rings -2 by 4-.
dand ara
e nte
ris
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
– Install threaded cap -arrow- and tighten to 25 Nm.
form
mer
atio
Further assembly is basically the reverse of the removal proce‐
om
dure.
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.28.3 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
– 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.
Polo 2002 ➤
A - Do not top up oil.

B - Oil can be replenishedwup
agento area -A-.
AG. Volkswagen AG d
oe
ks s no
Vol t
C - Oil must be replenished.
ed
by Oil level must then be at least
gu
arin
an upper
third of measuring
h oris area -B-. tee
t or
au a
– If oil level
ss is above -A- marking, drain or extract excess oil inc
order to avoid damage to catalytic converter.
ce
le
un
pt
an
d
itte
– If oil level is below marking -C-, replenish oil to marking -A-.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
4.29 Engine and components in engine com‐
es, in part or in w
t to the co
partment: inspecting for leaks and dam‐
age (from above and below)
rrectness of i
Inspect as follows:
l purpos
– Check engine and components in engine compartment for

leaks and damage.
nform
ercia
– Check lines, hoses and connections of

m
a
com
tio
♦ Fuel system
n in
r
te o
thi
♦ Cooling and heating system s
iva
do
r
rp
♦ And brake system

um
fo
en
ng
t.
yi
for leaks, abrasions, porosity and brittleness.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Note Prote
cted AG.
agen
♦ 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 .
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 .
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 .
Polo 2002 ➤
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).
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.
jection engines
– Pull off cover at positions marked -arrows-.

G. Volkswagen
Removing and installing engine
lksw
agencover panel -top-,
A AG do
e1.4
s no l FSI en‐
gines by
Vo t gu
a
is nt ed ra
– Pull off hoseuthfrom
or air filter housing to camshaft housing. ee or
sa ac
– Pull connector
s off intake air temperature sender.
ce
le
un
pt
– Pull out oil dipstick.

an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,

spec
t to the co

BMD
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2002 ➤

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

– 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 -B-

and pull out of guide forwards -C-.
Version 2
Removing:
lkswage es n
o ot g
yV
Note ir se
d b ua
ran
o tee
th or
u
The engine
ss cover panel consists of two individual parts.
a ac
ce
le
un
pt
an
d
1) Outer part -A-, shaded in illustration.

itte
y li
erm
ab
ility
ot p
2) Centre part -B-, not shaded in illustration.

wit
is n
h re
– Disengage engine cover panel carefully at individual securing

ole,
points and raise as follows.

spec
t to the co
-1-, -3-, -2-, -4-.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
Polo 2002 ➤ d byV gu
ara
e
Maintenance - Edition 02.2018 horis nte
eo
aut ra
ss c
– Remove outer part -1-.
ce
le
un
pt
an
– Disengage centre part -2- also carefully and remove.
d
itte
y li
rm
ab
Installing:
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Fit engine cover panel onto securing points -arrows- and press
on.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Then fit outer part -1- over retaining points -arrows- and press
on, so that cover engages.
Removing and installing engine cover panel -top-, 1.8 l -5-valve

engines
Removing:
– 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:
Polo 2002 ➤
»General body repairs, exterior« ⇒ General body repairs, exte‐

rior; Rep. gr. 50 ; Noise insulation »Noise insulation«
Note

4.32 Road test: performing (driving behav‐ lkswagen AG. Volkswagen AG does n
iour, noises, air conditioner etc.) sed by V
o ot g
ua
ran
i tee
or
Which of the following can be checked depends on vehicle
au
th equip‐ or
ac
ment and local conditions (urban/country). ss
ce
e
nl
pt
Check the following during a road test:
du
an
itte
y li
erm
– Engine: output, misfiring, idling speed, acceleration
ab
ility
ot p
– Clutch: pulling away, pedal pressure, odours
wit
, is n
h re
– Gear selection: ease of operation, stick position
hole
spec
es, in part or in w
– Automatic gearbox: selector lever position, shift lock/ignition
t to the co
key removal lock, shift behaviour, dash panel insert display.
– ABS function: pulsing must be felt at the brake pedal during
rrectness of i
ABS-regulated braking
l purpos
– Foot brake and handbrake: function, free travel and effective‐

ness, pulling to one side, juddering, squeal
nform
ercia
– Steering: function, steering free clearance, steering wheel

centred when vehicle is travelling straight ahead
m
at
om
io
– Tilting roof: function
n
c
in t
or
his
e
– Folding fabric sunroof: function

at
do
priv
c
– Radio: Reception, GALA, interference
um
for
en
ng
t.
yi
– Multi-function indicator (MFI): functions
Co
Cop py
t. rig
gh
– Air conditioner: Function. (At very low temperatures the func‐
ht
pyri by
Vo
tion of air conditioner must be checked in a workshop)
o
by c lksw
cted agen
Prote AG.
– Vehicle: pulling to one side when travelling straight-ahead
(level road)
– 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
Polo 2002 ➤
– 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
AG. Volkswagen AG d
agen oes
ksw
The cover caps protect the wheel bolts V and should be recon‐
l not
♦ by
o gu
ara
nected after the wheel securingorisbolts
ed
have been retightened. nte
th eo
Ensure that on some rims the a lug of the wheel hub trim locates
u
♦ ss
ra
c
in the groove of the rim.
ce
e
nl
pt
du
an
♦ After completing work, place adapter and puller hooks with
itte
y li
vehicle tool kit.
erm
ab
ility
ot p
wit
, is n
h re
– On vehicles with full wheel trim install full wheel trim so that
hole
the tyre filler valve is guided through the cut-out provided
spec
es, in part or in w
-arrow-.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
Loosening or tightening anti-theft wheel bolts

at
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
♦ The adapter to loosen and tighten the anti-theft wheel bolts
p by
co Vo
by lksw
can be found in the vehicle tool kit. Prote
cted AG.
agen
♦ If the adapter to loosen or tighten the anti-theft wheel bolts is

not available in the vehicle, use the adapter set for tamper-
proof 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.
AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Polo 2002 ➤
e nte
horis Maintenance
eo - Edition 02.2018
aut ra
ss c
♦ Adapter set for wheel bolts - T10101-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Slide adapter into anti-theft wheel bolt onto stop.
nform
ercia
– Slide the wheel bolt wrench onto adapter onto stop.

m
at
om
io
– Retighten the wheel securing bolts to correct torque setting.
n
c
in t
or
his
e
Retightening wheel securing bolts

at
do
priv
c
um
for
en
ng
t.
yi
♦ Torque wrench - V.A.G 1332-
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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.
Polo 2002 ➤
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.
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).
swage es n
• Available access for the user of the system “GeKo” (secrecy byV
olk ot g
ua
and component protection) ir se
d ran
tee
tho
u or
a ac
ss
Note
ce
e
nl
pt
du
an
itte
y li
♦ The radio codes can be read in the central database and can
erm
ab
be displayed on vehicle diagnostic tester .
ility
ot p
wit
, is n
♦ For radio activation the codes must be entered via radio but‐
h re
tons, as previously ⇒ page 87 .
hole
spec
es, in part or in w
t to the co
Procedure
– Switch on ignition. rrectness of i
l purpos
– On the screen, touch »GUIDED FUNCTIONS« field or button.

– Confirm with > button.
nf
ercia
orm
– Select one after another:

m
atio
om
♦ Brand
n in
or c
thi
e
♦ Model
t
sd
iva
o
r
rp
cu
♦ Model year
o
m
f
en
ng
t.
yi
♦ Engine code
Co
Cop py
t. rig
gh ht
– Confirm vehicle identification. yri
p by
co Vo
by lksw
cted
agen
Prote AG.
♦ “Radio system”
♦ “Reading radio code”
– Read code according to the information of “GUIDED FUNC‐
TIONS”.
Polo 2002 ➤
– 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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Note orise nte
eo
h
aut ra
s c
♦ The tyre sealant in the bottle has a limited shelf life. s
ce
le
un
pt
♦ Therefore the expiry date is indicated on the bottle -arrow-.

an
d
itte
y li
rm
ab
♦ Residual tyre sealant or bottles which are filled and the expiry
pe
ility
date has been exceeded, must be disposed of.

ot
wit
, is n
h re
♦ Old tyre sealant and/or remnants must not be mixed or dis‐

hole
posed of with other fluids.

spec
es, in part or in w
t to the co
– Check the expiry date and enter this in maintenance tables.

– Renew tyre sealant if the expiry date has been reached.
rrectness of i
• Observe relevant disposal regulations.

l purpos
4.37 Tyre Pressure Loss Indicator: perform‐

nform
ercia
ing basic setting

m
a
com
tio
– After changing the tyre pressures or after changing one or

n in
r
more wheels, the Tyre Pressure Loss Indicator must be set to

te o
thi
basic setting.
s
iva
do
r
rp
cum
– Adjust the prescribed tyre pressure on each tyre.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Polo 2002 ➤
– 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 .
AG. Volkswagen AG d
Headlight washer system: check spray jet settings ⇒ pageo94
lksw.
agen oes
not
yV gu
Checking wiper blade park position ⇒ page 94 . db ara
rise nte
tho eo
Wiper blades: checking setting angle ⇒ page 94s au. ra
c
s
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
When during a functional check it is determined that the wiper

wit
, is n
blades »judder« or make noises, check the setting angle of the

wiper blades ⇒ page 94 . h re
hole
spec
es, in part or in w
t to the co
4.39.1 Anti-freeze concentration in window
wiper and washer system: Checking
rrectness of i
and replenishing fluid if necessary

l purpos
Checking anti-freeze concentration:

nf
ercia
orm
♦ Refractometer - T10007 A-
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
Polo 2002 ➤
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‐
ter - T10007 A- . wage
e ks s no
Vol t gu
The scale -4- of the refractometer is calibrated
d b for Windscreen
y ara
Clear - G 052 164- . rise nte
ho t eo
au ra
Mixing ratio ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Frost protection Windscreen Water
to Clear
l purpos
G 052 164
In summer 1 part 4 parts
nf
ercia
o
-16 °C 1 part 2 parts
rm
m
atio
m
-35 °C 1 part 1 part

o
n in
or c
-40 °C 2 parts 1 part
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
Replenishing fluid:
yi Co
Cop py
t. rig
The fluid reservoir of the window washer system must be filled gh ht
yri by
completely. cop Vo
by lksw
cted agen
Prote AG.
Starting immediately, use only “Genuine Volkswagen Wind‐
screen Clear” year-round when replenishing window wiper and
washer system.
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).
Polo 2002 ➤
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
jets, otherwise the water passages Ain the
G. Volksspray jet
wagen AG dwill be
agen
damaged! Volksw
oes
not
by gu
ara
ed nte
oris eo
th
Preset spray jets forsswindscreen washer system au ra
c ce
le
The spray jets are preset. However, small differences in height

un
pt
an
d
may be corrected.
itte
y li
erm
ab
– If both spray fields are not at same height, adjust spray direc‐
ility
ot p
tion upwards or downwards as follows:

wit
is n
h re
ole,
spec
t to the co
rrectne
– Turn eccentric on spray jet -in direction of arrow- using a

ss
screwdriver, to adjust spray direction upwards.

o
cial p
f inform
– To adjust the spray direction downwards, turn eccentric on

mer
washer jet opposite to -direction of arrow-.

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Polo 2002 ➤
Or
– Adjust spray jet at adjuster -1- by hand upwards or down‐
wards.
Spray jet for rear window washer system

♦ Adjusting tool - T10127-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
♦ or adjusting tool - T40187-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Check jet setting.
r
te o
thi
s
Spray jet must spray to centre of wiped area.

iva
do
r
rp
cum
fo
– If necessary, adjust the spray jet using adjusting tool - T10127-

en
ng
t.
or adjusting tool - T40187- . Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
Note
c by lksw
cted agen
Prote AG.
Make sure that the spray is not directed into the rear window wiper
cover.
Polo 2002 ➤
wage
4.39.3 Headlight washer system: check jet set‐ lks es n
o ot g
byV ua
ting
d ran
ir se tee
tho
u or
a ac
ss
ce
le
Caution
un
pt
an
d
itte
y li
Only control function of spray jets but do not adjust them.
rm
ab
pe
ility
ot
wit
, is n
h re
Spray pattern of right headlight (adjustment of left headlight is a
hole
spec
mirror image)
es, in part or in w
t to the co
Up to ►2005
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
From 2006►
yi Co
Cop py
t. rig
Washer spray jet: checking settings gh ht
pyri by
Vo
co lksw
by
– Switch on dipped headlight. Prote
cted AG.
agen
– Operate windscreen washer system.

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.
Polo 2002 ➤

♦ Wiper setting tool - VAS 3358B-
– Set wiper arms to rest position.

– Remove wiper blade.
– Insert wiper arm -2- into wiper arm setting device - VAS 3358B-
and secure with locking screw -3-.
– Check setting angle.
Setting angle (specifications) for
LHD vehicles RHD vehicles AG. Volkswagen AG d
agen oes
ksw
Driver side -5° +5° by
Vol not
gu
ara
ed
Passenger side -5.5° +5.5° ho ris nte
eo
ut ra
Rear window wiper -5° -5°
ss a c
ce
le
Tolerance ±2° ±2°

un
pt
an
d
itte
y li
If required, proceed as follows to adjust setting angle according
rm
ab
to specification:
pe
ility
ot
wit
, is n
h re
– Fit 24 mm open jaw spanner -1- on setting device and adjust
hole
spec
wiper arm -2- to specification -arrows-.
es, in part or in w
t to the co
– Release wiper arm -2- from setting device and then resecure
with locking screw -3-.
– Check setting against table. If necessary, repeat setting and
rrectness of i
checking procedure until specification is achieved.
l purpos
– Remove setting device, and install wiper blade.

– Make sure that wiper system operates without juddering.
nform
mercia
a
com
tion in
r
te o
thi
s
4.40 Wiper blade protection: removing

iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
There are 3 different versions of wiper blade protection: by c lksw
cted agen
Prote AG.
Polo 2002 ➤
Version 1: blade protector with 2 securing clips

♦ Identification, blade protector with two securing clips
-arrows 1 + 2-.
Wiper blade protection, version 1: removing ⇒ page 96
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
Version 2: blade protector to slide on
erm
ab
ility
ot p
♦ Identification, the blade protector -arrow- is slid on the wiper
wit
is n
blade.
h re
ole,
spec
Wiper blade protection, version 2: removing ⇒ page 97
t to the co
rrectness o
cial p
f inform
mer
Version 3: transport wiper blade
atio
om
n
♦ Identification, the transport wiper blade is fitted without wind
c
i
or
n
deflector, it must be replaced by the standard wiper blade.
thi
te
sd
iva
o
r
Changing wiper blade protection, version 3 -transport wiper

p
cum
r
fo
blade- ⇒ page 98
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.40.1 Wiper blade protection, version 1: re‐

moving
– Switch ignition on and off briefly with bonnet closed.
– When engine is switched off move wiper lever down to touch-
wipe 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.
Polo 2002 ➤
– Remove upper securing clip upwards and lower securing clip

downwards -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
– Pull blade protector off wiper blade from bottom to top, as
an
itte
y li
shown in illustration.
erm
ab
ility
ot p
– Carefully place wiper arm back onto windscreen.
wit
, is n
h re
– Switch ignition on and briefly operate the wiper lever to move
hole
the wipers back to park position. Switch ignition off again.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
4.40.2 Wiper blade protection, version 2, re‐
orm
m
atio
moving
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
The wipers move in service position. C py
t. rig
gh ht
yri by
– Lift the wiper arm away from windscreen. op Vo
by c lksw
cted agen
Prote AG.
Caution
age.
– Pull blade protector off wiper blade upwards, as shown in il‐

lustration.
Polo 2002 ➤
4.40.3 Wiper blade protection, version 3 -trans‐

port wiper blade: changing
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
age.

4.41 Headlight adjustment: Check, adjust

headlights if necessary
swa
gen AG
. Volkswagen AG
does
not k
gu Vol
Test conditions ⇒ page 98sed by ara
nte
ri
o eo
Checking headlight adjustment
aut
h
using test screen without 15° set‐ ra
ting line ⇒ page 100 .
ss c
ce
e
nl
pt
du
Adjust headlights ⇒ page 101 .

an
itte
y li
erm
Fog lights and other additional lights: Adjust ⇒ page 102 .

ab
ility
ot p
4.41.1 Test requirements

wit
, is n
h re
hole
spec

es, in part or in w
t to the co
♦ Headlight adjustment unit - VAS 5046-

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
♦ Or
Co
Cop py
ht. rig
rig ht
py by
98
co Vo
by lksw
cted
agen
Prote AG.
Polo 2002 ➤
♦ Headlight adjustment unit - VAS 5047-

♦ Headlight adjustment unit - VAS 5208A-
♦ Headlight adjustment unit - VAS 5209A-
♦ Headlight adjustment unit - VAS 5209B-
The 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:
• Tyre pressure OK.
en AG. gen AG Volkswa
• Lenses must not wagdamaged
ksbe or dirty does not
Vol y gu
db a
• The vehicleor
ise must be rolled forward or backward several
ran
tee me‐
tres or
authfront and rear springs must be bounced fully several
or
ac
times
ss so that springs settle.
ce
le
un
pt
• Vehicle and headlight adjuster must be on a level surface. →
an
d
itte
Operating instructions for headlight adjusters VAS 5046, VAS
y li
rm
ab
5047, VAS 5208A, VAS 5209A, VAS 5209B.
pe
ility
ot
wit
• Vehicle and headlight adjuster must be aligned.
, is n
h re
hole
• Inclination must be set.
spec
es, in part or in w
• Reflectors and bulbs OK.

• Vehicle must be loaded. t to the co
rrectness of i
Loading: with one person or 75 kg on the driver seat and the ve‐
hicle otherwise unloaded (unladen weight).
l purpos
The unladen weight is weight of vehicle ready for operation with

filled fuel tank (at least 90 %) including weight of all equipment
nform
ercia
usually carried (e.g. spare wheel, tools, jack, fire extinguisher

etc.).
m
a
com
tio
If the fuel tank is not at least 90 % full, then load as follows:

n in
r
te o
thi
– Read level of fuel in fuel tank on fuel gauge. Determine addi‐

s
iva
do
tional weight from following table and place weight in luggage

r
rp
cum
fo
compartment.
en
ng
t.
yi Co
op
Fuel gauge table C py
t. rig
gh ht
yri by
Fuel gauge reading Additional weight in kg
cop Vo
by lksw
cted agen
Prote
To 1/4 30
AG.
To 1/2 20
To 3/4 10
Full 0
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.
Polo 2002 ➤
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.
AG. Volkswagen AG d
agen oes
ksw not
4.41.2 Checking headlight adjustment (using ol
byV gu
ara
ed
test screen without 15° setting line) ris nte
ho eo
aut ra
ss c
Headlights:
ce
le
un
pt
an
Check the following:
d
itte
y li
rm
– Whether, with the dipped beam switched on, the horizontal ab

pe
ility
bright/dark boundary contacts the dividing line -1- of the test
ot
wit
, is n
area and
h re
hole
spec
– Whether the breaking point -2- between the horizontal part of

es, in part or in w
the bright/dark boundary on the left and the rising part on the
t to the co
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.
rrectness of i
Note
l purpos
♦ To simplify the determination of the breaking point -2-, cover

nform
ercia
and uncover left (from driver perspective) half of the headlight

a few times. Then check dipped beam again.
m
a
com
tion in
♦ After correct adjustment of dipped beams, the centre point of

r
te o
the main beam must lie on the centre mark -3-.

thi
s
iva
do
r
♦ If the vehicle is equipped with separate dipped and main

rp
cum
fo
beam, adjust main beam additionally. When adjusting main

en
ng
t.
beam ensure that the adjustment unit is set to 0%.
yi Co
Cop py
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Fog lights: co Vo
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cted agen
Prote AG.

Polo 2002 ➤
– 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:

wage es n
The adjustment bolts for the left headlight are a mirror image.
yV
olks ot g
b ua
ed ran
– Set corresponding inclination on headlight adjustment
ho
ris unit. tee
t or
au ac
• The inclination for headlights with halogen bulbs
ss is “1.0 %”
ce
e
nl
pt
• For vehicles for the North American market, an inclination of
du
an
itte
0.7 % always applies.
y li
erm
ab
ility
ot p
wit
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Note
h re
hole
spec
Percentage given is based on a projection distance of 10 metres.
es, in part or in w
t to the co
Right headlights (the left headlight adjustment screws are a mirror
image):
rrectness of i
Up to ►2005
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2002 ➤
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. olkswage es n
ot g
byV ua
Location of adjustment screw on left-hand headlight is a mirrorrised ran
tee
image. utho
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
From 2006► spec

es, in part or in w
t to the co
– Unscrew bolt -1-, tightened to the air intake grille on the right
side in direction of travel.
rrectness of i
– Unclip the air intake grille -2-.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2002 ➤
– 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
– Check function of sunroof.
– Clean guide rails -arrows- and grease
agen
AG.with special
Volkswagen AGgrease G
does
060 751 A2. olksw not
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ed ran
oris tee
th or
au ac
ss
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le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
4.43 Service interval display: resetting

rrectne
Reset service interval display for vehicles with time or distance

dependent service or LongLife service
ss o
cial p
f in
Note
form
mer
atio
m
♦ If vehicles with LongLife service (PR number QG1) are not

o
n
c
using engine oil conforming to VW standard 503 00 (petrol

i
or
n thi
e
engine), VW standard 506 00 (TDI) or VW standard 506 01

t
sd
va
(TDI unit injector), the service interval display must be recoded

i
o
pr
cum
to non-flexible. ⇒ page 106

r
fo
en
ng
t.
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♦ Vehicles with LongLife service (PR number QG1), which have Cop py
an oil change service at approx. 15,000 km or 12 months the
t. rig
gh ht
yri
service interval display must be recoded to non-flexible. This
p by
co Vo
by lksw
ensures that these vehicles resume the normal LongLife serv‐ cted agen
Prote AG.
ice rhythm. Recoding service interval display to non-flexible:
⇒ page 106
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

Polo 2002 ➤
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
with an engine oil conforming to VW standard 503 00 (petrol . Volkswagen AG
gen AG
engine), VW standard 506 00 (TDI) or 506 01 (TDI unitolkinjector)
swa does
not
during inspection service, the service interval display
d by V must gu
ara
NOT be reset using the distance display andhclockoris
e
adjustment nte
eo
buttons on dash panel insert. Reason: When sa
ut
the service in‐ ra
c
terval display is reset using the adjustment buttons for dis‐
s ce
le
tance and clock on dash panel insert, the dash panel insert is
un
pt
automatically coded to non-flexible, i.e. to “time or distance

an
d
itte
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dependent” service.
erm
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ility
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♦ Vehicles with LongLife service (PR number QG1), which have

wit
is n
an oil change service at approx. 15,000 km or 12 months the

h re
ole,
service interval display must be recoded to non-flexible. Rea‐

spec
son: This ensures that these vehicles resume the normal

LongLife service rhythm.

t to the co
Reset the display as follows:

rrectne

s
– Press and hold button -1- next to speedometer.

s o
cial p
f i
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2002 ➤
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
olksw not
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rise nte
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– Turn
s a adjusting knob -1- next to speedometer to right.r ac
ut
s
The service displayed is being reset and the display in the dis‐
ce
le
un
pt
tance display or centre display changes to the normal state.

an
d
itte
y li
rm
ab

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4.43.2 Resetting service interval display using

diagnostic tester
nform
ercia

m
a
com
tio
– Touch the field or button on the screen for »GUIDED FUNC‐

n in
r
te o
TIONS«.
thi
s
iva
do
If the display is not as shown in the procedure: ⇒ Operating in‐

r
rp
cum
fo
structions for diagnostic tester

en
ng
t.
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op
C py
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cop Vo
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Prote
♦ Brand
AG.
♦ Model
♦ Model year
♦ Engine code
– Confirm vehicle identification.

Polo 2002 ➤
♦ “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-.
– Press the End button on display -arrow-.
– Press End button in End menu.
AG. Volkswagen AG d
– Switch on ignition. o lksw
agen oes
not
byV gu
After the ignition is rswitched
ised on, the type of service is no longer
ara
nte
displayed in the udistance
tho display in the dash panel insert. eo
ra
s a c
s
ce
le
un
pt
an
d
itte
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rm
ab
4.44 Service interval display: recoding

pe
ility
ot
wit
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h re
hole
spec
– On the screen, touch “GUIDED FUNCTIONS” field or button.

es, in part or in w
t to the co
Note
rrectness of i

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structions for vehicle diagnostic tester .

nform
ercia

m
♦ Brand
a
com
tion in
♦ Model
r
te o
thi
s
iva
♦ Model year
do
r
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fo
♦ Engine code
en
ng
t.
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op
– Confirm vehicle identification. C py
ht. rig
rig ht
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If the vehicle identification has been performed correctly, confirm co Vo
by lksw
with > button. cted agen
Prote AG.

Polo 2002 ➤

♦ “Dash panel insert” -ARROW-.
♦ “Adapting service interval extension”.
– Carry out adaption according to the information of “GUIDED
FUNCTIONS”.
Ending adaption
– Press GoTo button on display -arrow-.
– Press the End button on display -arrow-.
– Press End button in End menu.
– Switch off ignition and separate diagnosis connections. AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
4.45 Track rod ends: checking clearance, wit

, is n
h re
firm seating and boots
hole
spec
es, in part or in w

t to the co
– With the vehicle raised (wheels hanging free), check play by

moving track rods -arrow- and wheels. Clearance: zero clear‐
rrectness of i
ance
l purpos
– Check attachment.
– Check if boots are not damaged and are seated correctly.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Polo 2002 ➤
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

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. n AG. Volkswagen AG do

kswage es n
– Then, lubricate door arrester rollers by Vwith lubricating paste - G
ol ot g
ua
000 150- at positions marked withir se an -arrow-.
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2002 ➤
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.
Note
There is no requirement to remove the wheels.
– Relieve weight on springs by raising vehicle with a hoist.
– Slide suspension strut protective sleeve -arrow- upwards.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2002 ➤
– Push blocking piece -arrow- off piston rod.

– Slide suspension strut protective sleeve downwards onto sus‐
pension strut.
4.49 Recoding dash panel insert

AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
gu
d ara
ise nte
or
Recoding to non-flexible
aut
h intervals only valid for vehicles: eo
ra
ss c
ce
e
nl
• with LongLife service (visible on data sticker: “QG1”);

pt
du
an
itte
y li
• with time and distance dependent service (visible on data

erm
ab
sticker: “QG2”, “QG0”);

ility
ot p
wit
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• in countries listed in chapter “Countries where diesel has a

h re
high sulphur content” (ask your importer which countries have

hole
spec
diesel with a high sulphur content).

es, in part or in w
t to the co

– Press button »Vehicle self-diagnosis«.
rrectness of i
– Now select “17-Dash panel insert”.

l purpos
– Now select diagnostic function “07-Coding control unit”.

The actual four or five-digit code can be found on the upper right
nform
ercia
of screen next to “Coding”.

m
at
om
– Enter new code “xx0x” or “xxx0x” in display zone, only change

ion
c
2nd digit from right, “1” to “0”.

in t
or
his
ate
– For entry press button Q on lower right of display and confirm.

do
priv
cum
or
The control unit is now coded to “QG0”.

f
en
ng
t.
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op
– Press lower left button arrow .
C py
ht. rig
rig ht
py by
– Now select “10-Adaption”.
co Vo
by lksw
cted agen
Prote AG.
– 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”

Polo 2002 ➤
4.50 Clock: setting to correct time

Carry out adjustment as follows:
Setting hours:
– Turn setting knob -1- (on lower left next to speedometer) anti-
clockwise.
By turning the setting knob shortly, the clock will be altered by one
hour. By turning and holding the setting G. Volkthe
gen Aknob
swagen AG
alteration
doeswill be
wa
ks
continuous. by
Vol
not
gu
a
ed ran
Setting minutes: ris tee
tho or
au ac
– Turn setting knob
ss -1- clockwise.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
By turning the setting knob shortly, the clock will be altered by one
spec
minute. By turning and holding the setting knob the alteration will
be continuous.
t to the co
With the setting knob -1- the clock can be set exactly to the second
as follows:
rrectne
– Turn setting knob to right until the time is one minute before
time to be set.
ss o
cial p
f
– Turn adjustment knob to the right at the moment when the
inform
seconds indicator of accurate clock shows a full minute.
mer
atio
om
n
c
i
or
n thi
te
sd
va
4.51 Underseal: inspecting for damage to un‐

i
o
pr
cum
r
fo
derseal, underbody cladding, routing of

en
ng
t.
yi Co
lines and plugs Cop py
ht. rig
rig ht
py by
During inspection, also check floor pan, wheel housings and sills.
co Vo
by lksw
cted agen
Prote 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.

Polo 2002 ➤
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 (4-

cylinder 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
♦ Cracks, cross sectional breaks agen oes
olksw not
V gu
d by ara
♦ Layer separation (toothed belt body, tensile cords)
orise nte
h eo
ut ra
♦ Toothed belt body breakup ss a c
ce
e
nl
♦ Frayed cord strands
pt
du
an
itte
y li
♦ Surface cracks (synthetic coating)
erm
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ility
ot p
♦ Traces of oil and grease
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
If faults are found, always renew toothed belt. This can avoid
breakdowns and malfunctions. The replacement of a toothed belt
rrectness of i
is a repair measure.
l purpos
When checking condition, especially watch for following damage:

A - Cracks (coating)
nform
ercia
B - Side contact
m
at
om
ion
C - Fraying
c
in t
or
his
te
D - Cracks (in teeth base)

a
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.55 Renewing spark plugs

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

Polo 2002 ➤
♦ Spark plug socket - VAS 3122B-
♦ Puller - T40039-
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
♦ Torque wrench - V.A.G 1331/- (5-50 Nm)
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
♦ Assembly tool - T10118-

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2002 ➤
♦ Puller - T10094 A-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
s c
♦ »Power unit« ⇒ Power unit; Rep. gr. 28 ; Test data, spark s
ce
e
nl
plugs »Test data, spark plugs«
pt
du
an
itte
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4.55.1 Spark plugs: renewing, engine codes
erm
ab
ility
ot p
BUD, BTS
wit
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h re
hole
spec
es, in part or in w
– Unscrew the four bolts -1- and remove cover.
t to the co
Specified torque for bolts: 10 Nm
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
4.55.2 Spark plugs: renewing, engine codes

iv
o
r
rp
cu
o
AUA and AUB

f
en
ng
t.
yi Co
op py
. C rig
ht ht
rig by
py
– Remove engine cover panel. ⇒ page 81
co Vo
by lksw
cted agen
Prote AG.
– Take off oil sealing cap -1-.
– 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.

Polo 2002 ➤
– 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
Power unit; Rep. gr. 28 ; Test data,
lksw
agen spark plugs »Test
A n AG d
oesdata,
spark plugs«. o not
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by a d ran
ise
♦ Observe environmental
ut
ho
r
regulations for disposal. tee
or
a ac
ss
ce
– Fit spark plug connectors.
le
un
pt
an
d
itte
– Press ignition cables -2- into ignition cable guide.
y li
rm
ab
pe
ility
ot
– Fit oil sealing cap -1-.
wit
, is n
h re
– Install engine cover panel. ⇒ page 81
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
4.55.3 Renewing spark plugs, engine codes tion in

r
te o
thi
s
iva
AWY, BBY, BBZ, AXU, AZQ, BMD,

do
r
rp
cum
BME, BKY, BUD, BTS, BZG

fo
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
Only valid for BUD and BTS: cop Vo
by lksw
cted agen
Prote
AG.
– Unscrew the four bolts -1- and remove cover.

Valid for all:

Polo 2002 ➤
– 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«. G. Volkswage nA n AG d
wage oes
yV
olks not
gu
b ara
ed nte
oris eo
th
– Place puller - T10094 A- on ignition scoil
s with output stage. au ra
c
ce
le
– Push connector onto ignition coil with output stage until it en‐
un
pt
an
d
gages audibly.
itte
y li
rm
ab
– Push ignition coil with output stage in -direction of arrow- into
pe
ility
ot
cylinder head.
wit
, is n
h re
– Install engine cover panel. ⇒ page 81
hole
spec
es, in part or in w
Only valid for BUD and BTS:

t to the co
– Fit cover and tighten bolts of cover to 10 Nm. rrectness of i
l purpos
4.55.4 Renewing spark plugs, 1.8 l 5-valve en‐

gines
nform
mercia
Removing:
a
com
tion in
r
te o
thi
s
Note
iva
do
r
rp
cum
fo
♦ To pull off spark plugs, fit puller - T40039- on top, thick rib
en
ng
t.
yi Co
-arrow- of ignition coils with final output stages. t. Cop py
rig
gh ht
♦ If the lower ribs are used, they could be damaged. pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing and installing engine cover panel -top- ⇒ page 81 .

Polo 2002 ➤
– 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.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Remove the two ibolts
sed -1-.
b ara
nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Press connectors in direction of ignition coils with output

stages, press onto catch by hand and pull connectors
l purpos
-arrows- off.
– Pull all ignition coils out of cylinder head approx. 30 mm in
nform
ercia
direction of arrow using puller - T40039- .

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2002 ➤
– 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«.
Installing
– Screw in new spark plugs using spark plug socketswand agenexten‐
AG. Volkswagen AG d
oes
sion - 3122 B- and tighten to correct torque setting.
by
Volk not
gu
ara
ed nte
ris
ho e
– Insert ignition coils with output stage ainto
ut cylinder head. or
ac
ss
– Align ignition coils with output stages in respective recesses
ce
e
nl
pt
of cylinder head cover.
du
an
itte
y li
erm
– Fit all connectors onto ignition coils -arrows-.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Press ignition coils with output stages on spark plugs until stop
by hand. They must be felt to engage.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Secure cable guides with bolts -1-.
– Install vacuum reservoir -A- and tighten bolts to 5 Nm.
– Installing engine cover, ⇒ page 81 .

Polo 2002 ➤
4.56 Diesel particulate filter: check.
Note
When checking the diesel particulate filter the ash mass limit val‐
ue is read.

– On the screen, touch »GUIDED FUNCTIONS« field or button.
structions for vehicle diagnostic tester
– Select one after another: AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Brand ised b ara
nte
or eo
h
♦ Model s aut ra
c
s
♦ Model year
ce
le
un
pt
an
d
itte
♦ Engine code
y li
erm
ab
ility
– Confirm vehicle identification.
ot p
wit
is n
– Select vehicle system “Engine”.
h re
ole,
spec
– Select “Checking ash mass of diesel particulate filter”.
t to the co
Follow instructions on display.
– End test.
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2002 ➤
lkswage es n
o ot g
yV
5 Exhaust emissions test d b ua
ran
ir se tee
tho
u or
a ac
ss
ce
e
Note
nl
pt
du
an
itte
y li
erm
♦ Please observe the country specific legal regulations.
ab
ility
ot p
♦ The exhaust emissions test described below has been created
wit
, is n
according to the legal regulations valid in Germany.
h re
hole
spec
es, in part or in w
Exhaust emissions test for diesel engines ⇒ page 129
t to the co
Exhaust emissions test for petrol engines ⇒ page 120
5.1 Exhaust emissions test for petrol en‐
rrectness of i
gines
l purpos
Exhaust emissions test for petrol engines without OBD
nf
ercia
⇒ page 122
orm
m
Exhaust emissions test for petrol engines with OBD
atio
om
n in
c

or
thi
te
sd
a
♦ Exhaust gas testing station L - VAS 7320 A-

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
♦ The following description refers to vehicles fitted with “On‐
co Vo
by lksw
cted agen
board diagnosis” OBD. Prote AG.
♦ 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

Polo 2002 ➤
♦ Fuel type
♦ Mileage
The following vehicle data can be found in the vehicle registration n AG. Volkswagen A
certificate part 1: olks
wage
G do
es n
o
yV t gu
♦ Registration number: “e.g. WOB-HH 1234” db ara
rise nte
tho eo
♦ Emission key number “field 14.1 (code for field
ss
14)” au ra
c
ce
e
♦ Vehicle manufacturer: “field 2”, “field 2.1 (code for field 2)”
nl
pt
du
an
itte
y li
♦ Vehicle identification number “field E”
erm
ab
ility
ot p
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
wit
field D.2)”
, is n
h re
hole
Specified data input for EET
spec
es, in part or in w
There are different ways to enter the specified data:
t to the co
♦ 1. By manual input
rrectness of i
♦ 2. By bar code input from EET data sheet
l purpos
♦ 3. Through ELSA web service
nform
ercia
Note
m
at
om
io
♦ To use the ELSA web service, the exhaust gas testing station
n
c
in t
r
L which is used for the exhaust emissions test must be inte‐

o
his
te
grated in the workshop network.

a
do
priv
cum
or
♦ The ELSA web service automatically transmits the data for the
f
en
ng
specific vehicle via the network to the respective mask.

t.
yi Co
Cop py
ht. rig
rig ht
Manual specified data input for EET: py by
co Vo
by lksw
cted agen
Prote AG.
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 ➤
– 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.
G. Volkswage
♦ Faults (engine electronics)
lksw
identified
agenA whenn Aevent
G do memory is
es n
read must be rectified
by and the event memory then cleared.
Vo ot g
ua d ran
ise
♦ To prevent injuries
ut
ho
r
to personnel and/or damage to ignitionteand
eo
injection system,
ss
a the ignition system wiring (including high r ac
voltage wiring) should be connected and disconnected only
ce
e
nl
with ignition switched off.

pt
du
an
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
The following description refers to vehicles without OBD with

es, in part or in w
regulated catalytic converter.

t to the co

rrectness of i
♦ Emissions testing station - VAS 6300-

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
♦ Adapter for older vehicles - VAS 5051/2- Prote AG.
Or

Polo 2002 ➤
♦ 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:
• For bar code reading the EET data sheet must be printed out.
G. Volkswagen AG d
• Automatic gearbox: selector lever in position “P” orag“N”.
lksw
en A oes
not
o
yV gu
• Manual gearbox: gear lever in neutral ised b ara
nte
r
ho eo
• Parking brake applied aut ra
ss c
ce
e
nl
pt
du
display.
an
itte
y li
erm
ab
ility
Initial screen:
ot p
wit
, is n
– Select button “Exhaust emissions test” -arrow-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
An overview is displayed to select the respective EET type.

n
c
in t
or
his
e
– Select “EET petrol” -arrow-.

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2002 ➤
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: AG. Volkswagen AG d
agen oes
olksw not
The vehicle data input menu is displayed. d by V gu
ara
rise nte
tho eo
au ra
c
Note ss
ce
le
un
pt
an
d
♦ For new models the document previously known as the vehicle

itte
y li
erm
registration document is now called the vehicle registration
ab
ility
certificate part 1.
ot p
wit
is n
h re
ole,
log book is now called the vehicle registration certificate part

spec
2.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2002 ➤
♦ -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)
ment)
♦ -5- Key number for 2.2 (code to D2): “e.g. 358” (vehicle regis‐
♦ -6- Engine code “e.g. AQY”
♦ -7- Registration number: “e.g. WOB-HH 1234”
gen AG
. Volkswagen AG
a does
lksw not
♦ -8- Vehicle identification number:
db
y V “e.g.
o gu
ara
WVWZZZ1JZYW123456” or
ise nte
h eo
ut ra
– Enter mileage (km) sat
s a -item 9- “e.g. 32000”. c
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
ot
♦ Further functions can be called up using GoTo button.
wit
, is n
h re
♦ The test can be terminated using GoTo button.
hole
spec
es, in part or in w
t to the co
Specified data input for EET:
rrectness of i
Note
l purpos
♦ If specifications are not available as bar code, they are to be

entered manually.
nform
ercia
♦ All test conditions and data required for exhaust emissions

m
test, see EET data sheet for respective engine.

a
com
tion in
r
te o
Manual specified data input for EET:

thi
s
iva
do
r

rp
cum
fo
play.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2002 ➤
– Enter displayed values on EET data sheet in column “Test

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-.

All data required are shown on display.
– Press ► -arrow- to proceed.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
126
co Vo
by lksw
cted
agen
Prote AG.
Polo 2002 ➤
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.
– 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. ksw
agen AG do
es n
y Vol ot g
ua
♦ For some vehicles the rengine
ise
db speed adapter -VAS 5087/- ran
tee
must be used. utho
or
a ac
ss
ce
e
– Switch ignition on.

nl
pt
du
an
itte
– Insert emission probe in exhaust tail pipe.

y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
The exhaust emissions test is only continued when the test probe
es, in part or in w
t to the co
is in the exhaust tail pipe.
It is automatically switched to test for readiness of operation.

rrectness of i
Catalytic converter conditioning:

l purpos
It is automatically switched to warm-up phase of catalytic con‐

verter.
nf
ercia
orm
m

atio
om
n in
c
Measurement starts when the engine speed has reached the re‐
or
thi
e
quired level.
t
sd
iva
o
r
rp
cu
– Maintain engine speed in required engine speed range.

o
m
f
en
ng
t.
yi
The remaining time to perform the warm-up phase is displayed
Co
op py
-arrow A-.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2002 ➤
Warm-up phase:
It is automatically switched to display for measuring
n AG. Volkswengine
agen AG tem‐
perature. wage does
olks no
V t gu
by ara
ris
ed nte
tho eo
s au ra
c
s
ce
Note
le
un
pt
an
d
itte
y li
This is only indicated on display if engine temperature has not
erm
ab
reached 80°C.
ility
ot p
wit
is n
h re
– Bring engine to required temperature.
ole,
spec
t to the co
Measurement at increased idling speed:
It is automatically switched to display for measuring increased
idling speed.
rrectne
ss
o
cial p
f
quired level.
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
a
♦ Measurement can be skipped using ► button, i.e. the exhaust

iv
o
pr
c
emissions test has failed.
um
r
fo
en
ng
t.
♦ Measured values are reset using ← button, and the test can
yi Co
op py
be repeated.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
quired level.
-arrow A-.
Regulating probe test:
It is automatically switched to display for regulating probe test.
quired level.
-arrow A-.

Polo 2002 ➤
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.
– 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 Exhaust emissions test for dieselaen‐gen AG

. Volkswagen AG
does
ksw
gines db
y Vol not
gu
ar
e an
ris tee
Exhaust emissions test for diesel engines without
tho OBD with diesel or
tester V.A.G 1743 ⇒ page 129 s au ac
s
ce
le
Exhaust emissions test for diesel engines without OBD with emis‐
un
pt
an
d
sions testing station VAS 6300 ⇒ page 136

itte
y li
rm
ab
Exhaust emissions test for diesel engines with OBD
pe
ility
ot
⇒ page 145
wit
, is n
5.2.1 Exhaust emissions test for diesel en‐ h re

hole
spec
es, in part or in w
gines without OBD with diesel tester t to the co
V.A.G 1743
The test sequence is designed for the test with test unit combi‐
rrectness of i
nation for the emissions test.

l purpos

♦ Diesel tester - V.A.G 1743-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2002 ➤
♦ Engine speed adapter - VAS 5087 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ or
t to the co
♦ Engine speed adapter - VAS 6296-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
♦ Data reader - V.A.G 1798- Cop py
t. rig
gh ht
yri
♦ Or
p by
co Vo
by lksw
cted agen
♦ Data reader - V.A.G 1799-
Prote AG.
♦ ⇒ Data sheets for exhaust emissions test
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.

Polo 2002 ➤
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
of diesel tester - V.A.G 1743- . AG. Volkswagen AG d
agen oes
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– Set rotary switch to respective number of cylinders for engine,
ise d b ara
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e.g. “4” for 4-cylinder engine. hor eo
aut ra
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– Connect a cable from adapter - VAS 5087/1- to engine
s speed ce
le
adapter - VAS 5087 A- (socket VAS 5087/1).

un
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itte
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ility
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t to the co
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f inform
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– 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:
♦ Vehicle manufacturer = “NO. 2”
♦ Key number = “to NO. 2”
♦ Vehicle type = “NO. 3”
♦ Key number = “to NO. 3” (the first 3 digits) AG. Volkswagen AG d
agen oes
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♦ For vehicle identification number = “NO. 4” by Vol
gu
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♦ Engine code thor eo
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♦ Mileage s
ce
e
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– Confirm entry of vehicle identification data by pressing Q but‐

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Check input with -> button

, is n
Continue with Q button

h re
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spec

es, in part or in w
t to the co
Read bar code

Manual input with the -> button
rrectness of i
– Enter specifications using bar code reader of data reader, to

do this slide bar code reader over respective bar code of data
l purpos
sheet in “Exhaust emissions test” binder.

Or
nform
ercia
– Carry out entry by hand following instructions on data reader

m
at
display using → button.

om
ion
c
in t
r

o
his
ate
do
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Check input with the -> button

um
or
Continue with the Q button

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– Confirm vehicle data entered or read using Q button. Cop py
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5. Exhaust emissions test Prote AG.
Polo 2002 ➤

Visual check OK = y Not OK = n
– Enter result of visual check.

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.
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.
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
kstime.
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WARNING au
th ra
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If the rev limit is exceeded, lift off accelerator pedal immediately

un
pt
an
d
and perform repair measures.

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ility
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is n
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spec
Rev limit ->

Speed ACT. xxxx rpm SPEC. xxxx...xxxx rpm

t to the co
– Release accelerator pedal.

– Check actual values. To do this, switch the actual display to
rrectne
the next display by pressing the → button.

Rev limit not within specified range:
ss o
cial p
– If the values are not within specified range, a repair must be

inform
made.
mer
atio
m

o
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Idling speed 1st measurement 15 sec

fo
en
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Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm t.

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Polo 2002 ➤
– The data reader accepts the actual values within 15 seconds.

Data transfer to diesel tester
Depress accelerator quickly
– Depress accelerator pedal fully and hold.

Neutral accel. running
– Continue to depress and hold accelerator pedal.

If this message appears on the display: agen
AG. Volkswagen AG d
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Idling speed 2nd measurement 15 sec d b ara
Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm rise nte
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– Release accelerator pedal. s
ce
le
un
pt
The data reader accepts the actual values within 15 seconds.
an
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itte
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ab
ility
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spec
t to the co
rrectne
ss o
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f
inform
mer
atio
Idling speed 3rd measurement 15 sec
m
Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm

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or
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Cop py
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Data transfer to diesel tester gh ht
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Depress accelerator quickly co Vo
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Idling speed 4th measurement 15 sec
Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm


Polo 2002 ➤


Highest opacity figure ->
ACT. x.xx rpm SPEC. x...x.xx rpm

Average opacity figure ->
If the following is indicated on display:
Opacity band width ->
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: ss
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♦ Press F1 button and repeat test or carry out repair measures.

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Test n.OK Continue with Q button
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Repeat test with F1 button
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Enter remarks with -> button
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Continue with the Q button
t to the co
– Enter remarks if necessary after pressing the → button.
rrectness of i
– Press Q button.
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Select tester / manual input F3
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F1 XXXXX F2 XXXXX
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– Select tester or enter name using F1 to F3 buttons.

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– Press Q button, wait for log print-out.

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– End test by pressing the F2 button.

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Polo 2002 ➤
5.2.2 Exhaust emissionsagtest en AG.for

Volksdiesel
wagen AGen‐
does
gines without db
yOBD
Volksw
with emissions test‐
not
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ara
ing station VAS 6300
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Caution
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• Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐
rm
ab
pe
ility
CAUTIONS” in the operating instructions for VAS 6300.
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es, in part or in w
t to the co
Note
The following description refers to vehicles not fitted with “On‐
rrectness of i
board diagnosis”, OBD.
l purpos

♦ Emissions testing station - VAS 6300-
nform
mercia
a
com
tion in
r
te o
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Cop py
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♦ OBD adapter cable - VAS 5052/16-
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:
• For bar code reading of specified data for EET, the EET data
sheet must be printed out.
display.

Polo 2002 ➤
Initial screen:
– Select button “Exhaust emissions test” -arrow-.
An overview is displayed to select the respective EET type.
– Select “EET diesel” -arrow-.
The display for warm-up phase appears.
AG. Volkswagen AG d
agen oes
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ility
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t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
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or
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te
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Cop py
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Polo 2002 ➤
– Continue exhaust emissions test according to instructions on

display.
olkswagen AG
en AG. V
– If the EET specification selection is displayed,
ksw
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not
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tive “EET specification selection” -arrow-.
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♦ When exhaust emissions testauisthoperformed for the first time, eo
ra
either select “Standard values”,
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♦ Or “Last vehicle” when an exhaust emissions test is to be car‐ nl
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ried out again.
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– Select “Continue” -item 1- on display.
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Vehicle data input:
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spec
The vehicle data input menu is displayed.
es, in part or in w
t to the co
Note
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registration document is now called the vehicle registration

certificate part 1.
nf
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or
log book is now called the vehicle registration certificate part
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♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW”
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♦ -2- Vehicle type: “e.g. Golf”
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♦ -3- Key number for 1: “e.g. 11”
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♦ -4- Key number for 2: “e.g. 0603” (vehicle registration docu‐ Prote
cted AG.
agen
ment)
♦ -4- Key number for 2.1 (code to 2): “e.g. 0603” (vehicle regis‐
ment)
♦ -5- Key number for 2.2 (code to D2): “e.g. 358” (vehicle regis‐
♦ -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.

Polo 2002 ➤
– 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 G do
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♦ 1. By manual input Volks ot g
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♦ 2. By bar code input from EET orisdata sheet tee
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♦ 3. Through ELSA web service ss
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Note
erm
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♦ To use the ELSA web service, the vehicle diagnostic tester ,
, is n
h re
which is used for the exhaust emissions test, must be integra‐
hole
spec
ted in the workshop network.
es, in part or in w
t to the co
specific vehicle via the network to the respective mask.
rrectness of i
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Note
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orm
All test conditions and data required for exhaust emissions test
m
atio
m
⇒ Data sheets for exhaust emissions test for respective engine.

o
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play.
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– Enter displayed values on EET data sheet in column “Test Cop py
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values for exhaust emissions test” on display as follows: rig ht
py by
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1- Speed for conditioning Prote
cted AG.
agen
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)
10 - Select measuring mode
11 - Measured period portion
– When all data have been entered properly, press → button
-arrow-.

Polo 2002 ➤
All required data is shown on display -1-.

– Press → button -arrow- to continue procedure.
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Visual inspection:
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– Perform visual check.
es, in part or in w
t to the co
– If visual check is OK, press “OK” button -arrow-.
rrectness of i
Note
l purpos
When the "not OK" button is pressed, a check will be carried out.
nform
ercia
Connecting diagnostic connector:

m
a
com
ti
• Ignition is switched off.
on in
r
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thi
s
iva
The visual check is displayed with the request to connect the di‐
do
r
rp
agnostic connector -arrow A-
cum
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Prote AG.
– Follow instructions on display -arrow A- and -arrow B-.

Polo 2002 ➤
– 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.

If no conditioning is necessary, press → button -arrow- for the next
measurement.
Measuring engine temperature:
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pt
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itte
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ility
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is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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t.
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Cop py
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Prote AG.

Polo 2002 ➤
It is automatically switched to display for measuring engine tem‐

perature. wage
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– Follow instructions on display. ed by ara
ris nte
tho eo
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ss
Note
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un
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♦ This is only indicated on display if engine temperature has not
y li
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reached 80 °C.
pe
ility
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♦ Do not insert emission probe into exhaust tail pipe.
wit
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hole
♦ Using button “Alternative input” -arrow- other measured value
spec
inputs can be selected to measure the engine temperature.
es, in part or in w
t to the co
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.
rrectness of i
♦ The button “Alternative input” is only active, if previously a dif‐
ferent method has been selected at specified data input for
l purpos
EET for “Engine oil measurement”.
nform
ercia
Caution
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tion in
r
Measuring the engine temperature is normally carried out via

te o
thi
the oil temperature probe. The engine temperature must not
s
iva
do
r
be determined with engine running, otherwise the engine and

rp
cum
fo
probe could be damaged!
en
ng
t.
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Cop py
t. rig
gh ht
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– Bring engine to required temperature.
p by
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Measuring idling speed:
Prote AG.
It is automatically switched to display for measuring the idling

speed.

quired level.
Note

♦ 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.

-arrow-.
Measuring rev limit:

Polo 2002 ➤
It is automatically switched to display for measuring rev limit.

quired level.
n AG. Volkswagen A
– Operate throttle until theomeasurement
lksw
age is carried out.
G do
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this, immediately depress
d by V accelerator pedal. ua
r e an
ris tee
The remaining timeuthto
o perform measurement is displayed
or
-arrow-. ss a ac
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Air quality check:
rrectne
An air quality check is carried out before starting the free accel‐
eration. When doing this, no emission probe must be in the
s
exhaust tail pipe. Otherwise measuring errors or faulty signals
s o
could occur during further measurements.
cial p
f inform
– When the air quality check is carried out, insert emission probe
mer
atio
into exhaust tail pipe
om
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i
Free acceleration:
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It is automatically switched to display for “Free acceleration”.

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During “Free acceleration” the engine is revved up to rev limit

en
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t.
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without load as quickly as possible.
Co
Cop py
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The “Free acceleration” test consists of at least four throttle
rig ht
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Prote AG.
Free acceleration - phase 1:
– Follow instructions on display -arrow A- and -arrow C-.

– Maintain idling speed in engine speed range indicated
-arrow D-.
-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.

Polo 2002 ➤
– Follow instructions on display -arrow B-.

– Depress accelerator pedal fully when prompted and hold until
the prompt for idling is shown on display.
– 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:
AG. Volkswagen AG d
agen
♦ Three “Free accelerations” have been completed in succes‐
olks
w oes
not
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sion and the range of acceleration is OK. ed
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♦ All values are OK, with the exception of rangeau of acceleration,
th ra
and the test is continued by pressing the →ssbutton -arrow C-. c
ce
le
(In this case, the operator assesses if the value is OK).

un
pt
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♦ The values are not OK and the measurement is terminated/

rm
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skipped by pressing the → button -arrow C-.

pe
ility
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If the measured values are OK after three throttle bursts in suc‐

h re
cession, i.e. all fields are coloured white, the exhaust emissions
hole
spec
test is completed.
es, in part or in w
t to the co
Evaluation:
When the exhaust emissions test has been performed, the log is
rrectness of i
shown on display.
l purpos
The test result is displayed.

Now remarks concerning the exhaust emissions test can be en‐
nform
ercia
tered -arrow A-. They will then be included in the test log.
m
a
com
– When the exhaust emissions test is classed as passed, select

ion in
“EET sticker issued” and date in drop-down menu -arrow B-.

r
te o
thi
s
iva
– Then confirm with “Yes” -arrow C-.

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The exhaust emissions test log is shown on the display and can
en
ng
t.
be printed out as often as required in the menu “Print preview”
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using “Print” button -arrow A-. . C rig
ht ht
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Prote AG.

Polo 2002 ➤
– Press “Close” -arrow B- to close the “Print preview” menu.

– Take emission probe out of exhaust tail pipe.
AG. Volkswagen AG d
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– Then press → button -arrow B- ss c
ce
le
un
pt
The exhaust emissions test is completed, a new exhaust emis‐
an
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itte
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sions test can be performed.
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ab
pe
ility
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hole
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es, in part or in w
t to the co
rrectness of i
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5.2.3 Exhaust emissions test for diesel en‐
nform
ercia
gines with OBD

m
a
com
tion in
r
♦ Exhaust gas testing station L - VAS 7320 A-

te o
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Note
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t.
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Cop py
t.
♦ The following description refers to vehicles fitted with “On‐
rig
gh ht
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board diagnosis” OBD. cop Vo
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cted agen
Prote
♦ The OBD monitors all components and part systems influenc‐
AG.
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 .
Test requirements
• For bar code reading of specified data for EET, the EET data
sheet must be printed out.
• 12V battery fully charged (if battery charge is too low, raise
idling speed if necessary).

Polo 2002 ➤

display.
Vehicle data input
– Enter the following data:
♦ Key numbers
♦ Vehicle identification number
♦ Fuel type . Volkswagen AG
gen AG does
swa
♦ Mileage y Volk not
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The following vehicle data can be found in the vehicle registrationhoris
eo
certificate part 1: aut ra
ss c
ce
le
♦ Registration number: “e.g. WOB-HH 1234”
un
pt
an
d
♦ Emission key No. “field 14.1 (code for field 14)” itte
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ab
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ility
♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
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♦ Vehicle identification number “field E”
h re
hole
spec
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
es, in part or in w
field D.2)”
t to the co
♦ Nominal speed “field P4”
rrectness of i
Specified data input for EET
l purpos
There are different ways to enter the specified data:

♦ 1. By manual input
nform
ercia
♦ 2. By bar code input from EET data sheet

m
a
com
ti
♦ 3. Through ELSA web service
on in
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iva
do
Note
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rp
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ng
t.
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♦ If there is no ESP to deactivate the engine speed limiter, the
Co
op py
rev limit can be measured using the engine speed limited by
t. C rig
gh ht
yri
the control unit. To do this, all the EET specifications must be p by
o Vo
by c
entered manually.
lksw
cted agen
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♦ To use the ELSA web service, the exhaust gas testing station
L which is used for the exhaust emissions test must be inte‐
grated in the workshop network.
specific vehicle via the network to the respective mask (ex‐
ception: nominal speed can only be entered manually).

Polo 2002 ➤
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.

play.
– Enter displayed values on EET data sheet in column “Testagen AG. Volkswagen AG d
Vol
ksw
oes
not
g
by ua
ed ran
1- Speed for conditioning oris tee
h
ut or
2- Number of throttle bursts for conditioningss a ac
ce
e
nl
3- Engine oil temperature (min. value)
pt
du
an
itte
y li
4- Select engine oil temperature measurement procedure
erm
ab
ility
ot p
5- Idling speed
wit
, is n
h re
6- Governed speed
hole
spec
7- Nominal speed (registration certification part 1, vehicle
es, in part or in w
t to the co
document)
8- Governed speed measuring period (1 second)
rrectness of i
9- Type plate value ⇒ page 147
l purpos
10 - Select probe type (No. of probe)

11 - Select measuring mode
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or
12 - Measured period portion
m
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Note thi
te
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♦ When performing the exhaust emissions test, the respective

o
m
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ng
engineer must always use the vehicle-specific exhaust emis‐

t.
yi Co
op
sions limit value indicated on the type plate.
C py
t. rig
gh ht
yri by
♦ If no value is indicated on the type plate, the opacity figure cop Vo
by lksw
specified by the manufacturer and indicated in ELSA must be cted agen
Prote AG.
used.
♦ 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.

The nominal speed can only be entered manually.

Polo 2002 ➤
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
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.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
ss c
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le
un
pt
an
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itte
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erm
ab
ility
ot p
wit
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h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
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or
n thi
te
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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Polo 2002 ➤
6 Glossary yV
olkswage es n
ot g
d b ua
ran
ir se
Term Explanation tho tee
or
au a
ABS (anti-lock brake system);
ss that pre‐ the ABS is a regulating system in the brakecsystem,
ce
e
vents the wheels from locking up while braking. This helps to maintain directional stability
nl
pt
du
and steerability.
an
itte
y li
erm
ATF (Automatic transmission fluid); gear oil for automatic gearboxes
ab
ility
ot p
ATF level Filling level of ATF in gearbox
wit
, is n
h re
CO (Carbon monoxide); is produced when fuels containing carbon are not combusted com‐
hole
spec
pletely
es, in part or in w
CN (Cetane number); measurement unit for ignition quality of diesel fuel
t to the co
DIN Deutsches Institut für Normung e.V. (German Standards Authority)
Part no. Abbreviation for part number
rrectness of i
EN European standard
l purpos
EOBD European On-Board Diagnosis

FAME Fatty acid methyl ester
nform
ercia
FSI Fuel Stratified Injection

m
at
om
io
TFSI Turbo fuel stratified injection
n
c
in t
or
TSI From model year 2008 the designation TFSI is replaced by TSI. Therefore the desig‐
his
ate
nation TSI is given to TSI turbocharger and TSI twincharger.
do
priv
cum
or
TSI turbocharger: charging only with turbocharger

f
en
ng
t.
yi Co
TSI twincharger: charging with turbocharger and compressor t. Cop py
rig
gh
MIL (Malfunction indicator light); American designation for exhaust emissions warning lamp
ht
pyri by
Vo
K83
co lksw
by
cted agen
Prote AG.
OBD (Onboard diagnosis); the OBD monitors all components influencing the exhaust emis‐
sions quality.
OBD-II American onboard diagnosis
Unit injector Unit injector for diesel engines
PR No. Abbreviation for production control number. Identifies among other things optional
equipment and country-specific deviations
PM (Particulate matter); soot particulate value for diesel engine emissions
QG0 Vehicles “not” factory-fitted with components for LongLife service. For maintenance, the
intervals based on time and distance (non-flexible intervals) apply.
QG1 Vehicles are factory-fitted with active LongLife service. This means, vehicles have a
flexible service interval display and are fitted with the following components:
♦ Flexible service interval display in combi-instrument
♦ 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
♦ Brake lining wear indicator
Readiness code 8-digit binary code which indicates if all exhaust relevant diagnoses have been per‐
formed by the engine management.
RON Research octane number: measurement unit of the knock resistance of petrol
SAE (Society of Automotive Engineers); association which creates proposals/guidelines for
implementing legal requirements (e.g. standards).
SD Naturally aspirated diesel engine
6. Glossary 149
Polo 2002 ➤
Term Explanation
SDI Naturally aspirated diesel engine - direct injection. Volkswag
en AG
gen AG does
TDI Turbo diesel engine - direct injectionVolkswa not
y gu
DP Distributor injection pump edb ara
ris nte
ho eo
ULEV Ultra low emission vehicle s aut ra
c
s
ESI Extended service interval
ce
e
nl
pt
du
an
Common rail Refers to a common high-pressure injection line (rail), which supplies all cylinders of the
itte
y li
relevant cylinder bank with fuel.
erm
ab
ility
ot p
Diesel particulate The diesel particulate filter is installed behind the catalytic converter and filters soot
wit
, is n
filter particles of emissions.
h re
hole
LongLife service The LongLife service enables extremely long inspection or oil change intervals, de‐
spec
pending on individual driving style and conditions under which the vehicle is used. For
es, in part or in w
t to the co
the LongLife service a special engine oil is required.
Step-type probe 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
rrectness of i
lambda probe value is determined by a change in voltage. The probe is used as after
catalytic converter probe.
l purpos
Broad-band 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
nf
ercia
voltage. This enables to measure the lambda probe value via a larger measuring range
orm
(broad band). The probe is used as before catalytic converter probe.
m
atio
om
n in
TPMS, TPLI Tyre pressure monitoring, tyre monitor display
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
150 6. Glossary

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Service

Service Department. Technical Information

Copyright © 2018 Volkswagen AG, Wolfsburg P0050352920

2.4 Oil change service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.3 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.4 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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

Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

Engine code AZQ BBM BBU BBY

No. of cylinders/valves per 3/4 3/2 4/5 4/4

Torque Nm at rpm 112/3000 108/3000 235/1950 to 5000 126/3800

Bore ∅ mm 76,5 76,5 81,0 76,5

Stroke mm 86,9 86,9 86,4 75,6

Compression ratio 10,4 10,3 9,5 10,5

Injection/ignition Simos 3 PD Simos 9.1 Motronic ME 7.5 Magneti Marelli

Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

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

Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

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

Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

No. of cylinders/valves per 3/4 4/4 4/4 3/4

Power kW at rpm 47/5400 77/5600 59/5000 51/5400

Torque Nm at rpm 112/3000 153/3800 132/3800 112/3000

Bore ∅ mm 76,5 76,5 76,5 76,5

Stroke mm 86,9 86,9 75,6 86,9

Compression ratio 10,5 10,5 10,5 10,5

Camshaft drive Chain Chain Toothed belt Chain

No. of cylinders/valves per 3/2 4/2 4/2 4/2

Bore ∅ mm 79,5 79,5 79,5 79,5

Compression ratio 19,5 19,5 19,0 19,0

Diesel particle filters No No No No

Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

LongLife service ⇒ page 5

Time or distance dependent service ⇒ page 6

Service interval display ⇒ page 6

Vehicle IDs with the following PR number

“QG0” or “QG2” indicates time or distance dependent service.

2.1.2 LongLife service

Vehicles with PR number “QG1”

The LongLife service enables long service intervals, depending

For the LongLife service a special LongLife engine oil is required

service are non-flexible.

♦ Which were delivered without extended servicing intervals

ESI cannot be activated)

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

♦ When no LongLife engine oil was used

Vehicles with PR number “QG0”

2.1.4 Service interval display

Introduction of extended servicing intervals (ESI)

Flexible service interval display (only vehicles with LongLife serv‐

Non-flexible service interval display (only vehicles with time or

2.2 Service tables

♦ For combined kilometre and time display applies: whichever

♦ Depending on conditions under which the vehicle is used

⇒ page 34 and vehicle equipment, extra service work must

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

ice intervals with regard to the entries in the service schedule

2.2.1 SERVICE INTERVALS