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

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

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

Language : English
Pages : 174
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

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

1 Engine list 5
2 Service work 10
2 1 Service tables 10
2 1 1 VW engine oil standards 10
2 1 2 Filter change intervals 10
2 1 3 Toothed belt change intervals 11
2 1 4 Service intervals 11
2 2 Oil change service 11
2 2 1 Oil change service according to flexible service interval display 11
2 2 2 Oil change service every 15,000 km 12
2 3 Inspection service 13
2 3 1 Inspection service every 12 months 13
2 3 2 Inspection service every 30,000 km 16
2 4 Additional work based on time or distance 18
2 5 Delivery inspection 20
3 General information 23
3 1 Raising vehicle with lifting platform and trolley jack 23
3 1 1 Safety information 23
3 1 2 Lifting points for lifting platform and trolley jack 24
3 2 Connecting vehicle diagnostic tester 24
3 3 Vehicle data sticker 27
3 4 Engine code and engine number 27
3 5 Vehicle identification number 28
3 6 Type plate 28
3 7 Countries where diesel has a high sulphur content 28
3 8 RME fuel (biodiesel) 29
3 9 Attaching “Your next service” sticker: 30
4 Descriptions of work: 31
4 1 Removing and installing engine compartment cover (noise insulation) 32
4 2 Driver and front passenger airbags: visual check of airbag units 32
4 2 1 Driver side airbag vehicles ►09 99 32
4 2 2 Front passenger side airbag vehicles ►09 99 33
4 2 3 Driver side airbag vehicles 10 99► 33
4 2 4 Front passenger side airbag vehicles 10 99► 33
4 3 Self-diagnosis: reading fault memories of all systems 34
4 3 1 Reading fault memory of all systems using fault reader -V A G 1551- 34
4 3 2 Reading fault memories of all systems using vehicle diagnosis, testing and information system -VAS 5051B- or subsequent units 35
4 4 Service interval display: resetting 38
4 4 1 Vehicles ►09 99: resetting non-flexible display 39
4 4 2 Vehicles ►09 99 with engine code 1Y: resetting flexible display 39
4 4 3 Vehicles 10 99► 40
4 4 4 Resetting service interval display with adjustment button for distance display on dash panel insert 41
4 4 5 Resetting service interval display with fault reader -V A G 1551- 41
4 4 6 Resetting service interval display using vehicle diagnosis, testing and information system -VAS 5051B- or subsequent units 48
4 5 Door arrester and securing pins: lubricating 57
4 6 Sunroof: checking function, cleaning and greasing guide rails 58
4 7 Electric windows: initialising 58
4 8 Clock: setting to correct time 58
4 8 1 Vehicles ►09 99 58
4 8 2 Vehicles 10 99► 59
4 9 Radio: activating anti-theft coding 59
4 10 Window wash/wipe system and headlight washer system: checking function and settings 60
4 10 1 Checking Windscreen Clear with anti-freeze of windscreen wash/wipe system, replenishing with fluid if necessary 60
4 10 2 Windscreen wash/wipe system: checking spray jet settings, adjusting if necessary 62
4 10 3 Headlight washer system: checking spray jet settings, adjusting if necessary 64
4 11 Windscreen wiper blades: checking park position, if wiper blades judder: checking setting angle 65
4 11 1 Windscreen wiper blades: checking park position, adjusting if necessary 65
4 11 2 Rear window wiper blades: checking park position, adjusting if necessary 66
4 11 3 Wiper blades: checking setting angle, adjusting if necessary 67
4 12 Wheel securing bolts: tightening to specified torque 68
4 13 Tyres: checking condition, wear pattern, inflation pressure, tread depth 70
4 13 1 Checking condition 70
4 13 2 Wear pattern: checking 71
4 13 3 Tyre tread depth (including spare wheel): checking and entering 71
4 13 4 Tyre pressures (including spare wheel): checking, correcting if necessary 71
4 14 Engine oil level: checking 75
4 15 Engine oil: Draining or extracting and replenishing; renewing oil filter 76
4 15 1 Oil filter: renewing 78
4 16 Engine and components in engine compartment: inspecting for leaks and damage (from above and below) 80
4 17 V-belt: checking condition and tensioning 81
4 17 1 Checking V-belt condition 81
4 17 2 Checking V-belt tension, tensioning V belt if necessary 81
4 18 Poly V-belt: checking condition and tensioning belt 82
4 18 1 Tensioning belt (engines without automatic tensioning roller) 82
4 19 Boots: inspecting 84
4 20 Manual gearbox/final drive: checking oil level 84
4 20 1 4 and 5-speed manual gearbox 020 84
4 20 2 5-speed manual gearbox 085 up to build date 22 10 95 85
4 20 3 5-speed manual gearbox 085 from build date 23 10 95 85
4 20 4 5-speed manual gearbox 02A 86
4 21 Automatic gearbox: checking final drive oil level 86
4 22 Brake system: inspecting for leaks and damage 87
4 23 Front and rear brake pads/linings: checking thickness 87
4 23 1 Front brake pads 88
4 23 2 Rear drum brake pads 89
4 23 3 Rear brake pads 89
4 24 Underbody protection: visual check for damage 90
4 25 Track rod ends: checking clearance, firm seating and boots 90
4 26 Swivel joints: inspecting 91
4 27 Cooling system: checking coolant level and frost protection 91
4 27 1 Coolant level: checking, replenishing coolant if necessary 91
4 27 2 Frost protection: checking and replenishing coolant additive if necessary 92
4 28 Spark plugs: renewing 93
4 28 1 Engine codes ADZ, AFT and 1F 94
4 28 2 Engine codes AEE, AEX, AKV, ALM, ANX and APQ 94
4 28 3 Engine codes AEH, AKL, APF and AUR 95
4 28 4 Engine codes AKK, ANW and AUD 97
4 28 5 Engine codes APE, AQQ and AUA 98
4 29 Dust and pollen filter: renewing filter element 99
4 29 1 Removing 100
4 29 2 Installing 101
4 30 Camshaft drive belt: checking (petrol engine) 101
4 31 Toothed belt: checking for wear (SDI/TDI engines ►2000) 102
4 31 1 Engine codes AEY, AFN, AHB, AHU, AKW and ALE 102
4 31 2 Engine codes AGP, AGR, ALH, AQM, ASK and ASV 102
4 32 Camshaft drive toothed belt: checking condition and tension (diesel engine with engine code ALH and automatic gearbox) 103
4 32 1 Toothed belt: checking condition 103
4 32 2 Checking toothed belt tension 104
4 32 3 Tensioning toothed belt 104
4 33 Toothed belt: checking condition and tension (diesel engine with engine code 1Y) 106
4 33 1 Toothed belt: checking condition 106
4 33 2 Checking toothed belt tension 107
4 33 3 Tensioning toothed belt 107
4 34 Toothed belt: renewing (diesel engine with engine codes AGP, AGR, ALH, AQM, ASK, ASV and AYQ) 109
4 35 Toothed belt: renewing (diesel engine with engine codes AEY, AFN, AHB, AHU, AKW and ALE) 109
4 36 Air filter: cleaning housing and renewing filter element 110
4 36 1 Engine codes ADZ, AEY, AFN, AFT, AHB, AHU, AKW, 1F and 1Y 110
4 36 2 Engine codes AEE, AEX, ALM, ANX, AKV and APQ 110
4 36 3 Engine codes AEH, AGP, AGR, AKL, ALE, ALH, APF, AQM, ASK, ASV, AUR and AYQ 111
4 36 4 Engine codes AKK, ANW and AUD 112
4 36 5 Engine codes APE, AQQ and AUA 114
4 37 Fuel filter: renewing (diesel engine) 115
4 38 Fuel filter: draining water (diesel engine) 116
4 39 Automatic gearbox: checking ATF level 116
4 39 1 Checking oil temperature of automatic gearbox using -V A G 1551- 116
4 39 2 Checking oil temperature of automatic gearbox using vehicle diagnosis, testing and information system -VAS 5051B- or subsequent units 119
4 39 3 Checking oil level 121
4 40 Power assisted steering: checking fluid level 123
4 40 1 Oil in cold condition: 123
4 40 2 Fluid at operating temperature (above approx 50°C) 124
4 41 Changing brake fluid 124
4 42 Brake fluid level (dependent upon brake pad/lining wear): checking 127
4 43 Battery: checking battery terminal clamps for secure seating 128
4 44 Battery: checking 130
4 45 Idling speed: checking 130
4 46 Headlight adjustment: checking 130
4 46 1 Checking headlight adjustment (without 15° setting line) 132
4 46 2 Adjusting headlights 133
4 47 Carry out road test 134
5 Exhaust emissions test 135
5 1 Exhaust emissions test for vehicles with petrol engine without OBD with -Fehlerauslesegerät V A G 1551- 135
5 1 1 Engine codes ADZ, AEX, AKV, ANX, APQ and 1F 135
5 1 2 Engine codes AEE, AFT and ALM 139
5 1 3 Engine codes AEH, AKK, AKL, ANW, APE, APF, AQQ, AUA, AUD and AUR 143
5 2 Exhaust emissions test for vehicles with petrol engine without OBD with emissions testing station -VAS 6300- 146
5 2 1 Methods to activate disturbance variable at lambda control circuit test 153
5 3 Exhaust emissions test for vehicles with petrol engine and OBD 155
5 4 Exhaust emissions test for diesel engines without OBD 157
5 4 1 Exhaust emissions test with diesel tester V A G 1743 158
5 4 2 Exhaust emissions test with emissions testing station VAS 6300 164
6 Glossary 173

S.V 27/01/2025