Volkswagen Polo 2002 Maintenance Manual – PDF DOWNLOAD

Description

Volkswagen Polo 2002 Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Volkswagen Polo 2002 Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 154
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Volkswagen Polo 2002 Maintenance Manual – PDF DOWNLOAD

1 Engine list 5
2 Service work 9
2 1 Information on LongLife service and time or distance dependent service 9
2 1 1 Service identification 9
2 1 2 LongLife service 9
2 1 3 Time or distance dependent service 10
2 1 4 Service interval display 10
2 2 Service tables 11
2 2 1 SERVICE INTERVALS 12
2 2 2 VW ENGINE OIL STANDARDS 13
2 2 3 FILTER CHANGE INTERVALS 14
2 2 4 TOOTHED BELT CHANGE INTERVALS 14
2 2 5 Spark plug change intervals 15
2 3 Delivery inspection 15
2 4 Oil change service 17
2 5 Interval service 2008► 18
2 6 Inspection ►2007 20
2 7 Inspection service 2008► 22
2 8 Time or distance dependent additional work 24
2 9 Service intervals with market-specific deviations 28
3 General information 30
3 1 Stickers 30
3 1 1 Attaching “Your next service” sticker 30
3 1 3 Attaching hotline sticker 31
3 2 Entries in service schedule 31
3 3 Connecting vehicle diagnostic tester 32
3 4 Raising vehicle with lifting platform or trolley jack 33
3 4 1 Safety notes: 34
3 4 2 Lifting points for lifting platform or trolley jack: 34
3 5 Vehicle identification number 35
3 6 Vehicle data sticker 36
3 7 Countries where diesel has a high sulphur content 36
3 8 Engine code and engine number 37
3 9 RME fuel (biodiesel) 37
3 10 Severe operating conditions 38
3 11 Type plate 38
4 Descriptions of work: 40
4 1 Removable towing bracket: checking and cleaning if necessary 41
4 2 Swivel joints and suspension link mountings: inspecting 43
4 3 Automatic gearbox: checking ATF level 44
4 4 Automatic gearbox: changing ATF (09G gearbox) 44
4 5 Battery: checking battery terminal clamps for secure seating 45
4 6 Battery: Checking using battery tester with printer VAS 5097A or VAS 6161 46
4 7 Brake and clutch system: Changing brake fluid 46
4 8 Brake fluid level: checking 51
4 8 1 Procedure, brake fluid level (dependent upon lining/pad wear): checking 51
4 9 Front passenger airbag: checking key switch and “On/Off function” 52
4 10 Tyres: checking condition, wear pattern, tread depth, tyre pressure and age 53
4 10 1 Checking condition 53
4 10 2 Checking tyre wear pattern 54
4 10 3 Checking tyre tread depth (including spare wheel) 54
4 10 4 Tyre pressure (including spare wheel): Checking, correcting if necessary 54
4 11 Brake system and shock absorbers: inspecting for leaks and damage 62
4 12 Brakes, front and rear: checking thickness of brake pads and condition of brake discs 63
4 12 1 Front brake pads: 63
4 12 2 Rear brake pads: 64
4 12 3 Rear drum brake pads: checking 65
4 12 4 Brake discs: checking condition 66
4 13 Electric windows: Carry out initialisation (activation) 67
4 14 Vehicle system test: Carry out test 67
4 15 Bonnet: greasing arrester 68
4 16 Adding multi-purpose additive G17 68
4 17 Boots: inspecting 69
4 18 Checking expiry date of first-aid kit 69
4 19 Interior and exterior body: inspecting for corrosion with doors and flaps open 69
4 20 Poly V-belt: Checking tension, adjusting if necessary 69
4 21 Poly V-belt: checking condition 69
4 22 Checking number plate on vehicle bumper (Polo Cross) 70
4 23 Fuel filter: Renewing (diesel engine) 70
4 24 Fuel filter: Draining water (diesel engine) 71
4 25 Cooling system: checking frost protection and coolant level 73
4 25 1 Frost protection: checking, replenishing coolant additive if necessary 73
4 25 2 Coolant level: checking, replenishing coolant if necessary 74
4 25 3 Mixing ratio: 75
4 26 Air filter: Cleaning housing and renewing filter element 75
4 26 1 Air filter: Clean housing and renew filter element, engine codes BUD and BTS 75
4 26 2 Air filter: Cleaning housing and renewing filter element, 1 4 l injection engines 76
4 26 3 Air filter: Clean housing and renew filter element, engine codes: AWY, AZQ, BMD, BME and 4-cylinder FSI engines 77
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 77
4 27 Engine oil level: Check, replenish engine oil if necessary 78
4 28 Engine oil: Draining or extracting and replenishing; renewing oil filter 79
4 28 1 Engine oil: draining or extracting 79
4 28 2 Renewing oil filter 81
4 28 3 Replenishing engine oil 84
4 29 Engine and components in engine compartment: inspecting for leaks and damage (from above and below) 85
4 30 Removing and installing engine cover panel -top- 85
4 31 Removing and installing engine cover -bottom- (noise insulation) 88
4 32 Road test: performing (driving behaviour, noises, air conditioner etc ) 89
4 33 Wheel securing bolts: tightening to specified torque 89
4 34 Radio/radio navigation system: entering PIN of anti-theft coding and storing local radio stations to station buttons 91
4 35 Radio code: reading using vehicle diagnostic tester 92
4 36 Tyre repair set: checking 93
4 37 Tyre Pressure Loss Indicator: performing basic setting 93
4 38 Manual gearbox/final drive: Checking oil level, replenishing oil if necessary 94
4 39 Window wiper and washer system and headlight washer system: Checking function 94
4 39 1 Anti-freeze concentration in window wiper and washer system: Checking and replenishing fluid if necessary 94
4 39 2 Window wiper and washer system: Checking spray jet settings 96
4 39 3 Headlight washer system: check jet setting 98
4 39 4 Checking wiper blade park position 98
4 39 5 Wiper blades: Check setting angle 98
4 40 Wiper blade protection: removing 99
4 40 1 Wiper blade protection, version 1: removing 100
4 40 2 Wiper blade protection, version 2, removing 101
4 40 3 Wiper blade protection, version 3 -transport wiper blade: changing 102
4 41 Headlight adjustment: Check, adjust headlights if necessary 102
4 41 1 Test requirements 102
4 41 2 Checking headlight adjustment (using test screen without 15° setting line) 104
4 41 3 Adjusting headlights 105
4 41 4 Fog lights and other auxiliary lights: adjusting 106
4 42 Sunroof: checking function, cleaning and greasing guide rails 107
4 43 Service interval display: resetting 107
4 43 1 Resetting service interval display with adjustment buttons for distance display and clock on dash panel insert 108
4 43 2 Resetting service interval display using diagnostic tester 109
4 44 Service interval display: recoding 110
4 45 Track rod ends: checking clearance, firm seating and boots 111
4 46 Dust and pollen filter: renew filter element 112
4 47 Door arrester: grease 112
4 48 Transportation device: Remove blocking pieces from front axle springs 113
4 49 Recoding dash panel insert 114
4 50 Clock: setting to correct time 115
4 51 Underseal: inspecting for damage to underseal, underbody cladding, routing of lines and plugs 115
4 52 Toothed belt and tensioning roller: Renew 115
4 53 Camshaft drive toothed belt: Renewing (4-cylinder 5-valve petrol engine) 116
4 54 Camshaft drive toothed belt: Check (4-cylinder petrol engine) not for engine code AXU 116
4 55 Renewing spark plugs 116
4 55 1 Spark plugs: renewing, engine codes BUD, BTS 118
4 55 2 Spark plugs: renewing, engine codes AUA and AUB 118
4 55 3 Renewing spark plugs, engine codes AWY, BBY, BBZ, AXU, AZQ, BMD, BME, BKY, BUD, BTS, BZG 119
4 56 Diesel particulate filter: check 123
5 Exhaust emissions test 124
5 1 Exhaust emissions test for petrol engines 124
5 2 Exhaust emissions test for diesel engines 133
5 2 1 Exhaust emissions test for diesel engines without OBD with diesel tester V A G 1743 133
5 2 2 Exhaust emissions test for diesel engines without OBD with emissions testing station VAS 6300 140
5 2 3 Exhaust emissions test for diesel engines with OBD 149
6 Glossary 153

S.V 03/02/2025