1. Introduction
This manual provides comprehensive repair and maintenance instructions for Volkswagen Polo vehicles equipped with specific gasoline engines from model year 2011 onwards. It is intended for qualified technicians and experienced DIY enthusiasts. The content covers detailed procedures for servicing, repairing, and troubleshooting the vehicle's systems, with a particular focus on the engine variants listed.
The manual includes technical data, wear values, and essential information regarding specialized tools and replacement parts required for proper vehicle service.
This image displays the front cover of the VW Polo Repair Manual, Band 1325. It features a grey VW Polo car, the Volkswagen logo, and text indicating it covers gasoline engines from model year 2010 onwards, focusing on maintenance, care, and troubleshooting. The cover also highlights that it includes technical data, wear values, and information on tools and spare parts.
2. Safety Information
Always prioritize safety when performing any maintenance or repair work on the vehicle. Failure to follow proper safety procedures can result in serious injury or damage to the vehicle.
- Ensure the vehicle is on a stable, level surface and properly supported with jack stands before working underneath it.
- Disconnect the battery's negative terminal before working on electrical components.
- Wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and protective clothing.
- Allow engine and exhaust components to cool down before handling to prevent burns.
- Be aware of hazardous fluids (fuel, oil, coolant, brake fluid) and dispose of them responsibly.
- Do not smoke or use open flames near fuel or battery.
3. Preparation for Service and Repair
Before commencing any service or repair, ensure you have the necessary tools, diagnostic equipment, and genuine Volkswagen replacement parts. Refer to the specific sections for detailed tool requirements for each procedure.
3.1. Required Tools and Equipment
A comprehensive set of metric wrenches, sockets, screwdrivers, and specialized Volkswagen tools are essential. Diagnostic scan tools compatible with VW vehicles are highly recommended for electronic system troubleshooting.
3.2. Replacement Parts
Always use genuine Volkswagen parts or approved equivalents to ensure proper fitment, performance, and longevity. Refer to the parts catalog for correct part numbers.
4. Maintenance Procedures (Wartung & Pflege)
Regular maintenance is crucial for the longevity and optimal performance of your VW Polo. This section outlines routine service intervals and procedures.
4.1. Engine Oil and Filter Change
- Warm up the engine to operating temperature.
- Safely lift and support the vehicle.
- Place a drain pan under the oil drain plug.
- Remove the drain plug and allow oil to drain completely.
- Remove the old oil filter.
- Install a new oil filter, ensuring the gasket is properly seated.
- Reinstall the drain plug with a new washer and torque to specification.
- Lower the vehicle and fill with the specified type and quantity of new engine oil.
- Check oil level and inspect for leaks.
4.2. Air Filter Replacement
Detailed steps for inspecting and replacing the engine air filter to ensure optimal engine breathing and fuel efficiency.
4.3. Spark Plug Inspection and Replacement
Instructions for checking spark plug condition, gap, and replacement intervals for each engine type.
4.4. Fluid Level Checks and Top-ups
Guidance on checking and topping up coolant, brake fluid, power steering fluid (if applicable), and windshield washer fluid.
5. Troubleshooting (Störungssuche)
This section provides diagnostic guidance for common issues encountered with the VW Polo, helping to identify the root cause of problems before attempting repairs.
5.1. Engine Starting Problems
- Engine cranks but won't start: Check fuel supply, ignition system, and engine compression.
- Engine does not crank: Inspect battery charge, starter motor, and ignition switch.
5.2. Poor Engine Performance
- Loss of power: Investigate air intake system, fuel delivery, turbocharger (TSI models), and exhaust system.
- Rough idling: Examine spark plugs, ignition coils, fuel injectors, and vacuum leaks.
5.3. Warning Lights on Dashboard
Explanation of common warning lights (e.g., Check Engine, Oil Pressure, Battery) and initial diagnostic steps. Use of a diagnostic scan tool is recommended to retrieve fault codes.
6. Technical Specifications and Wear Values
This section provides critical technical data, torque specifications, fluid capacities, and wear limits for various components of the VW Polo gasoline engines.
6.1. Engine Specifications
| Parameter | 1.2L MPI (44/51 kW) | 1.2L TSI (77 kW) | 1.4L MPI (63 kW) |
|---|---|---|---|
| Engine Type | 3-Cylinder, 12V MPI | 4-Cylinder, 16V TSI | 4-Cylinder, 16V MPI |
| Displacement | 1198 cm³ | 1197 cm³ | 1390 cm³ |
| Power Output | 44 kW (60 PS) / 51 kW (70 PS) | 77 kW (105 PS) | 63 kW (85 PS) |
| Engine Oil Capacity (with filter) | Refer to specific model year data | Refer to specific model year data | Refer to specific model year data |
Note: Specific torque values for fasteners, fluid types, and capacities are detailed within the respective repair sections of the full manual. Always consult the latest Volkswagen service information for precise data.
6.2. Wear Limits
This subsection provides critical wear limits for components such as brake pads, brake discs, tire tread depth, and engine component tolerances (e.g., crankshaft journals, cylinder bore diameter). Adhering to these limits is essential for vehicle safety and performance.
