2002-2010 Volkswagen Polo OEM Service & Repair Manual
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P rote cte d b y c o p yrig ht. C o p yin g fo r p riv a t e o r c o m m e r c i a l p u r p o s e s , i n p a r t o r i n wh o l e , i s n o t p e r m itte d u n le s s a uth o ris e d b y V olk s w a g e n A G . V olks w a g e n A G d o e s n ot g u ara nte e o r a c c e p t a n y lia b ilit y w it h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a ti o n in t h is d o c u m e n t. C o p yrig ht b y V olk s w a g e n A G . Workshop Manual Polo 2002 ➤ 3-cylinder diesel engine Engine ID AMF BAY BNM BNV BMS BWB Edition 12.2011 Service Service Department. Technical Information
P rote cte d b y c o p yrig ht. C o p yin g fo r p riv a t e o r c o m m e r c i a l p u r p o s e s , i n p a r t o r i n wh o l e , i s n o t p e r m itte d u n le s s a uth o ris e d b y V olk s w a g e n A G . V olks w a g e n A G d o e s n ot g u ara nte e o r a c c e p t a n y lia b ilit y w it h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a ti o n in t h is d o c u m e n t. C o p yrig ht b y V olk s w a g e n A G . 1.6 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 1.7 Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 1.8 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 2.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 2.2 Removing and installing anti-theft engine control unit , engine codes AMF, BAY, BNM, BNV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 2.3 Removing and installing anti-theft engine control unit , engine codes BMS, BWB . . . . . . 161 2.4 Reading and clearing engine control unit event memory . . . . . . . . . . . . . . . . . . . . . . . . . . 162 2.5 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 1.1 Assembly overview - front exhaust pipe with catalytic converter and silencer . . . . . . . . . . 165 1.2 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 167 1.3 Assembly overview - silencer, vehicles with particulate filter . . . . . . . . . . . . . . . . . . . . . . . . 168 1.4 Removing and installing front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . 169 1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 2.1 Assembly overview - parts of exhaust gas recirculation system, engine code AMF . . . . . . 173 2.2 Assembly overview - parts of exhaust gas recirculation system, engine codes BAY, BNM, BNV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 2.3 Assembly overview - parts of exhaust gas recirculation system, engine codes BMS, BWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 2.4 Assembly overview - exhaust gas recirculation cooler, engine codes BMS, BWB . . . . . . 176 2.5 Removing and installing exhaust gas recirculation cooler, engine codes BMS, BWB . . . . 177 2.6 Vacuum hose assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 1.2 Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 1.3 Removing, installing and checking ceramic glow pin plugs . . . . . . . . . . . . . . . . . . . . . . . . 181 Polo 2002 ➤ 3-cylinder diesel engine - Edition 12.2011 Contents iii
P rote cte d b y c o p yrig ht. C o p yin g fo r p riv a t e o r c o m m e r c i a l p u r p o s e s , i n p a r t o r i n wh o l e , i s n o t p e r m itte d u n le s s a uth o ris e d b y V olk s w a g e n A G . V olks w a g e n A G d o e s n ot g u ara nte e o r a c c e p t a n y lia b ilit y w it h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a ti o n in t h is d o c u m e n t. C o p yrig ht b y V olk s w a g e n A G . Polo 2002 ➤ 3-cylinder diesel engine - Edition 12.2011 iv Contents
P rote cte d b y c o p yrig ht. C o p yin g fo r p riv a t e o r c o m m e r c i a l p u r p o s e s , i n p a r t o r i n wh o l e , i s n o t p e r m itte d u n le s s a uth o ris e d b y V olk s w a g e n A G . V olks w a g e n A G d o e s n ot g u ara nte e o r a c c e p t a n y lia b ilit y w it h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a ti o n in t h is d o c u m e n t. C o p yrig ht b y V olk s w a g e n A G . 00 – Technical data 1 Technical data Engine number ⇒ page 1 Engine data ⇒ page 1 1.1 Engine number The engine number („code letters“ and „serial number“) can be found at the joint between engine and gearbox. Additionally there is a sticker on the toothed belt guard with „en‐ gine code“ and „serial number“. The engine code is also included on the vehicle data sticker. 1.2 Engine data Edition 12.2011 Version 10 Engine code AMF BAY BNM BNV Manufactured 11.01 ► 11.01 ► 03.05 ► 03.05 ► Capacity l 1.4 1.4 1.4 1.4 Output kW at rpm 55/4000 55/4000 51/4000 58/4000 Torque Nm at rpm 195/2200 195/2200 155/2200 195/2200 Bore ∅ mm 79.5 79.5 79.5 79.5 Stroke mm 95.5 95.5 95.5 95.5 Compression ratio 19.5 19.5 19.5 19.5 Fuel according to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590 Firing order 1-2-3 1-2-3 1-2-3 1-2-3 Catalytic converter yes yes yes yes Diesel particulate filter no no no no Exhaust gas recirculation yes yes yes yes Turbocharging/supercharging yes yes yes yes Charge air cooling yes yes yes yes Engine code BMS BWB Manufactured 01.06 ► 06.06 ► Capacity l 1.4 1.4 Output kW at rpm 59/4000 51/4000 Torque Nm at rpm 195/2200 155/2200 Polo 2002 ➤ 3-cylinder diesel engine - Edition 12.2011 1. Technical data 1
P rote cte d b y c o p yrig ht. C o p yin g fo r p riv a t e o r c o m m e r c i a l p u r p o s e s , i n p a r t o r i n wh o l e , i s n o t p e r m itte d u n le s s a uth o ris e d b y V olk s w a g e n A G . V olks w a g e n A G d o e s n ot g u ara nte e o r a c c e p t a n y lia b ilit y w it h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a ti o n in t h is d o c u m e n t. C o p yrig ht b y V olk s w a g e n A G . Engine code BMS BWB Bore ∅ mm 79.5 79.5 Stroke mm 95.5 95.5 Compression ratio 19.5 19.5 Fuel according to DIN EN 590 DIN EN 590 Firing order 1-2-3 1-2-3 Catalytic converter yes yes Diesel particulate filter yes yes Exhaust gas recirculation yes yes Turbocharging/supercharging yes yes Charge air cooling yes yes Polo 2002 ➤ 3-cylinder diesel engine - Edition 12.2011 2 Rep. gr.00 - Technical data
P rote cte d b y c o p yrig ht. C o p yin g fo r p riv a t e o r c o m m e r c i a l p u r p o s e s , i n p a r t o r i n wh o l e , i s n o t p e r m itte d u n le s s a uth o ris e d b y V olk s w a g e n A G . V olks w a g e n A G d o e s n ot g u ara nte e o r a c c e p t a n y lia b ilit y w it h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a ti o n in t h is d o c u m e n t. C o p yrig ht b y V olk s w a g e n A G . 10 – Removing and installing engine 1 Removing and installing engine Removing engine ⇒ page 3 . Securing engine to assembly stand ⇒ page 9 . Notes on installing ⇒ page 10 . Assembly mountings ⇒ page 11 Additional information and assembly work for vehicles with air conditioner ⇒ page 12 . 1.1 Removing engine Special tools and workshop equipment required ♦ Lifting tackle -VAS 2024A- ♦ Engine bracket -T10012- ♦ Support clamp -VW 313- ♦ Engine and gearbox sup‐ port -VW 540- or engine and gearbox support -VAS 6095- ♦ Workshop hoist -V.A.G 1202 A- or workshop crane -VAS 6100- ♦ Drip tray -V.A.G 1306- or drip tray -VAS 6208- Polo 2002 ➤ 3-cylinder diesel engine - Edition 12.2011 1. Removing and installing engine 3
P rote cte d b y c o p yrig ht. C o p yin g fo r p riv a t e o r c o m m e r c i a l p u r p o s e s , i n p a r t o r i n wh o l e , i s n o t p e r m itte d u n le s s a uth o ris e d b y V olk s w a g e n A G . V olks w a g e n A G d o e s n ot g u ara nte e o r a c c e p t a n y lia b ilit y w it h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a ti o n in t h is d o c u m e n t. C o p yrig ht b y V olk s w a g e n A G . ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Engine and gearbox jack - V.A.G 1383/A- ♦ Spring-type clip pliers -VAS 5024- ♦ Stepladder -VAS 5085- ♦ Support bracket -10-222A- ♦ Engine support -T40076- (vehicles with no air conditioner) Not illustrated: ♦ Container for removed parts -V.A.G 1698- ♦ Engine bung set -VAS 6122- ♦ Grease -G 000 100- ♦ Cable ties Polo 2002 ➤ 3-cylinder diesel engine - Edition 12.2011 4 Rep. gr.10 - Removing and installing engine
The 2002-2010 Volkswagen Polo OEM Service & Repair Manual is a comprehensive resource designed for both professional mechanics and DIY enthusiasts. It offers detailed instructions for servicing and repairing various Volkswagen Polo models from 2002 to 2010, covering a range of engines including 1.0L, 1.2L, 1.4L, 1.6L, and 1.8L petrol engines, as well as 1.4L and 1.6L diesel engines.
Volkswagen Polo 1.0L petrol engine
Volkswagen Polo 1.2L petrol engine
Volkswagen Polo 1.4L petrol engine
Volkswagen Polo 1.6L petrol engine
Volkswagen Polo 1.8L petrol engine
Volkswagen Polo 1.4L diesel engine
Volkswagen Polo 1.6L diesel engine
Whether you need to perform routine maintenance or tackle complex repairs, this OEM manual provides step-by-step instructions, detailed illustrations, and precise diagrams to guide you. It encompasses a wide range of tasks, including oil and filter changes, brake pad and spark plug replacements, along with thorough insights into the vehicle's electrical system, engine, transmission, suspension, and brakes.
By utilizing the 2002-2010 Volkswagen Polo OEM Service & Repair Manual, you can confidently maintain and repair your vehicle, ensuring optimal performance and longevity.
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2002-2010 Volkswagen Polo OEM Service & Repair Manual