Volkswagen polo 2002

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Service.

Self-Study Programme 263

Polo Model Year 2002

The visual appearance of the new Polo features the 4-eyed face with round headlights and the hatchback.

The new Polo again sets news standards in its class by offering improved spatial comfort, innovative state-of-the-art technology and all-round safety. It also meets high quality standards.

In this Self-Study Programme, wewill present the new technical features and innovations of the new Polo.

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The following Self-Study Programmes relating to the Polo 2002 are also available: SSP 259 "Electro-hydraulic Power Steering" SSP 260 "1.2-litre 3-cylinder Petrol Engines" SSP 264 "Brake Assistant System (BAS)" SSP 265 "Vehicle Electrical System in Polo Model Year 2002"
New Important Note

ThisSelf-Study Programme explains the design and function of new developments! The contents are not updated.

Please always refer to the relevant Service Literature for current inspection, adjustment and repair instructions.

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At a glance
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 6

Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Running gear . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Heater, air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . 44

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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Summary
The Polo Model Year 2002 is available in 2-door and4-door body versions. The vehicle is at the cutting edge with regard to safety, quality, performance, running gear and equipment.

A semi-automatic air conditioning system - Climatic - ensures a pleasant climate inside the passenger cabin.

An electro-hydraulic power steering system provides needs-oriented steering assistance.

Easy entry seats with memory function facilitate access to the rearseats.

Two low-emission 3-cylinder petrol engines are available as entry-level units.

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The front end obtains a certain friendly appearance from the round front headlights. A hydraulic brake assistant system (BAS) assists the driver with braking in hazardous situations.

A vehicle electrical system control unit is responsible for load management of electrical system components.It monitors automotive components not integrated in the two CAN bus systems.

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Dimensions and weights
75 kg

2460 mm 3897 mm

1650 mm

1465 mm

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Length Width Height Wheelbase Turning circle Tank capacity

3897 mm 1650 mm 1465 mm 2460 mm 10,6 m 45 l
*

Front track width Rear track width
Max. permissible gross weight

1435 mm 1425 mm 1560 kg* 1025 kg* 75 kg 0,32Kerb weight Max. permissible roof load Drag coefficient cd
Specifications refer to a 2-door Polo

with 1.4-litre 55 kW engine and manual gearbox

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Body
Body
The body of the Polo is fully galvanised and partly consists of high-strength panels. The front and rear side members, the B pillars and the front left and right floor pans are made of high-strength sheet metal. By increasing bodyrigidity, the shutlines of the doors and flaps have been reduced still further.

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A new technique is used to join the bonnet and tailgate. The sheet-metal panels are joined by clinching. Advantages: – Uniform appearance – Low-cost method Clinching entails press-fitting metal sheets together by means of a mould and a plunger.

By optimising the design of the front, rear and lateral...
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