Get Descriptions of work Guide for Volkswagen Lupo 2 Door First Generation (1998-2005)

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4

Descriptions of work:

♦ Removing and installing engine compartment cover (noise in‐

sulation) ⇒ page 25

♦ Battery: checking battery terminal clamps for secure seating

⇒ page 26

♦ Battery: check ⇒ page 28

♦ Wheel securing bolts: tightening to specified torque

⇒ page 28

♦ Clock: setting to correct time ⇒ page 29

♦ Radio: Activate anti-theft coding ⇒ page 30

♦ Transportation devices: removing blocking pieces from

springs on front axle ⇒ page 31

♦ Engine oil level: Check, replenish if necessary ⇒ page 32

♦ Driver and front passenger airbags: Visual check of airbag

units ⇒ page 33

♦ Window wash/wipe system and headlight washer system:

checking function ⇒ page 34

♦ Wiper blades: Check for damage; check park position, adjust

if necessary; if wiper blades “judder”: Check setting angle, ad‐

just if necessary ⇒ page 38

♦ Carrying out vehicle system test ⇒ page 40

♦ Automated manual gearbox (DSG): Carry out basic setting

⇒ page 43

♦ Service interval display: resetting ⇒ page 43

♦ Door arrester: lubricating ⇒ page 55

♦ Sunroof: checking function, cleaning and lubricating guide

rails ⇒ page 55

♦ Folding fabric sunroof: Clean and grease guide rails

⇒ page 56

♦ Engine and components in engine compartment: inspecting

for leaks and damage (from above and below) ⇒ page 56

♦ Cooling system: checking frost protection and coolant level

⇒ page 57

♦ Spark plugs: renewing ⇒ page 65

♦ Power assisted steering: checking fluid level ⇒ page 71

♦ Fuel filter: renew (diesel engine) ⇒ page 72

♦ Fuel filter: Draining water (diesel engine) ⇒ page 75

♦ Dust and pollen filter: Renew filter element ⇒ page 75

♦ Toothed belt: Check for wear (diesel engine ► 2000)

⇒ page 76

♦ Camshaft drive toothed belt: Check (4-cylinder petrol engine)

⇒ page 78

♦ Toothed belt: Renew (diesel engine with engine code AKU)

⇒ page 79

♦ Toothed belt and camshaft drive tensioning roller: Renew (die‐

sel engine with engine codes AMF, ANY, AYZ) ⇒ page 79

♦ Engine oil: Drain or extract and top up; Renew oil filter

⇒ page 79

24

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Poly V-belt: checking condition ⇒ page 83

♦ Protective bellows: inspecting ⇒ page 83

♦ Manual gearbox/final drive: Check oil level, fill oil if necessary

⇒ page 83

♦ Automated manual gearbox (DSG): Check oil level, top-up

hydraulic oil if necessary ⇒ page 86

♦ Brake system: visual check for leaks and damage

⇒ page 89

♦ Front and rear brake pads: Check thickness ⇒ page 90

♦ Underbody protection: carry out visual check for damage

⇒ page 92

♦ Track rod ends: checking clearance, security and boots

⇒ page 92

♦ Swivel joints: inspecting ⇒ page 93

♦ Checking breakdown set ⇒ page 94

♦ Tyres (including spare wheel): Check condition and wear pat‐

tern ⇒ page 94

♦ Tyre tread depth (including spare wheel): Check

⇒ page 95

♦ Tyre pressures (including spare): Check, correct if necessary

⇒ page 95

♦ Automatic gearbox: Check ATF level, top-up ATF if necessary

⇒ page 98

♦ Brake and clutch system: changing brake fluid ⇒ page 98

♦ Brake fluid level (dependent upon lining wear): checking

⇒ page 100

♦ Headlight adjustment: Check, adjust headlight if necessary

⇒ page 100

♦ Carrying out road test ⇒ page 111

4.1

Removing and installing engine com‐

partment cover (noise insulation)

Carry out following procedure:

4.1.1

Engine codes AER, AFK, AHT, AHW,

AKU, AKQ, ALD, ALL, ANV, AQQ, ARR,

AUA, AUB, AUC, AUD, AVY, BBY

– Remove hexagon nuts and unclip securing clips -arrows-.

Swing noise insulation tray down and remove.

Note

Do not reuse securing clips, they must be renewed each time the

noise insulation is removed.

Installation is carried out in the reverse sequence of removal.

4. Descriptions of work:

25

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.1.2

Engine codes ANY, AYZ

– Remove bolts and unclip securing clips -arrows-. Swing noise

insulation tray down and remove.

Note

Do not reuse securing clips, they must be renewed each time the

noise insulation is removed.

Installation is carried out in the reverse sequence of removal.

4.2

Battery: checking battery terminal

clamps for secure seating

4.2.1

Engine codes AER, AFK, AHT, AHW,

AKU, AKQ, ALD, ALL, ANV, AMF, APE,

AQQ, AUA, AUB, AUC, AUD, BBY

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331-

Note

A securely seated battery clamp ensures trouble free function and

long service life of the battery.

Carry out following procedure:

– Press lugs -arrows- together and open cover sidewards.

26

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Check if battery terminal clamps -3- and -4- are seated se‐

curely on the battery terminals by moving the battery positive

wire -1- and the battery negative wire -2- to and fro.

WARNING

If the battery terminal clamp is not seated securely on the pos‐

itive terminal, first disconnect battery earth clamp on battery

negative terminal to prevent possible accidents.

If the battery clamp is not seated securely on positive terminal:

– Disconnect battery terminal clamp -4- on battery negative ter‐

minal first.

– Tighten battery clamp -3- on battery positive terminal to 5 Nm.

– Reconnect battery clamp -4- to battery negative terminal and

tighten to 5 Nm.

If the battery clamp on negative terminal is not seated securely:

– Tighten battery clamp -4- on battery negative terminal to 5 Nm.

4.2.2

Engine codes ANY, ARR, AVY, AYZ

Note

♦ For vehicles with engine codes ANY, ARR, AVY and AYZ the

battery is located in the luggage compartment.

♦ On some vehicles with engine code ANY the battery has been

installed in the engine compartment. For these vehicles ap‐

plies ⇒ page 26 .

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331-

Note

A securely seated battery clamp ensures trouble free function and

long service life of the battery.

Carry out following procedure:

4. Descriptions of work:

27

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Press lugs -arrows- together and remove cover upwards.

– Check battery terminal clamps -3- and -4- are seated securely

on the battery terminals by moving the battery positive wire

-1- and -5- and the battery negative wire -2- to and fro.

WARNING

If the battery terminal clamp is not seated securely on the pos‐

itive terminal, first disconnect battery earth clamp on battery

negative terminal to prevent possible accidents.

If the battery clamp is not seated securely on positive terminal:

– Disconnect battery terminal clamp -4- from battery negative

terminal first.

– Tighten battery clamp -3- on battery positive terminal to 5 Nm.

– Reconnect battery clamp -4- to battery negative terminal and

tighten to 5 Nm.

If the battery clamp on negative terminal is not seated securely:

– Tighten battery clamp -4- on battery negative terminal to 5 Nm.

4.3

Battery: Check

– Procedure: »Electrical system« ⇒ Electrical system; Rep. gr.

27 ; Checking battery »Checking battery«

4.4

Wheel bolts: tightening to specified tor‐

que

Special tools and workshop equipment required

28

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Torque wrench - V.A.G 1332- (40-200 Nm)

Wheel bolts

The adapter to loosen and tighten the anti-theft wheel bolts can

be found in the vehicle tool kit.

Note

Ensure that wheel bolts are tightened diagonally and alternately

to the following torque setting:

Specified torque: 110 Nm

– Place adapter in vehicle tool kit after completing work.

4.5

Clock: setting to correct time

Engine code AVY ⇒ page 29

Carry out adjustment as follows:

Setting hours:

– Press briefly, preferably with a ball pen on button -1-, to ad‐

vance the time one hour. Pressing the button continuously

speeds up selection of hours.

Setting minutes:

– Press briefly, preferably with a ball pen on button -2-, to ad‐

vance the time one minute. Pressing the button continuously

speeds up selection of minutes.

With the minute button the clock can be set exactly to the second:

– Press button until time is one minute before time to be set.

Turn button at the moment when the seconds indicator of ac‐

curate clock shows a full minute.

4.5.1

Engine code AVY

Carry out adjustment as follows:

4. Descriptions of work:

29

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Press the button briefly -1-, to reset the time one minute.

Pressing the button continuously speeds up selection of mi‐

nutes and hours anti-clockwise.

– Press the button briefly -2-, to advance the time one minute.

Pressing the button continuously speeds up selection of mi‐

nutes and hours clockwise.

4.6

Radio: Activating anti-theft coding

The radio units are supplied with a fixed code. Fixed code means

that each radio unit with an anti-theft coding is programmed with

its own code number. This fixed code is not active when leaving

the factory.

The security coding of the ready to play radio is not activated until

the fixed code is entered.

Activate fixed code as follows:

– Switch radio unit on.

– “SAFE” appears on digital display.

– After approx. 3 seconds “1000” appears on display.

– With the help of station buttons 1 to 4 enter code number

applied on radio card. Use button 1 to enter the first digit of

the code number, button 2 to enter the 2nd digit and so on.

– Then press the search function -1- or manual setting -2- rocker

switch for longer than 2 seconds. Release button.

If the correct code has been entered, the actual radio frequency

will appear after a short “learning phase”. During this pause the

stations with the best reception will be automatically stored to an

internal memory list and can be called up.

The LED on the lower left of the radio must flash when the ignition

key is removed. When the diode flashes the radio is ready-for-use

and the anti-theft coding is activated.

30

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.7

Transportation devices: removing block‐

ing pieces from springs on front axle

Blocking pieces are fitted to front axle springs for some vehicle

versions. These vehicles are identified by a warning tag on the

mirror -arrow-.

Note

The blocking pieces prevent the springs compressing and possi‐

ble damage to the vehicle when being driven onto a vehicle

transporter or railway wagon.

WARNING

The blocking pieces must be removed without reservation be‐

fore delivering the vehicle. A “Warning” notice, attached to the

interior mirror, specifically reminds of this.

Carry out following procedure:

Note

There is no requirement to remove the wheels.

– Relieve weight on springs by raising vehicle with a hoist.

– Slide suspension strut protective sleeve upwards -arrow-.

4. Descriptions of work:

31

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Push blocking pieces -arrows- off piston rod.

– Slide suspension strut protective sleeve downwards onto sus‐

pension strut.

4.8

Engine oil level: Check, replenish if nec‐

essary

Please note the following:

After shutting off engine, wait at least 3 minutes so that the oil can

flow back into the sump.

– Pull out dipstick, wipe with a clean cloth and push dipstick in

again to limit stop.

Note

Observe environmental regulations for disposal.

4.8.1

Engine codes AER, AFK, AHT, AHW,

AKU, AKQ, ALD, ALL, ANV, APE, AQQ,

ARR, AUA, AUB, AUC, AUD, AVY, BBY

– Pull dipstick out again and read oil level.

♦ Area -a-: Oil must be replenished. After replenishing it is suf‐

ficient when the oil level is somewhere in area -b-.

♦ Area -b-: Oil must not be replenished.

Note

A danger exists of damaging the catalytic converter when oil level

is above area -c-.

32

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.8.2

Engine code AMF

– Pull dipstick out again and read oil level.

♦ Area -a-: Oil must be replenished. After replenishing it is suf‐

ficient when the oil level is somewhere in area -b-.

♦ Area -b-: Oil must not be replenished.

Note

A danger exists of damaging the catalytic converter when oil level

is above area -c-.

4.8.3

Engine codes ANY, AYZ

– Pull dipstick out again and read oil level.

♦ Area -a-: Oil must be replenished. After replenishing it is suf‐

ficient when the oil level is somewhere in area -b-.

♦ Area -b-: Oil must not be replenished.

Note

A danger exists of damaging the catalytic converter when oil level

is above area -c-.

Continued for all vehicles:

– When oil level is below min. marking, replenish with oil to max.

marking. Oil specification: Petrol engines and diesel engines

4.9

Driver and front passenger airbags: Vis‐

ual check of airbag units

4.9.1

Driver side airbag:

Airbag recognition, is via the inscription “AIRBAG” on the steering

wheel padded plate.

– Carry out visual check of padded plate -1- for exterior damage.

WARNING

♦ The steering wheel padded plate surface must not have

stickers attached or be covered or otherwise be modified.

This ensures that the future function of the airbag is guar‐

anteed. Ensure the customer is aware of these instruc‐

tions.

♦ The steering wheel padded plate must only be cleaned

with a dry cloth or a cloth moistened with water.

4. Descriptions of work:

33

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.9.2

Front passenger airbag:

Airbag recognition by the inscription “AIRBAG” on the right-hand

side of dash panel (front passenger side).

– Carry out visual check of dash panel surface -2- for exterior

damage.

WARNING

♦ The surface of the front passenger airbag module must

not have stickers attached or be covered or be modified

otherwise. This ensures that the future function of the air‐

bag is guaranteed. Ensure the customer is aware of these

instructions.

♦ The surface of the airbag module must only be cleaned

with a dry cloth or a cloth moistened with water.

4.10

Window wiper and washer system and

headlight washer system: Checking

function

Note

When during a functional check it is determined that the wiper

blades “judder” or make noises, check the setting angle of the

wiper blades ⇒ page 38 .

4.10.1

Replenishing with fluid

Special tools and workshop equipment required

♦ Refractometer - T10007-

The fluid reservoir of the window washer system must be filled

completely. If fluid has to be replenished, add Windscreen Clear

- G 052 164- to the water.

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4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Note

♦ Vehicles with fan-type spray jets must always be filled with

“Genuine Volkswagen Windscreen Clear”, as this fluid has a

low viscosity at temperatures below freezing. Otherwise the

complicated spray jet system can become blocked by the

crystallised washer fluid, which affects the spray pattern of the

spray jet. “Genuine Volkswagen window cleaner” ensures that

the fan -type washer jets remain fully functional at low tem‐

peratures.

♦ Genuine Volkswagen Windscreen Clear - G 052 164- protects

the spray jets, fluid reservoir and connecting hoses from freez‐

ing.

♦ Use Genuine Volkswagen Windscreen Clear - G 052 164- in

the warmer periods of the year also. The powerful cleanser

removes wax and oil residue from the glass.

♦ The frost protection for the window washer system must be

guaranteed to approx. -25℃.

♦ Read precise value for the following tests at light-dark border.

Using a pipette, place a drop of water on the glass to improve

the readability of the light-dark border. The light-dark border

can be clearly recognised on the “WATERLINE”.

– Check concentration of anti-freeze additive using refractome‐

ter - T10007- (refer to operating instructions).

The scale -1- of the refractometer is calibrated for Genuine Volks‐

wagen Windscreen Clear - G 052 164- .

The scale -2- is designed for commercially available windscreen

washer fluid as well as a mixture of commercially available Wind‐

screen clear - G 052 164- .

Mixing ratio:

Frost protection

to

Windscreen

Clear

Water

G 052 164

In summer

-16 °C

-35 °C

1 part

2 parts

4 parts

2 parts

1 part

-40 °C

4.10.2

Window washer system: Checking jet

setting, adjusting jets if necessary

Windscreen

The spray jets are preset. However, small differences in height

may be corrected.

4. Descriptions of work:

35

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Note

If the spray field is uneven due to soiling in the spray jet, remove

spray jet, and rinse with water opposite to direction of spray. Sub‐

sequent blowing through with compressed air against the spray‐

ing direction is permitted. Never use solid objects to clean the

washer jets!

If both spray fields are not at same height, adjust spray direction

upwards or downwards as follows:

Note

Two different types of washer jets have been installed.

– Turn eccentric on spray jet -in direction of arrow- using a

screwdriver, to adjust spray direction upwards.

– To adjust the spray direction downwards, turn eccentric on

spray jet opposite to -direction of arrow-.

or

– Adjust spray jet at adjuster -1- by hand upwards or down‐

wards.

Rear window:

Special tools and workshop equipment required

36

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Adjusting tool - T10127-

Note

If the spray field is uneven due to soiling in the spray jet, remove

spray jet, and rinse with water opposite to direction of spray. Sub‐

sequent blowing through with compressed air against the spray‐

ing direction is permitted. Never use solid objects to clean the

washer jets!

– Check jet setting.

Rear window jet setting figures:

Spray jet must spray to centre of wiped area.

– If necessary adjust jet using adjusting tool - T10127- .

4.10.3

Headlight washer system: Checking jet

setting, adjusting jets if necessary

Special tools and workshop equipment required

♦ Adjusting tool - T10167-

Jet adjustment dimension for the right-hand headlight (left-hand

mirror image):

– Check jet setting.

•

-a-: 40 mm

-b-: 5 mm

– Adjust jets as follows if necessary:

4. Descriptions of work:

37

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Pull spray jet -arrow- out onto stop and align onto respective

spray point with adjusting tool - 3019 A-

Note

If the spray field is uneven due to soiling in the spray jet, remove

spray jet, and rinse with water opposite to direction of spray. Sub‐

sequent blowing through with compressed air against the spray‐

ing direction is permitted. Never use solid objects to clean the

washer jets!

4.11

Wiper blades: Checking for damage;

checking park position, adjusting if nec‐

essary; if wiper blades “judder”: Check‐

ing setting angle, adjusting if necessary

4.11.1

Wiper blades: Checking park position,

adjusting if necessary

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331- (5-50 Nm)

Windscreen of LHD vehicles:

– Check park position.

Driver side:

The distance -A- between wiper blade and lower edge of wind‐

screen must be 20 mm.

– Adjust park position by moving wiper arm if necessary.

Specified torque for wiper arm: 20 Nm

38

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Front passenger side:

The distance -A- between wiper blade and lower edge of wind‐

screen must be 20 mm.

– Adjust park position by moving wiper arm if necessary.

Specified torque for wiper arm: 20 Nm

Rear window:

– Check park position.

The distance -A- between wiper rubber and lower edge of wind‐

screen must be 25 mm.

– Adjust park position by moving wiper arm if necessary. Speci‐

fied torque for wiper arm: 15 Nm

4.11.2

Wiper blades: Checking setting angle,

adjusting if necessary (not valid for aero

wiper)

Note

Check setting angle only if wiper blades “judder” or make noises.

Special tools and workshop equipment required

♦ Wiper setting tool - 3358 B-

Carry out following procedure:

– Set wiper arms to rest position.

– Remove wiper blade.

4. Descriptions of work:

39

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Insert wiper arm -2- into wiper arm setting device - 3358 B-

and secure with locking screw -3-.

– Check setting angle.

Setting angle (specifications) for

LHD vehicles

RHD vehicles

Driver side

-7°

-6.5°

0°

+7°

+6.5°

0°

Passenger side

Rear window wiper

Tolerance

±2°

Adjust setting angle to specification, if required, as follows:

– Fit 24 mm open jaw spanner -1- on setting device and adjust

wiper arm -2- to specification -arrows-.

– Release wiper arm -2- from setting device and then resecure

with locking screw -3-.

– Check setting against table. If necessary, repeat setting and

checking procedure until specification is achieved.

– Remove setting tool, and install wiper blade.

– Check if wiper system operates “without juddering”.

4.12

Carry out vehicle system test

Special tools and workshop equipment required

♦ Vehicle diagnostic, testing and information system - VAS

5051-

40

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Diagnostic cable - VAS 5051/6A-

♦ Vehicle diagnostic and service information system - VAS

5052-

♦ Diagnostic cable, 2 m - VAS 5052/3 A-

Note

Ensure that the fault reader is only used with the respective di‐

agnostic cable.

4.12.1

Reading fault memory of all systems us‐

ing vehicle diagnosis, testing and infor‐

mation system - VAS 5051- or vehicle

diagnosis and service information sys‐

tem - VAS 5052-

Continued for all vehicles:

– Switch on ignition.

4. Descriptions of work:

41

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Select operating mode "Guided fault finding" on display

-arrow-.

Note

If the display is not as shown in the procedure: ⇒ Operating in‐

structions for vehicle diagnosis, testing and information system -

VAS 5051- or ⇒ Operating instructions for vehicle diagnosis and

service information system - VAS 5052- .

– Perform vehicle identification.

The programme now automatically performs a vehicle system test

and reads all control units available for this vehicle type.

– Press ► Continue button.

Now all faults are listed.

Note

At this point it is useful to change to operating mode guided func‐

tions to carry out further operations with VAS 5051 and to prevent

a second vehicle identification on tester.

– To do this, press button “operating mode” and then item “gui‐

ded functions”.

– For further procedure see respective work descriptions e.g.

“Resetting service interval display”.

– To return to guided fault finding, press button “operating mode”

and then “guided fault finding”.

Caution

The vehicle must always be delivered to the customer with fault

memory cleared.

Static faults

If one or more static faults are found in the fault memory, we rec‐

ommend in agreement with the customer to rectify these faults

using guided fault finding.

Sporadic faults

If only sporadic faults or notes are stored in the fault memory and

the customer has no complaints in conjunction with the electronic

vehicle system, clear fault memory.

– Press ► Continue button again to reach the test plan.

– Now complete guided fault finding using “GoTo” button and

then “End”.

All fault memories are read again.

Now it is shown on display that all sporadic faults have been

cleared, the diagnosis log is sent "online" automatically.

The vehicle system test is completed.

42

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.13

Automated manual gearbox (DSG):

Carrying out basic setting

– Carry out basic setting of automated manual gearbox (DSG):

⇒ Vehicle diagnostic tester; vehicle diagnosis, testing and in‐

formation system or the - VAS 5051- or the vehicle diagnosis

and service information system - VAS 5052- in function “gui‐

ded fault finding”.

Procedure: »5-speed manual gearbox 085 DS« ⇒ 5-speed man‐

ual gearbox 085 DS ; Rep. gr. 34 ; Controls, housing; Changing

oil and filter of dual clutch gearbox »Controls, housing; Changing

oil and filter of dual clutch gearbox«

4.14

Service interval display: Resetting

Function

The service interval display electronics is comprised of, amongst

other items:

♦ a time recorder

and

♦ two distance recorders.

The electronics evaluates both recorders so that the customer

♦ after a predetermined time period is exceeded or

or

♦ after a predetermined distance is reached

is informed via the service interval display that a service is re‐

quired (whichever occurs first).

Service interval display

Between services, only the total distance and distance travelled

(trip recorder) is shown in the distance display -2-.

If a service is due, the following is indicated in the distance display

-2- below the total mileage:

♦ with ignition switched off “service”

♦ after the ignition is switched on and up to 3 minutes after the

engine is started the type of service (see table).

Note

After the engine is started the display switches back to “service”

after 3 minutes.

4. Descriptions of work:

43

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Service type:

Type of Service:

(indicated on display):

Mileage and service OIL

Oil change service every

15,000 km

or:

Mileage and service INSP

Inspection service every 12

months or every 30,000 km

(whichever occurs first)

One or both service types must be reset depending on which

service was completed, therefore:

♦ If a “service OIL” (oil change service every 15,000 km) is car‐

ried out, only “service OIL” must be reset.

♦ If a “service INSP” (inspection service every 12 months or ev‐

ery 30,000 km) has been performed “service INSP” and “serv‐

ice OIL” must be reset.

♦ If a “service INSP” (inspection service every 12 months or ev‐

ery 30,000 km) without an oil change has been performed,

then only “service INSP” must be reset.

The service interval display can be reset using one of two meth‐

ods:

♦ With adjustment button for the distance display on dash panel

insert ⇒ page 44 ,

or using

♦ vehicle diagnosis, testing and information system - VAS 5051-

or vehicle diagnosis and service information system - VAS

5052- ⇒ page 45 .

4.14.1

Resetting service interval display with

adjustment button for distance display

on dash panel insert

The service interval display must be reset (adapted) during

♦ delivery inspection

♦ every oil change service

♦ every inspection

!

Note

Each service must be reset individually as only the distance re‐

corder and time counter of the actual service can be reset.

Reset the display as follows:

– Switch off ignition.

44

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Press and hold button -1- below speedometer.

– Switch on ignition and hold button -1- depressed (min. 10 sec‐

onds) until three dashes (- - -) or the next service appears in

the display. Only then the service is reset.

– Release button -1-.

– Switch off ignition.

After resetting the service interval display the previous trip re‐

corder display is indicated again.

Note

♦ Note that only the actual service type indicated on display can

be reset.

♦ To reset a further service, repeat these steps.

4.14.2

Reset service interval display vehicle di‐

agnosis, testing and information system

- VAS 5051- or vehicle diagnosis and

service information system - VAS 5052-

The service interval display must be reset (adapted) during

♦ delivery inspection

♦ every oil change service

♦ every inspection

.

Special tools and workshop equipment required

♦ Vehicle diagnostic, testing and information system - VAS

5051-

♦ Diagnostic cable - VAS 5051/6A-

4. Descriptions of work:

45

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Vehicle diagnostic and service information system - VAS

5052-

♦ Diagnostic cable, 2 m - VAS 5052/3 A-

Note

Ensure that the fault reader is only used with the respective di‐

agnostic cable.

Connect vehicle diagnosis, testing and information system - VAS

5051- or vehicle diagnosis and service information system - VAS

5052- .

– Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral.

– Dual clutch gearbox: Move selector lever to position “N” or

“STOP”.

Connect vehicle diagnostic, testing and information system - VAS

5051- or vehicle diagnostic and service information system - VAS

5052- with ignition switched off as follows:

– Lever cover or ashtray insert out of centre console.

– Connect vehicle diagnosis, testing and information system -

VAS 5051- or vehicle diagnosis and service information sys‐

tem - VAS 5052- using diagnostic cable - VAS 5051/6A- with

ignition switched off.

– Switch on ignition.

46

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

Select operating mode:

– Press button for Vehicle self-diagnosis on display

-arrow-.

Note

If the display is not as shown in the procedure: ⇒ Operating in‐

structions for vehicle diagnostic, testing and information system -

VAS 5051A- or ⇒ Operating instructions for vehicle diagnostic

and service information system - VAS 5052- .

Indicated on display:

Select vehicle system:

– Press “17 - Dash panel insert” on display -arrow-.

Indicated on display:

The control unit identification and coding are displayed -arrow-.

Indicated on display:

– Press “10 - Adaption” on display -arrow-.

4. Descriptions of work:

47

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press the adaption channel for the service which is to be reset

on the display number block -arrow-:

♦ for display “service OIL” on dash panel insert channel 10

♦ for display “service INSP” on dash panel insert channel 10, 11

and 12

Adaption table:

Type of service:

Adaption channel:

Counter contents:

Adaption value to

reset:

service OIL

service INSP

10

11

12

Distance in 100s of km

Time in days

150

300

360

Note

♦ Entering the relevant adaption values for the distance recorder

is only possible in steps of 100 km. Therefore this is shown on

the display in 100 km.

♦ The entered values count down to 0 km.

♦ The counter for “INSP service” can be adapted to max. 360

days.

Resetting service interval display

service OIL (oil change service) ⇒ page 48

service INSP (inspection every 12 months) ⇒ page 49

service INSP (inspection every 30,000 km) ⇒ page 51

4.14.3

Service OIL (oil change service)

Indicated on display:

– Press buttons 1 and 0 on display number block -arrow-.

– Confirm entry with Q key on display number block.

48

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Move the position indicator -arrow- on the display until 150 is

displayed over the scroll bar -1- (equates to 15,000 km).

Note

♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Indicated on display:

– Press the Accept button on display -arrow-.

– End output.

4.14.4

Service INSP (inspection every 12

months)

Indicated on display:

– Press buttons 1 and 2 on display number block -arrow-.

– Confirm entry with Q key on display number block.

4. Descriptions of work:

49

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Move the position indicator -arrow- on the display until -1- 360

is displayed over the scroll bar (equates 360 days).

Note

♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Indicated on display:

– Press the Accept button on display -arrow-.

If an inspection service was performed without oil change, end

output.

If an inspection service was performed with an oil change, con‐

tinue as follows:

Indicated on display:

– Press ← -arrow- on display.

Indicated on display:

– Press “10 - Adaption” on display -arrow-.

50

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press buttons 1 and 0 on display number block -arrow-.

– Confirm entry with Q key on display number block.

Indicated on display:

– Move the position indicator -arrow- on the display until 150 is

displayed over the scroll bar -1- (equates to 15,000 km).

Note

♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Indicated on display:

– Press the Accept button on display -arrow-.

– End output.

4.14.5

Service INSP (inspection every 30,000

km)

Indicated on display:

– Press buttons 1 and 1 on display number block -arrow-.

– Confirm entry with Q key on display number block.

4. Descriptions of work:

51

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Move the position indicator -arrow- on the display until 300 is

displayed over the scroll bar -1- (equates to 30,000 km).

Note

♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Indicated on display:

– Press the Accept button on display -arrow-.

For the inspection every 30,000 km, also the inspection service

every 12 months and the oil change service must be reset as fol‐

lows:

Indicated on display:

– Press ← -arrow- on display.

Indicated on display:

– Press “10 - Adaption” on display -arrow-.

52

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press buttons 1 and 2 on display number block -arrow-.

– Confirm entry with Q key on display number block.

Indicated on display:

– Move the position indicator -arrow- on the display until -1- 360

is displayed over the scroll bar (equates 360 days).

Note

♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Indicated on display:

– Press the Accept button on display -arrow-.

Indicated on display:

– Press ← -arrow- on display.

4. Descriptions of work:

53

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press “10 - Adaption” on display -arrow-.

Indicated on display:

– Press buttons 1 and 0 on display number block -arrow-.

– Confirm entry with Q key on display number block.

Indicated on display:

– Move the position indicator -arrow- on the display until 150 is

displayed over the scroll bar -1- (equates to 15,000 km).

Note

♦ Pressing the scroll bar briefly to the right -2- of the position

indicator moves the value to the next number.

♦ Pressing the scroll bar briefly on the left -3- of the position in‐

dicator moves the value to the previous number.

– Press the Save button on display -4-.

Indicated on display:

– Press the Accept button on display -arrow-.

– End output.

End output

54

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press GoTo button on display -arrow-.

Indicated on display:

– Press the End button on display -arrow-.

– Press End button in End menu.

– Switch off ignition and separate diagnosis connections.

– Switch on ignition.

After the ignition is switched on, the type of service is no longer

displayed in the distance display in the dash panel insert.

The service interval display is now reset.

– Switch off ignition.

– Install cover in centre console or ashtray insert.

4.15

Door arrester: grease.

Carry out following procedure:

– Grease door arrester at points shown -arrows-.

– Grease door arrester in side area -arrow A- with grease -G

000 150- .

4.16

Sunroof: checking function, cleaning

and greasing guide rails

Carry out following procedure:

– Check function of sunroof.

4. Descriptions of work:

55

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Clean guide rails -arrows-, and lubricate them with special

grease -G 000 450 02- .

4.17

Folding fabric sunroof: Cleaning and

greasing guide rails

– Clean guide rail -arrows- and lubricate with special grease -G

000 450 02- .

– Check function of folding fabric sunroof.

4.18

Engine and components in engine com‐

partment: inspecting for leaks and dam‐

age (from above and below)

Inspect as follows:

– Check engine and components in engine compartment for

leaks and damage.

– Check lines, hoses and connections of

♦ Fuel system

♦ Cooling and heating system

♦ Lubrication system

♦ Air conditioning system

♦ Intake system

♦ And brake system

For leaks, abrasions, porosity and brittleness.

Note

♦ Arrange for defects to be rectified as repair measures.

♦ If fluid loss is greater than can be expected through normal

use, determine source and rectify (repair measure).

56

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.19

Cooling system: checking frost protec‐

tion and coolant level

Note

♦ The water used for mixing has a major influence on the effec‐

tiveness of the coolant. Because the water quality differs from

country to country and even from region to region, the quality

of the water to be used in the cooling system has been speci‐

fied by Volkswagen. Distilled water fulfils all requirements.

Therefore, only ever use distilled water when mixing coolant

for topping up or renewing coolant.

♦ Use only coolant additives which conform with the ⇒ Elec‐

tronic parts catalogue (ETKA) . Other coolant additives may

reduce corrosion protection substantially. The resulting dam‐

age could lead to loss of coolant and subsequent severe

damage to the engine.

♦ Mixed in the proper proportions, coolant inhibits frost and cor‐

rosion damage as well as scaling. Coolant additives also raise

the boiling point of the coolant. Therefore, the cooling system

must be filled all year round with a coolant additive.

♦ Because of its high boiling point, the coolant improves engine

reliability under heavy loads, particularly in countries with trop‐

ical climates.

♦ Use ONLY refractometer - T10007A- for determining current

anti-freeze value.

♦ Frost protection must be guaranteed down to -25°C as a min‐

imum and, in countries with arctic conditions, down to approx.

-36°C. Increasing the frost protection is permissible only if cli‐

matic conditions require stronger frost protection. It may, how‐

ever, be increased only to a maximum of -48°C. Otherwise,

the cooling effect will be impaired.

♦ Do not reduce the coolant concentration by adding water even

in warmer seasons and in warmer countries. Frost protection

must be guaranteed down to at least -25°C.

♦ Read off anti-freeze figures for respective replenished coolant

additive.

♦ The temperature read off the refractometer - T10007A- corre‐

sponds to the »ice flocculation point«. Flakes of ice may start

forming in the coolant at this temperature.

♦ Never reuse old coolant.

♦ Use only a water/coolant additive mixture as a slip agent for

coolant hoses.

4.19.1

Frost protection: checking and replen‐

ishing coolant additive if necessary

Special tools and workshop equipment required

4. Descriptions of work:

57

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Refractometer - T10007 A-

Note

Read precise value for the following tests at light-dark border.

Using a pipette, place a drop of water on the glass to improve the

readability of the light-dark border. The light-dark border can be

clearly recognised on the “WATERLINE”.

– Check concentration of coolant additive using refractometer -

T10007 A- (refer to operating instructions).

The scale -1- of the refractometer is calibrated for coolant addi‐

tives G12; G12 Plus, G12 Plus Plus and G11.

The scale -2- is only calibrated for coolant additive G13.

– If frost protection is too low, you must drain some coolant and

add coolant additive .

Note

♦ If the currently used coolant additive cannot be determined

precisely, use the scale -2- for coolant additive G13.

♦ Observe environmental regulations for disposal.

– Check coolant additive concentration after road test again.

4.19.2

Coolant level: checking, replenishing

coolant if necessary

– Check coolant level on expansion tank with engine cold.

♦ Delivery inspection: Coolant level at max. marking.

♦ Inspection service: Coolant level between min. and max.

marking.

– If coolant is too low, add required amount according to mixture

ratio.

Note

If fluid loss is greater than can be expected through normal use,

determine source and rectify (repair measure).

58

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.19.3

Mixing ratio:

Caution

Use only distilled water for mixing coolant additives. The use

of distilled water ensures optimum protection against corro‐

sion.

Frost protection to

Coolant additive

portion

Distilled water

-25 °C

-36 °C

approx. 40%

approx. 50 %

approx. 60 %

approx. 50 %

4.20

Air filter: Cleaning housing and renew‐

ing filter element

4.20.1

Engine codes AER, ALL

Carry out following procedure:

Removing:

Note

♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted

to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm

♦ Specified torque: max. 3 Nm

– Unscrew securing bolts -arrows-.

– Lift filter housing upper part and remove upwards.

4. Descriptions of work:

59

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Take out used filter element -arrow-.

Note

Observe environmental regulations for disposal.

Installing:

– Clean filter housing and install new filter element.

– Insert filter housing upper part and tighten bolts -arrows-.

4.20.2

Engine code AHT

Carry out following procedure:

Removing:

– Loosen cross head bolts -1-.

Note

♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted

to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm

♦ Specified torque: max. 3 Nm

– Unscrew hexagon socket head bolts -2-.

– Raise filter housing upper part and remove upwards.

– Take out used filter element -arrow-.

Note

Observe environmental regulations for disposal.

Installing:

– Clean filter housing and install new filter element.

60

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Insert filter housing upper part and tighten cross head bolts

-1-.

– Tighten hexagon socket head bolts -2-.

4.20.3

Engine codes AFK, AHW, AKQ, APE,

AQQ, AUA, AUB, AVY, BBY

Carry out following procedure:

Removing:

– Remove hexagon socket head bolts -arrows- and take off en‐

gine cover.

Note

For vehicles with engine code AVY the engine cover is clipped

and not bolted.

– Pull crankcase breather hose -arrow- off filter housing upper

part and unclip throttle cable -1-.

– Remove cross-head bolts -arrows-.

Note

♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted

to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm

♦ Specified torque: max. 3 Nm

– Raise filter housing upper part and remove upwards.

4. Descriptions of work:

61

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Take out used filter element -arrow-.

Note

Observe environmental regulations for disposal.

Installing:

– Clean filter housing and install new filter element.

– Screw in cross head bolts -arrows-.

– Connect crankcase breather hose -arrow- on filter housing

upper part and clip in throttle cable -1-.

Note

For maintenance operation “Renew spark plugs” the engine cover

must remain removed if necessary.

4.20.4

Engine code AKU

Carry out following procedure:

Removing:

– Raise vehicle.

– Release securing clips -arrows- and remove filter housing low‐

er part downwards.

62

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Take out used filter element -arrow- downwards.

Note

Observe environmental regulations for disposal.

Installing:

– Clean filter housing and install new filter element.

– Insert filter housing lower part and secure clips -arrows-.

4.20.5

Engine codes ALD, ANV, AUC, AUD

Special tools and workshop equipment required

♦ Spring-type clip pliers - V.A.G 1921-

Carry out following procedure:

Removing:

– Unclip caps -1- and remove bolts (below caps).

– Remove ignition cable -2- from air filter housing.

– Loosen hose clamp -3- using pliers for spring-type clips -

V.A.G 1921- and pull hose off.

– Pull crankcase breather hose -arrow- off air cleaner housing

and remove filter housing.

4. Descriptions of work:

63

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Unscrew cross head bolts -1- and remove filter housing lower

part.

Note

♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted

to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm

♦ Specified torque: max. 3 Nm

– Take out used filter elements -arrows-.

Note

Observe environmental regulations for disposal.

Installing:

– Clean filter housing and insert new filter elements.

– Insert filter housing lower part and tighten cross head bolts

-1-.

Note

♦ The bolts must be loosened or tightened only by hand. When

loosening or tightening the securing bolts it is only permitted

to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm

♦ Specified torque: max. 3 Nm

Note

For maintenance operation “Renewing spark plugs” the air filter

housing must remain removed if necessary.

4.20.6

Engine codes AMF, ANY, ARR, AYZ

Carry out following procedure:

Removing:

– Raise vehicle.

64

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Unscrew securing bolts -arrows-.

– Swing cover downwards and unclip.

Note

The cover is not fitted on all engines.

– Remove Torx bolts -arrows- and take out filter housing lower

part downwards.

– Take out used filter element -arrow- downwards.

Note

Observe environmental regulations for disposal.

Installing:

– Clean filter housing and install new filter element.

– Insert filter housing lower part and tighten Torx bolts

-arrows-.

Note

Install cover if necessary.

4.21

Spark plugs: Renewing

Special tools and workshop equipment required

4. Descriptions of work:

65

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Spark plug socket - 3122 B-

♦ Torque wrench - V.A.G 1331- (5-50 Nm)

♦ Spark plug designation see »Injection engine« ⇒ Injection en‐

gine; Rep. gr. 28 ; Test data, spark plugs »Test data, spark

plugs«

4.21.1

Engine codes AER, ALL

Carry out following procedure:

– Pull intake air preheating hose -arrow- off exhaust manifold.

Note

♦ The air filter securing bolts must be loosened or tightened only

by hand. When loosening or tightening the securing bolts it is

only permitted to use a power screwdriver if:

♦ Speed of power screwdriver max. 200 rpm

♦ Specified torque: max. 3 Nm

– Unscrew bolts -arrows- and remove air filter completely.

66

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Pull off spark plug connector and unscrew spark plugs with

spark plug socket and extension - 3122 B- .

Note

♦ Spark plug designation and torque setting »Injection engine«

⇒ Injection engine; Rep. gr. 28 ; Test data, spark plugs »Test

data, spark plugs«

♦ Observe environmental regulations for disposal.

– Insert filter housing and tighten cross head bolts -arrows-.

4.21.2

Engine code AHT

Carry out following procedure:

– Remove oil filler cap -1-.

– Unclip cap -2-, unscrew nut located below and remove engine

cover.

– Unscrew hexagon socket head bolts -arrows- and remove ig‐

nition transformer with final output stages.

4. Descriptions of work:

67

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Unscrew spark plugs using spark plug socket - 3122 B- .

– Screw in new spark plugs with spark plug wrench - 3122 B- .

Note

♦ Spark plug designation and torque setting »Injection engine«

⇒ Injection engine; Rep. gr. 28 ; Test data, spark plugs »Test

data, spark plugs«

♦ Observe environmental regulations for disposal.

– Install ignition transformer with final output stages.

– Install cover.

4.21.3

Engine codes AFK, AHW, AKQ, APE,

AQQ, AUA, AUB, AVY, BBY

Carry out following procedure:

– Remove hexagon socket head bolts -arrows- and take off en‐

gine cover.

Note

For vehicles with engine code AVY the engine cover is clipped

and not bolted.

– Remove oil filler cap -1-.

– Take ignition cables -2- out of cover -3- and pull cover upwards

slightly.

– Pull off spark plug connectors and place ignition cables with

cover to side.

– Unscrew spark plugs using spark plug socket - 3122 B- .

– Screw in new spark plugs with spark plug wrench - 3122 B- .

Note

♦ Spark plug designation and torque setting »Injection engine«

⇒ Injection engine; Rep. gr. 28 ; Test data, spark plugs »Test

data, spark plugs«

♦ Observe environmental regulations for disposal.

– Install spark plug cover.

68

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Install oil filler cap -1-.

– Fit spark plug connectors.

– Press ignition cables -2- into channels in spark plug cover.

– Install engine cover and secure with hexagon socket head

bolts -arrows-.

4.21.4

Engine codes ALD, ANV, AUC, AUD

Carry out following procedure:

– Unclip caps -1- and remove bolts (below caps).

– Remove ignition cable -2- from air filter housing.

– Loosen hose clamp -3- using pliers for spring-type clips -

V.A.G 1921- and pull hose off.

– Pull crankcase breather hose -arrow- off air cleaner housing

and remove filter housing.

– Pull off spark plug connector and unscrew spark plugs with

spark plug socket and extension - 3122 B- .

– Screw in new spark plugs with spark plug wrench - 3122 B- .

Note

♦ Spark plug designation and torque setting »Injection engine«

⇒ Injection engine; Rep. gr. 28 ; Test data, spark plugs »Test

data, spark plugs«

♦ Observe environmental regulations for disposal.

– Fit spark plug connectors.

– Insert filter housing.

4. Descriptions of work:

69

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Tighten securing bolts and fit caps -1-.

– Press ignition cables -2- into air filter housing.

– Fit hose and secure with hose clip -3-.

– Connect crankcase breather hose -arrow- to air filter housing.

4.21.5

Engine code ARR

Carry out following procedure:

– Unclip engine cover and remove upwards.

– Remove oil filler cap -1-.

– Unclip rubber funnel -2- from oil filler neck.

– Pull crankcase breather hose connection -3- off oil filler neck

-arrow-.

– Separate connectors -5- at ignition coils.

– Carefully pull out ignition coils with final output stage -4- using

puller - T10094- .

– Unscrew spark plugs using spark plug socket - 3122 B- .

– Screw in new spark plugs with spark plug wrench - 3122 B- .

Note

♦ Spark plug designation and torque setting »Injection engine«

⇒ Injection engine; Rep. gr. 28 ; Test data, spark plugs »Test

data, spark plugs«

♦ Observe environmental regulations for disposal.

– Carefully fit ignition coils with final output stage -4-.

– Connect connectors -5- at ignition coils with final output stage

-4-.

– Connect crankcase breather hose connection -3- to oil filler

neck.

– Fit rubber funnel -2- and oil filler cap -1-.

– Insert engine cover and fasten clips.

70

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.22

Power assisted steering: Check fluid

level

Note

♦ Vehicles with engine codes ANY, AYZ have an electro-me‐

chanical power assisted steering, for this reason there is no

oil level check.

♦ On vehicles with FSI engine and electro-hydraulic power as‐

sisted steering there is also no oil level check.

Carry out following procedure:

4.22.1

Oil in cold condition:

– Do not start engine but bring front wheels to straight-ahead

position.

Engine codes AER, AHT, AKU, ALL, AMF

– Fit a suitable screwdriver into cap recess -arrow- and unscrew

cap with oil dipstick.

– Wipe off dipstick using a clean cloth.

– Screw filler cap on hand tight and unscrew again.

Engine codes AFK, AHW, AKQ, ALD, ANV, APE, AQQ, AUA,

AUB, AUC, AUD, AVY, BBY

– Fit a suitable screwdriver into cap recess -arrow- and unscrew

cap with oil dipstick.

– Wipe off dipstick using a clean cloth.

– Screw filler cap on hand tight and unscrew again.

Continued for all vehicles:

Note

The cap must be fully screwed on in order to obtain an accurate

fluid level reading.

– Checking oil level: The oil level must be within the area of the

grid -A-.

Note

♦ If fluid level is above specified range, fluid must be extracted.

♦ If fluid level is below specified range, the hydraulic system

must be checked for leaks (repair measure). It is not sufficient

just to fill fluid. If the hydraulic system is not leaking, replenish

power assisted steering oil - G 009 300 A2- .

– Screw cap on hand tight (with a screwdriver).

4. Descriptions of work:

71

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Maintenance - Edition 03.2018

4.22.2

Fluid at operating temperature (above

approx. 50° C)

– Do not start engine but bring front wheels to straight-ahead

position.

Engine codes AER, AHT, AKU, ALL, AMF

– Fit a suitable screwdriver into cap recess -arrow- and unscrew

cap with oil dipstick.

– Wipe off dipstick using a clean cloth.

– Screw filler cap on hand tight and unscrew again.

Engine codes AFK, AHW, AKQ, ALD, ANV, APE, AQQ, AUA,

AUB, AUC, AUD, AVY, BBY

– Fit a suitable screwdriver into cap recess -arrow- and unscrew

cap with oil dipstick.

– Wipe off dipstick using a clean cloth.

– Screw filler cap on hand tight and unscrew again.

Continued for all vehicles:

Note

The cap must be fully screwed on in order to obtain an accurate

fluid level reading.

– Checking oil level: The oil level must be between min. and

max. markings.

Note

♦ If oil level is above max. marking, the excessive oil must be

extracted.

♦ If oil level is below min. marking, the hydraulic system must be

checked for leaks (repair measure). It is not sufficient just to

fill fluid. If the hydraulic system is not leaking, replenish power

assisted steering oil - G 009 300 A2- .

– Screw cap on hand tight (with a screwdriver).

4.23

Fuel filter: Renewing (diesel engine)

Engine code AKU

4.23.1

Note

♦ Ensure that no diesel fuel contacts coolant hoses. Clean ho‐

ses immediately if soiled.

♦ Observe environmental regulations for disposal.

72

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Carry out following procedure:

Removing:

– Pull off retaining clip -1- and remove regulating valve -2- with

fuel lines connected.

– Pull off fuel hoses -3- and -4-.

– Loosen cross head bolt -5- on clamp and take out filter up‐

wards.

Installing new filter:

– Fit new O-ring to seal regulating valve.

Note

Fuel flow direction is marked by arrows (do not interchange con‐

nections).

– Fill new filter with clean Diesel. This allows the engine to start

quicker.

– Fit filter and secure by tightening the cross head bolt -5-.

– Install regulating valve -2- and fit retaining clip -1-.

– Push fuel hoses -3- and -4- over hose connections and secure

hoses with hose clips.

– Start engine and check fuel system for leaks (visual check).

– Operate throttle several times. Then fuel must flow bubble-free

through the transparent line -4- when engine is at idling speed.

4.23.2

Engine codes AMF, ANY, AYZ

Note

♦ Ensure that no diesel fuel contacts coolant hoses. Clean ho‐

ses immediately if soiled.

♦ Observe environmental regulations for disposal.

Carry out following procedure:

4. Descriptions of work:

73

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Maintenance - Edition 03.2018

Removing:

– Pull off retaining clip -1- and remove regulating valve -2- with

fuel lines connected.

– Pull off fuel hoses -3- and -4-.

– Remove bolt -5- and cap nuts -6- and pull filter slightly up‐

wards.

– Loosen cross head bolt on clamp and take out filter upwards.

Installing new filter:

– Fill new filter with clean Diesel. This allows the engine to start

quicker.

– Fit filter and secure by tightening the cross head bolt at clamp.

– Fit new O-ring to seal regulating valve.

Note

Fuel flow direction is marked by arrows (do not interchange con‐

nections).

– Install regulating valve -2- and fit retaining clip -1-.

– Push fuel hoses -3- and -4- over hose connections and secure

hoses with hose clips.

– Tighten bolt -5- and cap nuts -6-.

– Start engine and check fuel system for leaks (visual check).

– Operate throttle several times to bleed fuel system.

74

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.24

Fuel filter: Draining water (diesel en‐

gine)

4.24.1

Engine code AKU

Note

♦ Ensure that no diesel fuel contacts coolant hoses. Clean ho‐

ses immediately if soiled.

♦ Observe environmental regulations for disposal.

Carry out following procedure:

– Pull off retaining clip -1- and remove regulating valve -2- with

fuel lines connected.

– Fit hose onto water drain screw connection -3-, open screw

and drain approx. 0.1 l of fluid.

– Tighten water drain screw -3- and remove hose.

– Fit new O-ring to seal regulating valve.

– Install regulating valve -2- and fit retaining clip -1-.

– Start engine and check fuel system for leaks (visual check).

– Operate throttle several times. Then fuel must flow bubble-free

through the transparent line -4- when engine is at idling speed.

4.25

Dust and pollen filter: renew filter ele‐

ment

The filter is located on right in the plenum chamber under a cover.

Carry out following procedure:

4. Descriptions of work:

75

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Maintenance - Edition 03.2018

Removing:

– Pull off plastic cover -1-.

– From the right-hand side of plenum chamber cover pull rubber

seal -2- off upwards to vehicle centre.

– Unscrew bolts -3- and remove cover -4-.

– Unclip cover cap in front of lugs -B- and remove (if fitted).

– Press filter housing lugs -B- in -direction of arrow- and take

filter element with frame out upwards.

– Separate filter element from frame.

Note

Observe environmental regulations for disposal.

Installing:

– Guide frame -A- on left and right into the first lamination of the

new filter element -arrows B-.

– Guide frame lugs -A- into filter housing recesses -B- and press

frame with filter element downwards.

– If necessary clip in cover cap in front of lugs -B-.

– Tighten plenum chamber cover and press on rubber seal.

4.26

Toothed belt: Checking for wear (diesel

engine ►2000)

4.26.1

Engine code AKU

Special tools and workshop equipment required

76

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Vernier caliper (commercially available)

Carry out following procedure:

– Open clips -1- on upper toothed belt guard.

– Unhook toothed belt guard -2- and pull to side.

– Measure the width of the toothed belt with a vernier caliper.

Wear limit: 21 mm

Note

When a toothed belt has reached a width of 21 mm, the wear limit

has been reached and it must be renewed (repair measure). In‐

form customer!

WARNING

The engine must never under any circumstances be turned

over using the camshaft when checking and making adjust‐

ments. Not observing this can lead to severe engine damage.

4.26.2

Engine codes AMF, ANY

Special tools and workshop equipment required

♦ Workshop vernier caliper - VAS 5276-

Carry out following procedure:

4. Descriptions of work:

77

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Maintenance - Edition 03.2018

– Pull out oil dipstick -1- and remove oil filler cap -2-.

– Unclip engine cover and remove upwards.

– Open clips -1- on upper toothed belt guard.

– Unhook toothed belt guard -2- and pull to side.

– Measure the width of toothed belt with a workshop vernier cal‐

iper - VAS 5276- .

Wear limit: 27 mm

Note

When a toothed belt has reached a width of 27 mm, the wear limit

has been reached and it must be renewed (repair measure). In‐

form customer!

WARNING

The engine must never under any circumstances be turned

over using the camshaft when checking and making adjust‐

ments. Not observing this can lead to severe engine damage.

4.27

Camshaft drive toothed belt: Checking

(4-cylinder petrol engine)

Toothed belt: checking condition

– Open clips for upper toothed belt guard and remove cover.

– Check condition of toothed belt for:

♦ Cracks, cross sectional breaks

♦ Layer separation (toothed belt body, tensile cords)

♦ Toothed belt body breakup

♦ Frayed cord strands

♦ Surface cracks (synthetic coating)

♦ Traces of oil and grease

78

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Note

If faults are found, always renew toothed belt. This can avoid

breakdowns and malfunctions. The replacement of a toothed belt

is a repair measure.

When checking condition, especially watch for following damage:

•

-A- Cracks (coating)

-B- Side contact

-C- Fraying

-D- Cracks (in teeth base)

4.28

Toothed belt: Renewing (diesel engine

with engine code AKU)

Note

Generally it is not necessary to renew the toothed belt before the

actual change interval is reached. Especially cracks on the belt

side are not relevant for service life and cannot be covered by

goodwill or warranty processing.

– Carry out procedure: »Engine mechanics; Crankshaft« ⇒ En‐

gine mechanics; Crankshaft; Rep. gr. 13 ; Removing and

installing toothed belt »Removing and installing toothed belt«

4.29

Toothed belt and camshaft drive ten‐

sioning roller: Renewing (diesel engine

with engine codes AMF, ANY and AYZ)

Note

Generally it is not necessary to renew the toothed belt before the

actual change interval is reached. Especially cracks on the belt

side are not relevant for service life and cannot be covered by

goodwill or warranty processing.

– Carry out procedure:»Engine mechanics; Cylinder head, valve

gear« ⇒ Engine mechanics; Cylinder head, valve gear; Rep.

gr. 15 ; Removing and installing toothed belt »Removing and

installing toothed belt«

4.30

Engine oil: Draining or extracting and re‐

plenishing; renewing oil filter

Special tools and workshop equipment required

4. Descriptions of work:

79

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Maintenance - Edition 03.2018

♦ Oil extractor - V.A.G 1307 A-

♦ or

♦ Used oil collection and extraction unit - V.A.G 1358 A-

♦ or

♦ Used oil collection and extraction unit - V.A.G 1782-

♦ Torque wrench - V.A.G 1331- (5-50 Nm)

♦ Oil spill cloth - VAS 6204/1-

80

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Note

♦ If the engine oil is drained and not extracted with an oil ex‐

tractor, renew the oil drain plug. This prevents leaks.

♦ Capacities with filter change: ⇒ Maintenance tables or »En‐

gine mechanics« ⇒ Engine mechanics; Rep. gr. 17 ; Oil

capacities »Oil capacities«

♦ On some vehicles with engine code AKQ, fitted with air con‐

ditioner and power assisted steering, the exhaust pipe must

be unscrewed at front in order to remove the oil filter.

♦ Observe environmental regulations for disposal.

Turbo engines: After changing engine oil and oil filter, check fol‐

lowing after first engine start:

– The engine must only run at idling speed as long as the oil

pressure warning lamp lights up in dash panel. Do not rev up!

If the engine is revved up the turbocharger can be damaged

or fail completely.

– The full oil pressure is not attained until the warning lamp has

gone out, only then can the engine be revved up.

Note

Remember that the following torque details must not be excee‐

ded. Excessive torque can cause leaks in the area of the oil drain

plug or even damage.

Oil drain plug torque setting: 30 Nm

Because of the positive oil properties, use only the following ap‐

proved engine oils ⇒ page 6 :

– After replenishing with oil, wait at least 3 minutes and then

check oil level.

– Pull out dipstick, wipe with a clean cloth and push dipstick in

again to limit stop.

Note

Observe environmental regulations for disposal.

4.30.1

Checking oil level

⇒ page 32

4.30.2

Oil filter: renewing

Vehicles with petrol engine:

Carry out following procedure:

4. Descriptions of work:

81

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Loosen oil filter -arrow- from below with a 30 mm open jaw

spanner and remove oil filter.

Note

Observe environmental regulations for disposal.

– Clean engine sealing surface.

– Oil rubber seal lightly on new filter. The oil filter can adhere

better when tightening, which assures best possible sealing.

– Screw in filter and tighten hand-tight.

Vehicles with diesel engine and engine code AKU:

Special tools and workshop equipment required

♦ Oil filter tool

♦ or

♦ Oil filter strap wrench

Carry out following procedure:

– Loosen oil filter -arrow- from below with oil filter tool and re‐

move oil filter.

Note

Observe environmental regulations for disposal.

– Clean engine sealing surface.

– Oil rubber seal lightly on new filter. The oil filter can adhere

better when tightening, which assures best possible sealing.

– Screw in filter and tighten hand-tight.

Vehicles with diesel engine and engine codes AMF, ANY, AYZ:

Special tools and workshop equipment required

♦ 36 mm socket insert

Carry out following procedure:

– Unscrew cover cap -arrow- with 36 mm socket insert and re‐

move cover with oil filter insert.

– Pull used oil filter insert off cover cap.

Note

♦ Make sure that there are no foreign bodies in the filter housing.

♦ Observe environmental regulations for disposal.

– Renew O-ring of cover cap.

– Insert new filter element.

82

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Tighten cover cap -arrow-.

Cover cap torque setting: 25 Nm

4.31

Poly V-belt: checking condition

Carry out following procedure:

– Raise vehicle.

– Crank engine at vibration damper/belt pulley -arrow- using a

socket.

– Check poly V-belt -1- from below for:

♦ Sub-surface cracks (cracks, core ruptures, cross sectional

breaks)

♦ Layer separation (top layer, cord strands)

♦ Base break-up

♦ Frayed cord strands

♦ Flank wear (material wear, frayed flanks, flank brittleness -

glassy flanks-, surface cracks)

♦ Traces of oil and grease

Note

If faults are found, it is essential for the poly V-belt to be renewed.

This can avoid breakdowns and malfunctions. The replacement

of a poly V-belt is a repair measure.

4.32

Boots: inspecting

Carry out following procedure:

– Check outer joint bellows -arrow- and inner joint bellows (not

shown in illustration) for leaks and damage.

4.33

Manual gearbox/final drive: Checking oil

level, filling oil as required

♦ 5-speed manual gearbox 085 ⇒ page 84

4. Descriptions of work:

83

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ 5-speed manual gearbox 002 ⇒ page 84

♦ 5-speed manual gearbox 02J ⇒ page 85

♦ 5-speed manual gearbox 02T and 6-speed manual gearbox

02U ⇒ page 85

4.33.1

5-speed manual gearbox 085

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331- (5-50 Nm)

♦ Socket

♦ 17 mm hexagon socket insert

Carry out following procedure:

– Remove oil filler plug -arrow-.

– Checking oil level: The oil level must be to lower edge of filler

plug drilling.

– If necessary top up gearbox oil “Specification G 50 SAE

75W90 (synthetic oil)” to lower edge of filler plug drilling.

– Fit oil filler plug and tighten to 25 Nm.

4.33.2

5-speed manual gearbox 002

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331- (5-50 Nm)

Carry out following procedure:

84

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Remove oil filler plug -arrow-.

– Checking oil level: The oil level must be to lower edge of filler

plug drilling.

– If necessary top up gearbox oil “Specification G 50 SAE

75W90 (synthetic oil)” to lower edge of filler plug drilling.

– Clean sealing surfaces of oil filler plug and gearbox housing

and coat with DreiBond 1324 sealant.

– Fit oil filler plug and tighten to 25 Nm.

4.33.3

5-speed manual gearbox 02J

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331- (5-50 Nm)

Carry out following procedure:

– Remove noise insulation tray below engine and gearbox, if fit‐

ted.

– To check gear oil, unscrew oil plug -arrow-.

The oil level is correct, when the gearbox is filled to lower edge

of filler hole.

Use gearbox oil specification “G50 SAE 75W90”.

– Screw in plug -arrow-, and tighten to 25 Nm.

4.33.4

5-speed manual gearbox 02T and 6-

speed manual gearbox 02U

Special tools and workshop equipment required

4. Descriptions of work:

85

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Socket - 3357-

♦ Torque wrench - V.A.G 1331- (5-50 Nm)

Carry out following procedure:

– Remove noise insulation tray below engine and gearbox, if fit‐

ted.

– To check gear oil, unscrew oil plug -arrow-.

The oil level is correct, when the gearbox is filled to lower edge

of filler hole.

Use gearbox oil specification “G50 SAE 75W90”.

– Screw in plug -arrow-, and tighten to 25 Nm.

4.34

Automated manual gearbox (DSG):

Checking oil level, filling hydraulic oil as

required

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331- (5-50 Nm)

86

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Torque wrench - V.A.G 1783-

4.34.1

Checking oil level

Carry out following procedure:

Requirement

•

Vehicle standing on level ground

– Disconnect battery terminal clamp on battery negative termi‐

nal.

Note

♦ It is absolutely necessary to disconnect the battery, because

the hydraulic pump even starts running with ignition switched

off and hydraulic oil flows out of system.

♦ The battery is located in luggage compartment. On some ve‐

hicles however the battery is installed in engine compartment.

– Loosen pressure accumulator 1/2 turn using AF 24 open jaw

spanner (the hydraulic oil level in reservoir rises).

– Checking oil level: The oil level must be within the area of the

grid -arrow-; if necessary correct oil level ⇒ page 88 .

– If oil level is OK, tighten pressure accumulator to torque set‐

ting. Specified torque: 40 Nm

Note

When the battery is reconnected, check the vehicle equipment

(radio, clock, electric windows) as per workshop manual and/or

operating instructions.

– Tighten battery clamp on battery negative terminal to 5 Nm.

– Switch on ignition (hydraulic oil level in expansion tank drops).

– Carry out visual check of hydraulic system for leaks.

4. Descriptions of work:

87

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Maintenance - Edition 03.2018

4.34.2

Correcting oil level

Carry out following procedure:

Requirement

•

Vehicle standing on level ground

– Disconnect battery terminal clamp on battery negative termi‐

nal.

Note

♦ It is absolutely necessary to disconnect the battery, because

the hydraulic pump even starts running with ignition switched

off and hydraulic oil flows out of system.

♦ The battery is located in luggage compartment. On some ve‐

hicles however the battery is installed in engine compartment.

– Loosen pressure accumulator 1/2 turn using AF 24 open jaw

spanner (the hydraulic oil level in reservoir rises).

– Open reservoir filler cap.

– Replenish or extract oil: The oil level must be within the area

of the grid -arrow-.

Note

♦ If fluid level is above specified range, fluid must be extracted.

♦ If fluid level is below above-mentioned area, hydraulic system

must be checked for leaks (repair measure). It is not sufficient

just to fill fluid. If the hydraulic system is not leaking, replenish

central hydraulic oil - G004 000 M2- .

– Tighten pressure accumulator to torque. Specified torque: 40

Nm

– Tighten reservoir filler cap. Specified torque: 2 Nm

– Connect battery terminal clamp on battery negative terminal.

– Switch on ignition (hydraulic oil level in fluid reservoir drops).

– Now select a few gears.

The complete hydraulic system is now bled.

– Disconnect battery terminal clamp on battery negative termi‐

nal again.

88

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Loosen pressure accumulator 1/2 turn using AF 24 open jaw

spanner (the hydraulic oil level in reservoir rises).

– Checking oil level: The oil level must be within the area of the

grid -arrow-; if necessary correct oil level again.

Specified torques

Pressure accumulator to hydraulic unit 40 Nm

Reservoir cap 2 Nm

Note

When the battery is reconnected, check the vehicle equipment

(radio, clock, electric windows) as per workshop manual and/or

operating instructions.

– Tighten battery terminal clamp on battery negative terminal to

5 Nm.

– Switch on ignition (hydraulic oil level in expansion tank drops).

– Carry out visual check of hydraulic system for leaks.

4.35

Brake system: inspect for leaks and

damage.

Check following components for leaks and damage:

♦ Brake master cylinder

♦ Brake servo (for anti-lock brake system: hydraulic unit)

♦ Brake pressure regulator and

♦ Brake caliper

– Ensure that brake hoses are not twisted.

– Additionally ensure that brake hoses do not touch any vehicle

components when steering is at full lock.

– Check brake hoses are not porous or brittle.

– Check brake hoses and lines for chafing.

– Check brake connections and fastenings for correct seating,

leaks and corrosion.

WARNING

Faults found must always be rectified (repair measure).

4. Descriptions of work:

89

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Maintenance - Edition 03.2018

4.36

Front and rear brake pads/linings:

Check thickness

Special tools and workshop equipment required

♦ Pliers - 3314-

♦ Torque wrench - V.A.G 1332- (40-200 Nm)

♦ Electric hand torch

Carry out following procedure:

4.36.1

Front brake pads:

Note

♦ Experience has shown that brake pad wear due to roadside

debris is slightly more on passenger side than on driver side.

It is therefore better to remove the passenger-side front wheel

to determine the remaining pad thickness.

♦ The adapter to loosen and tighten the anti-theft wheel bolts

can be found in the vehicle tool kit. Please ask the customer

if the adapter is not available.

– For better evaluation of remaining pad thickness remove the

front wheel on the passenger side.

– Mark position of wheel relative to brake disc.

90

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– If necessary, pull off wheel bolt covers using pliers - 3314- .

– Unbolt wheel bolts and remove wheel.

– Measure thickness of inner and outer pads.

•

-a- Pad thickness without backplate

Wear dimension: 2 mm

The brake pads have reached their wear limit at a pad thickness

of 2 mm (without backplate) and must be renewed (repair meas‐

ure). Inform customer!

Note

When replacing brake pads, always check brake discs as well for

wear! Checking and if necessary replacing the brake discs is a

repair measure.

– Check brake disc for wear »Running gear; Brake system« ⇒

Running gear; Brake system; Rep. gr. 46 ; Repairing front

brakes »Repairing front brakes«

– Install wheel in marked position.

– Tighten wheel bolts diagonally and alternately to following

specified torque:

Specified torque: 110 Nm

– Reinstall wheel bolt covers if necessary.

4.36.2

Rear drum brake pads:

– Check brake pad thickness through inspection hole in brake

backplate -arrow- (using electric hand torch).

•

Wear limit: 2.5 mm (pad thickness only)

At a pad thickness of 2.5 mm the brake pads have reached their

wear limit and must be renewed (repair measure). Inform cus‐

tomer!

Note

Check pads for brake fluid or grease contamination.

4.36.3

Rear brake pads:

– Illuminate area behind hole in wheel using an electric hand

torch.

4. Descriptions of work:

91

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Maintenance - Edition 03.2018

– Inspect outer pad to determine thickness.

– Illuminate inner pad with an electric hand torch and mirror.

– Inspect inner pad to determine thickness.

•

-a- Inner and outer pad thickness without packing plate

Wear dimension: 2 mm

The brake pads have reached their wear limit at a pad thickness

of 2 mm (without backplate) and must be renewed (repair meas‐

ure). Inform customer!

Note

When replacing brake pads, always check brake discs as well for

wear! Checking and if necessary replacing the brake discs is a

repair measure.

– Check brake disc for wear »Running gear; Brake system« ⇒

Running gear; Brake system; Rep. gr. 46 ; Repairing rear

brakes »Repairing rear brakes«

4.37

Underbody protection: Carry out visual

check for damage

During inspection, also check floor pan, wheel housings and sills.

Note

Faults found must always be rectified (repair measure). This in‐

hibits corrosion and rusting through.

4.38

Track rod ends: checking clearance,

firm seating and boots

4.38.1

Engine codes AER, AFK, AHT, AHW,

AKU, AKQ, ALD, ALL, ANV, AMF, APE,

AQQ, ARR, AUA, AUB, AUC, AUD,

AVY, BBY

Carry out following procedure:

– With vehicle raised (wheels hanging free), check play by mov‐

ing track rods -arrow- and wheels. Clearance: zero clearance

– Check attachment.

– Check if boots are not damaged and are seated correctly.

4.38.2

Engine codes ANY, AYZ

Carry out following procedure:

92

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– With vehicle raised (wheels hanging free), check play by mov‐

ing track rods -arrow- and wheels. Clearance: zero clearance

– Check attachment.

– Check if boots are not damaged and are seated correctly.

4.39

Swivel joints: inspecting

4.39.1

Engine codes AER, AFK, AHT, AHW,

AKU, AKQ, ALD, ALL, ANV, AMF, APE,

AQQ, ARR, AUA, AUB, AUC, AUD,

AVY, BBY

Carry out following procedure:

– Check swivel joint boots -arrow- for leaks and damage.

4.39.2

Engine codes ANY, AYZ

Carry out following procedure:

– Check swivel joint boots -arrow- for leaks and damage.

4. Descriptions of work:

93

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.40

Checking breakdown set

Note

♦ Breakdown set is located in luggage compartment.

♦ The breakdown set contains also a tyre sealant bottle with

sealant.

4.40.1

Checking expiry date

– Check the expiry date and enter this in maintenance table.

The expiry date is printed on a sticker on the tyre sealant container

-arrow-.

– Renew tyre sealant if the expiry date has been reached. (The

tyre sealant must not be more than 4 years old.)

Note

♦ If the tyre sealant has already been used, it must be renewed.

♦ Observe environmental regulations for disposal.

4.41

Tyres (including spare wheel): Checking

condition and wear pattern

Note

For safety reasons, only tyres of same type and tread pattern

should be fitted on a vehicle!

4.41.1

Checking condition

Carry out following procedure:

Delivery inspection:

– Check tyre treads and side walls for damage and remove for‐

eign bodies such as, for example, nails or glass splinters.

Note

If damage is determined, always check to see if a new tyre should

be fitted.

Inspection service:

– Check tyre treads and side walls for damage and remove for‐

eign bodies such as, for example, nails or glass splinters.

– Check tyres for cupping, one-sided wear, porous side walls,

cuts and punctures.

Note

The customer must be informed of any faults found.

94

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.41.2

Wear pattern: checking

The wear pattern on the front tyres will indicate, for example, if

toe and camber settings should be checked:

♦ Feathering on tread indicates incorrect toe setting.

♦ One-sided tread wear is mainly attributed to incorrect camber.

When wear of this nature is noticed determine cause by carrying

out alignment checks (repair measure).

4.42

Tyre tread depth (including spare

wheel): Checking

– Check tyre tread depth.

Minimum tread depth: 1.6 mm

Note

♦ This figure may vary according to legislation in individual coun‐

tries.

♦ The minimum tread depth is reached when the tyres have

worn down level with the 1.6 mm high tread wear indicators

positioned at intervals around the tyre.

♦ If the tread depth is approaching the minimum allowed depth,

inform the customer.

4.43

Tyre pressure (including spare wheel):

Checking, correcting if necessary

Special tools and workshop equipment required

♦ Tyre inflator - VAS 5216-

Note

♦ The pressures in the table apply to cold tyres. Do not reduce

increased pressures of warm tyres.

♦ Important information on recommended winter tyres can be

found in ⇒ ElsaWin - “Technical information; Guidelines

Wheels, Tyres” .

♦ Tyre pressures for the relevant model can also be found on a

sticker attached to the inside of fuel tank flap.

Tyre pressure table for vehicles ►2000

(for all factory fitted tyre sizes)

4. Descriptions of work:

95

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Tyre pressures in bar

7) These vehicles are not fitted with a spare wheel.

Half load

Full load

Front

Rear

Front

Rear

Vehicles with petrol engine

37 kW

with tyres

155/70 R 13

175/65 R 13

185/55 R 14

2,1

1,9

2,3

2,1

2,8

2,6

44 kW

with tyres

155/70 R 13

175/65 R 13

185/55 R 14

2,2

2,0

2,1

1,9

2,5

2,2

2,8

2,6

55 kW

with tyres

175/65 R 13

185/55 R 14

2,1

1,9

2,4

2,6

74 kW

with tyres

185/55 R 14

195/55 R14

2,0

2,2

1,9

2,0

2,2

2,4

2,6

77 kW⁷⁾

with tyres

175/60 R 14

2,0

2,3

2,8

92 kW⁷⁾

with tyres

185/55 R 14

205/45 R15

2,2

2,0

2,6

3,0

Half load

Full load

Front

Rear

Front

Rear

Vehicles with diesel engine

44 kW

with tyres

175/65 R 13

185/55 R 14

2,0

2,2

1,9

2,0

2,2

2,4

2,6

45 kW⁷⁾

with tyres

155/65 R 14

2,3

2,1

2,4

2,8

55 kW

with tyres

185/55 R 14

195/55 R14

2,1

2,2

1,9

2,0

2,3

2,5

2,6

2,7

Temp. spare

4.2

standard wheel

Keep to the highest pressure required for the vehicle.

96

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Tyre pressure table for vehicles 2001►

Tyre pressures in bar

Half load

Full load

Front

Rear

Front

Rear

Vehicles with petrol engine

37 kW

with tyres

155/70 R 13

175/65 R 13

185/55 R 14

2,2

1,9

2,0

1,9

2,4

2,1

2,8

2,5

44 kW

with tyres

155/70 R 13

175/65 R 13

185/55 R 14

2,2

2,0

2,1

1,9

2,5

2,2

2,8

2,6

55 kW

with tyres

175/65 R 13

185/55 R 14

195/45 R 15

2,0

2,2

1,9

2,0

2,2

2,4

2,6

74 kW

with tyres

185/55 R 14

195/45 R15

2,0

2,2

2,1

2,0

2,2

2,4

2,6

77 kW⁷⁾

with tyres

175/60 R 14

2,0

2,3

2,8

92 kW⁷⁾

with tyres

185/55 R 14

205/45 R15

2,2

2,0

2,6

3,0

Half load

Full load

Front

Rear

Front

Rear

Vehicles with diesel engine

44 kW

with tyres

175/65 R 13

185/55 R 14

195/45 R 15

2,0

2,2

1,9

2,0

2,2

2,4

2,6

45 kW⁷⁾

with tyres

155/65 R 14

2,3

2,1

2,4

2,8

55 kW

with tyres

185/55 R 14

195/45 R 15

2,1

2,2

1,9

2,0

2,3

2,5

2,6

2,7

Temp. spare

4.2

standard wheel

Keep to the highest pressure required for the vehicle.

4. Descriptions of work:

97

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.44

Automatic gearbox: Checking ATF level,

filling ATF as required

Procedure: »Automatic gearbox« ⇒ Automatic gearbox; Rep. gr.

37 ; Checking ATF level and topping up »Checking ATF level and

topping up«

4.45

Brake and clutch system: Changing

brake fluid

Operation and safety notes

Note

♦ From model year 2006 a new brake fluid is used.

♦ The new brake fluid can also be used for older vehicles.

♦ For this purpose it can be mixed with the previous brake fluid.

WARNING

♦ Never allow brake fluid to come into contact with fluids that

contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐

eral oils damage the seals and boots in the brake system.

♦ Brake fluid is poisonous. In addition, due to its corrosive

nature, it must not come into contact with paint.

♦ Brake fluid is hygroscopic, which means it absorbs mois‐

ture from the ambient air and should therefore always be

stored in air-tight containers.

♦ Rinse off spilled brake fluid using plenty of water.

♦ Observe relevant disposal regulations.

♦ Do not reuse drained (used) brake fluid.

Brake fluid specification

♦ Brake fluid conforming to US standard FMVSS 116 DOT 4

(previous brake fluid)

♦ Brake fluid conforming to VW standard, VW 501 14 (new brake

fluid).

Procedure, changing brake fluid

Special tools and workshop equipment required

♦ Brake filling and bleeding equipment - VAS 5234-

98

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Brake filling and bleeding equipment - V.A.G 1869-

♦ Adapter - V.A.G 1869/1-

♦ Brake pedal actuator - V.A.G 1869/2-

♦ Extractor bottle

– Extract as much brake fluid as possible using suction hose

from brake filling and bleeding unit - VAS 5234- .

– Connect brake filling and bleeding unit to brake fluid reservoir

(do not switch on).

– Fit brake pedal actuator - V.A.G 1869/2- between driver seat

and brake pedal and pretension.

– Switch on brake filling and bleeding equipment .

Vehicles with manual gearbox

– Connect bleeder hose -A- on slave cylinder and open bleeder

valve.

– Allow approx. 0.1 litre of brake fluid to flow out.

– Open bleeder screws of respective brake calipers and allow

the corresponding brake fluid quantity to flow out (see follow‐

ing table). Used brake fluid is pushed out of the system by

pumping in new fluid.

Sequence:

Brake fluid quantity which must flow out of wheel brake cylinders or brake

calipers:

Wheel brake cylinders,

brake calipers

3

Rear right

Rear left

Front right

200-250 cm

3

4. Descriptions of work:

99

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Sequence:

Brake fluid quantity which must flow out of wheel brake cylinders or brake

calipers:

Wheel brake cylinders,

brake calipers

3

Front left

200-250 cm

Total quantity: approx. 1.1 litres

– Close bleeder screws after procedure.

– Switch off brake filling and bleeding unit.

– Take connection off brake fluid reservoir and remove brake

pedal depressor.

– Check pedal pressure and brake pedal free play. Free play:

1

max. / of pedal travel.

3

– Depress clutch pedal several times.

4.46

Brake fluid level (dependent upon brake

pad/lining wear): check.

♦ Instructions for use and safety ⇒ page 98

♦ Brake fluid specification ⇒ page 98

Please note the following:

Delivery inspection:

At delivery inspection the fluid level must be at MAX. marking.

Note

To prevent that brake fluid flows out of reservoir, the MAX marking

must not be exceeded.

Inspection service:

– The fluid level must always be judged in conjunction with lin‐

ing/pad wear. When vehicle is in use, fluid level tends to drop

slightly due to lining/pad wear and automatic adjustment.

– When fluid level is at MIN. marking or just above, fluid should

not be topped up if linings are almost at wear limit.

– If linings/pads are new or well within wear limit, then fluid level

must be between MIN. and MAX. markings.

– If fluid level is below MIN. marking, the brake system should

be checked before fluid is added. (repair measure).

4.47

Headlight adjustment: Checking, adjust‐

ing if necessary

Adjusting headlights with gas discharge bulbs ⇒ page 104 .

Special tools and workshop equipment required

100

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Headlight adjustment unit - VAS 5046-

♦ or:

♦ Headlight adjustment unit - VAS 5047-

The following test and adjustment instructions are applicable in

all countries. However, national guidelines and regulations of the

respective country are to be followed.

Conditions for testing and adjustment:

♦ Tyre pressures OK.

♦ Lenses must not be damaged or dirty

♦ Reflectors and bulbs OK.

♦ Vehicle must be loaded.

Loading: with one person or 75 kg on the driver seat and the ve‐

hicle otherwise unloaded (unladen weight).

The unladen weight is the weight of vehicle ready for operation

with a full fuel tank (at least 90 %) including weight of all equip‐

ment normally carried (e.g. spare wheel, tools, jack, fire extin‐

guisher etc.).

If the fuel tank is not at least 90 % full, then load as follows:

– Read off fuel level in fuel tank on fuel gauge -arrow-. Deter‐

mine additional weight from following table and place weight

in luggage compartment.

Fuel gauge table

Fuel

Additional weight

in kg

gauge

1/4

1/2

3/4

Full

20

15

5

0

Example:

4. Descriptions of work:

101

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

When the fuel tank is half full an additional weight of 15 kg must

be placed in the luggage compartment.

Note

The additional weight is best produced using fuel canisters filled

with water (a 5 litre fuel canister filled with water weighs approx.

5 kg).

The vehicle must be rolled forward or backward several metres

or front and rear springs must be bounced fully several times so

that springs settle.

♦ Vehicle and headlight adjuster must be on a level surface. ⇒

Headlight adjuster operating instructions.

♦ Vehicle and headlight adjuster must be aligned.

♦ Inclination must be set.

Inclination information in “%” is stamped into trim above headlight.

Headlights must be adjusted according to this information. Per‐

centage given is based on a projection distance of 10 metres.

Example: Converting a dip setting of e.g. 1.2 % is equivalent to

12 cm.

Note

♦ The main beam is only height-adjustable. The lateral adjust‐

ment is preset and must not be changed.

♦ If the vehicle is equipped with separate dipped and main

beam, adjust main beam additionally. When adjusting main

beam ensure that the adjustment unit is set to 0%.

♦ The headlight range control thumb wheel must be in position

(-).

4.47.1

Checking headlight adjustment (using

test screen without 15° setting line)

Headlights:

Please check the following:

– Whether, with the dipped beam switched on, the horizontal

light-dark border contacts the dividing line -1- of the test area

and

– Whether the breaking point -2- between the horizontal part of

the bright/dark boundary on the left and the rising part on the

right lies on the vertical line of the central point -3-. The bright

core of the light beam must be to the right of the vertical line.

102

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Note

♦ To simplify finding the breaking point -2-, cover and uncover

left (from driver perspective) half of the headlight a few times.

Then check dipped beam again.

♦ After correct adjustment of dipped beams, the centre point of

the main beam must lie on the centre mark -3-.

♦ The 15° setting line on the test screen must be ignored.

Fog lights:

– Check whether the upper bright/dark boundary touches the

setting line and runs horizontally over the entire width of the

test screen.

Other additional lights:

Additionally retrofitted lights of other systems must be checked

and set according to valid guidelines.

4.47.2

Adjusting headlights

Left headlight

•

-1- Lateral adjustment

-2- Height adjustment

Both adjustment screws on right-hand headlight are a mirror im‐

age.

– Adjust headlight at front using a suitable cross head screw‐

driver.

Note

Please check also that both headlights move evenly when head‐

light range control is operated.

Left fog light:

Engine codes ANY, AYZ

4. Descriptions of work:

103

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– To adjust the fog light, unclip cover -arrow- in lower part of

bumper.

Continued for all vehicles:

– To reduce the beam range turn adjustment screw -arrow- to

the right. There is no provision for lateral adjustment.

Location of adjustment screw on right-hand headlight is a mirror

image.

4.47.3

Headlights with gas discharge bulbs:

adjusting

The following test and adjustment instructions are applicable in

all countries. However, national guidelines and regulations of the

respective country are to be followed.

The following are prerequisites for adjusting headlights gas dis‐

charge bulbs:

•

Tyre pressures OK.

Lenses must not be damaged or dirty

Reflectors and bulbs OK.

Handbrake must be released and no gear selected.

The steering wheel must be in straight-ahead position.

The vehicle must not be moved during the basic settings (do

not “open or close” doors or lean on or enter vehicle).

•

Nobody may be in the vehicle and the vehicle must not be

loaded.

The vehicle must be rolled forward or backward several me‐

tres or front and rear springs must be bounced fully several

times so that springs settle.

•

Vehicle and headlight adjuster must be on a level surface. ⇒

Headlight adjuster operating instructions.

•

Vehicle and headlight adjuster must be aligned.

Inclination must be set.

Inclination information in “%” is stamped into trim above headlight.

Headlights must be adjusted according to this information. Per‐

centage given is based on a projection distance of 10 metres.

Example: Converting a dip setting of e.g. 1.2 % is equivalent to

12 cm.

104

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Headlights

Note

Vehicles with gas discharge bulbs are equipped with automatic

headlight range control. On these vehicles, the procedure “Basic

setting” for adjusting headlights must be carried out.

Because the automatic headlight range control does not have a

manual adjustment, the basic setting procedure must be per‐

formed to adjust the headlights.

After the headlights have been adjusted, the fault memory must

be read. Therefore, the procedure described here must be strictly

followed.

4.47.4

Carrying out basic setting using vehicle

diagnosis, testing and information sys‐

tem - VAS 5051- or vehicle diagnosis

and service information system - VAS

5052-

Special tools and workshop equipment required

♦ Vehicle diagnostic, testing and information system - VAS

5051-

♦ Diagnostic cable - VAS 5051/6A-

4. Descriptions of work:

105

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Vehicle diagnostic and service information system - VAS

5052-

♦ Diagnostic cable, 2 m - VAS 5052/3 A-

♦ Headlight adjustment unit - VAS 5046-

♦ or

♦ Headlight adjustment unit - VAS 5047-

Carry out following procedure:

Connect vehicle diagnosis, testing and information system - VAS

5051- or vehicle diagnosis and service information system - VAS

5052- .

– Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral.

Connect vehicle diagnostic, testing and information system - VAS

5051- or vehicle diagnostic and service information system - VAS

5052- with ignition switched off as follows:

– Pull ashtray insert out of centre console.

– Connect vehicle diagnostic, testing and information system -

VAS 5051- or vehicle diagnostic and service information sys‐

tem - VAS 5052- using diagnostic cable - VAS 5051/6A- with

ignition switched off.

106

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Switch on ignition.

Indicated on display:

Select operating mode:

– Press button for Vehicle self-diagnosis on display

-arrow-.

Note

If the display is not as shown in the procedure: ⇒ Operating in‐

structions for vehicle diagnosis, testing and information system -

VAS 5051- or ⇒ Operating instructions for vehicle diagnosis and

service information system - VAS 5052- .

Indicated on display:

– Press “55 - Headlight range control” on display -arrow-.

Indicated on display:

The control unit identification and coding are displayed -arrow-.

Indicated on display:

– Press “04 - Initiate basic setting” on display -arrow-.

4. Descriptions of work:

107

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press 001 in number block of display -arrow- (001 selects

“display group number 001”).

– Confirm entry with Q button on display number block.

After “Wait” is indicated on display, the following message ap‐

pears:

Indicated on display:

– Now adjust headlights ⇒ page 110 .

– After adjusting headlights, press ← -arrow- on display.

Indicated on display:

– Press 002 in number block of display -arrow- (002 selects

“display group number 002”).

– Confirm entry with Q button on display number block.

Indicated on display:

The reference position of the headlight will now be “learnt” by the

control unit.

– Press ← -arrow- on display.

108

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press ← -arrow- on display.

Indicated on display:

– Press “02 - Read fault memory” on display -arrow-.

Indicated on display:

Any system faults that are stored will be displayed one after the

other.

If faults are stored, repairs are necessary. The fault log must ac‐

company vehicle to repair.

– Press ← -arrow- on display.

Indicated on display:

– Press GoTo button on display -arrow-.

4. Descriptions of work:

109

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press the End button on display -arrow-.

– Press End button in End menu.

– Switch off ignition and separate diagnosis connections.

– Install ashtray insert.

4.47.5

Adjusting headlights

Headlight adjustment: checking

Headlights:

Please check the following:

– Whether, with the dipped beam switched on, the horizontal

light-dark border contacts the dividing line -1- of the test area

and

– Whether the breaking point -2- between the horizontal part of

the bright/dark boundary on the left and the rising part on the

right lies on the vertical line of the central point -3-. The bright

core of the light beam must be to the right of the vertical line.

Note

♦ To simplify finding the breaking point -2-, cover and uncover

left (from driver perspective) half of the headlight a few times.

Then check dipped beam again.

♦ After correct adjustment of dipped beams, the centre point of

the main beam must lie on the centre mark -3-.

Left headlight

•

-1- Lateral adjustment

-2- Height adjustment

Both adjustment screws on right-hand headlight are a mirror im‐

age.

– Adjust headlight at front using a suitable cross head screw‐

driver.

110

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.47.6

Adjusting main beam

Headlight adjustment: checking

– Check whether the upper bright/dark boundary touches the

setting line and runs horizontally over the entire width of the

test screen.

Main beam (right):

•

-1- Lateral adjustment

-2- Height adjustment

Both adjustment screws on the left-hand headlight are a mirror

image.

– Adjust headlights using a 6 mm socket.

Other additional lights:

Additionally retrofitted lights of other systems must be checked

and set according to valid guidelines.

4.48

Carry out road test

Which of the following can be checked depends on vehicle equip‐

ment and local conditions (urban/country).

– Check the following during a road test:

♦ Engine: output, misfiring, idling speed, acceleration

♦ Clutch: pulling away, pedal pressure, odours

♦ Gear selection: ease of operation, stick position

♦ Automatic gearbox: Selector lever position, shift lock / ignition

key removal lock, shift behaviour

♦ Dual clutch gearbox: Selector lever position, shift lock / ignition

key removal lock, shift behaviour

♦ Foot brake and handbrake: function, free travel and effective‐

ness, pulling to one side, juddering, squeal

♦ Steering: function, steering free clearance, steering wheel

centred when vehicle is travelling straight ahead

♦ Tilting roof: function

♦ Folding fabric sunroof: function

♦ Radio: Reception, GALA, interference

♦ Multi-function indicator (MFI): functions

♦ Air conditioning system: function

♦ Vehicle: pulling to one side when travelling straight-ahead

(level road)

♦ Imbalance: Wheels, drive shafts

4. Descriptions of work:

111

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Wheel bearings: noises

♦ Engine: hot starting behaviour

112

4. Descriptions of work:

Descriptions of work for Your Volkswagen Lupo 2 Door First Generation (1998-2005)

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