1998-2005 Volkswagen Lupo 2 Door Service work User Manual
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Service work for Your Volkswagen Lupo 2 Door First Generation (1998-2005)

Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
2
Service work  
This chapter provides information on the following subjects:  
♦ Service tables ⇒ page 6  
♦ Oil change service ⇒ page 7  
♦ Inspection every 12 months ⇒ page 8  
♦ Inspection every 30,000 km ⇒ page 11  
♦ Additional work based on time or distance ⇒ page 13  
♦ Delivery inspection ⇒ page 15  
2.1  
Service tables  
VW engine oil standards ⇒ page 6  
Filter change intervals ⇒ page 6  
Toothed belt change intervals ⇒ page 7  
Service intervals ⇒ page 7  
2.1.1  
VW engine oil standards  
LUPO  
VW ENGINE OIL STANDARDS  
PETROL ENGINES  
4-cylinder engines incl. FSI  
VW 502 00,  
1
VW 504 00 or VW 501 01  
DIESEL ENGINES  
Diesel engines without unit injector  
VW 505 00,  
1
VW 507 00 or VW 505 01  
1
Diesel engines with unit injector  
VW 505 01, VW 507 00  
1
Lupo 3L TDI with engine codes ANY and AYZ  
VW 50600, VW 50601 or VW 507 00  
1
Combination product: VW 504 00/507 00  
2.1.2  
FILTER CHANGE INTERVALS  
LUPO  
FILTER CHANGE INTERVALS  
ENGINE OIL FILTER  
AIR FILTER  
All engine types  
Every 15,000 km or 1 year  
All engine types except engine codes  
Every 60,000 km or 4 years  
Every 60,000 km or 6 years  
AKU, AMF, ANY, ARR and AYZ  
Engine codes AKU, AMF, ANY, APR  
and AYZ  
FUEL FILTER  
All diesel engines  
Diesel Diesel not  
conforming to EN conforming to EN  
590 590  
Diesel conforming to  
EN 14214 (FAME)  
Chang‐ Drain wa‐ Chang‐ Drain wa‐ Changing Drain water  
ing ter ing ter  
6
2. Service work  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
LUPO  
FILTER CHANGE INTERVALS  
Every  
60,000  
km  
Every  
30,000  
km  
Every  
30,000  
km  
Every  
15,000  
km  
Every  
Every  
30,000 15,000 km  
km  
DUST AND POLLEN FILTER  
All engine types  
Every 30,000 km or 2 years  
2.1.3  
TOOTHED BELT CHANGE INTERVALS  
LUPO  
TOOTHED BELT CHANGE INTERVALS  
Change intervals  
Tensioning roller  
DIESEL ENGINES  
Engine code AKU ►2000  
Engine code AKU 2001►  
Every 60,000 km  
Every 90,000 km  
Every 60,000 km  
---  
---  
Engine codes AMF, ANY,  
Every 60,000 km  
AYZ ►2000  
Engine codes AMF, ANY,  
AYZ 2001►  
Engine code AMF 2004►  
Every 90,000 km  
Every 120,000 km  
Every 90,000 km  
Every 240,000 km  
2.1.4  
SERVICE INTERVALS  
LUPO  
SERVICE INTERVALS  
Since introduction Diesel, in countries where the sulphur content Oil change service  
in fuel is high  
every 7,500 km or 1 year  
Since introduction For all vehicles  
Oil change service  
every 15,000 km  
Since introduction For all vehicles  
Since introduction For all vehicles  
Inspection  
every 12 months  
Inspection  
every 30,000 km  
2.2  
Oil change service  
Note  
Inform the customer if faults are found during service and repair  
measures are necessary.  
2. Service work  
7
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
Caution  
♦ If RME fuel (biodiesel) is used, always note the information  
on RME fuel (biodiesel) ⇒ page 22 .  
♦ When using RME (biodiesel) according to “EN 14214”, the  
fuel filter must be renewed every 15,000 km.  
Caution  
♦ In countries where diesel has a high sulphur content,  
change oil every 7,500 km. Affected countries with a high  
sulphur content ⇒ page 21 .  
– Ask the customer if he requires:  
•
•
New wiper blades  
Replenish Windscreen Clear G 052 164 (cleanser and anti-  
freeze).  
– Check if storage life date of first aid box has been exceeded  
and if warning triangle is fitted.  
– Removing and installing engine compartment cover -bottom-  
(noise insulation) ⇒ page 25  
The sequence of the individual service tasks has been tested and  
optimised. Therefore, it should be followed to avoid unnecessary  
interruptions in the work.  
Vehicles driving more than 15,000 km per year:  
– Toothed belt: Check for wear  
Page  
⇒ page 76  
•
Only valid for vehicles with TDI/SDI engines ►2000 with engine codes AKU,  
AMF and ANY  
– Fuel filter: Drain water  
⇒ page 75  
•
•
Only valid for vehicles with diesel engines and distributor injection pump  
Only valid for vehicles with diesel engines and distributor injection pump using  
biodiesel according to EN 14214  
•
Only valid for vehicles using diesel not conforming to EN 590  
– Engine oil: Drain or extract, renew oil filter  
– Front disc brake pads: check thickness.  
– Engine oil: Replenish  
⇒ page 79  
⇒ page 90  
⇒ page 79  
⇒ page 43  
⇒ page 19  
– Service interval display: reset.  
– Enter date of next service on sticker and attach sticker to driver side door pillar  
(B-pillar).  
2.3  
Inspection service every 12 months  
Note  
Inform the customer if faults are found during service and repair  
measures are necessary.  
8
2. Service work  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
Caution  
♦ If RME fuel (biodiesel) is used, always note the information  
on RME fuel (biodiesel) ⇒ page 22 .  
♦ When using RME (biodiesel) according to “EN 14214”, the  
fuel filter must be renewed every 15,000 km.  
Caution  
♦ In countries where diesel has a high sulphur content,  
change oil every 7,500 km. Affected countries with a high  
sulphur content ⇒ page 21 .  
– Ask the customer if he requires:  
•
•
New wiper blades  
Replenish Windscreen Clear G 052 164 (cleanser and anti-  
freeze).  
– Check if storage life date of first aid box has been exceeded  
and if warning triangle is fitted.  
– Removing and installing engine compartment cover -bottom-  
(noise insulation) ⇒ page 25  
The sequence of the individual service tasks has been tested and  
optimised. Therefore, it should be followed to avoid unnecessary  
interruptions in the work.  
Work to be completed for inspection service every 12 months  
Electrics  
Page  
– Front and tail lights, turn signals, hazard warning lights: Check function  
– Interior light, cigarette lighter, sockets, warning lamps and horn: Check  
function  
– Driver's and passenger airbag: Visual check of airbag units for external  
damage  
⇒ page 33  
– Vehicle system test: Carry out test  
⇒ page 40  
⇒ page 43  
1
–
Automated manual gearbox (DSG): Carry out basic setting  
– Service interval display: reset.  
⇒ page 43  
1
Only valid for vehicles type “6E” with gearbox type 085  
Vehicle exterior  
Page  
– Window wash/wipe system and headlight washer system: Check function  
and settings  
⇒ page 34  
– Wiper blades: Check for damage; check park position, adjust if necessary;  
⇒ page 38  
⇒ page 55  
only if wiper blades “judder”: Check setting angle, adjust if necessary  
•
Do not adjust setting angle on aero wipers  
– Door arrester: grease.  
Tyres  
Page  
1
–
⇒ page 94  
Tyres (including spare wheel) : Check condition and wear pattern  
2. Service work  
9
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
Tyres  
Page  
1
–
–
⇒ page 95  
⇒ page 95  
⇒ page 94  
Tyre tread depth (including spare) : Check and enter  
1
Tyre pressures (including spare) : Check, correct if necessary  
– Check expiry date of tyre sealant in breakdown set (if fitted), renew if  
necessary  
1
Vehicles type “6E” are not fitted with spare wheel  
Underside of vehicle  
Page  
– Engine oil: Drain or extract; renew oil filter  
⇒ page 79  
⇒ page 56  
– Engine and components in engine compartment: inspect for leaks and  
damage (from below).  
– Gearbox, final drive and drive shaft boots: inspect for leaks and damage.  
– Brake system: inspect for leaks and damage.  
– Front and rear brake pads/linings: Check thickness  
⇒ page 83  
⇒ page 89  
⇒ page 90  
– Exhaust system: inspect for leaks, firm seating and damage.  
– Track rod ends: checking clearance, firm seating and boots  
– Swivel joints: Visual check of swivel joint boots for leaks and damage  
– Automated manual gearbox (DSG): Check gear selector boots (on gear‐  
⇒ page 92  
⇒ page 93  
1
box) for leaks and damage  
1
Only valid for vehicles type “6E” with gearbox type 085  
Engine compartment  
– Engine oil: Replenish  
– Battery: Check  
Page  
⇒ page 79  
⇒ page 28  
⇒ page 56  
– Engine and components in engine compartment: visual check for leaks  
and damage (from above)  
– Window wiper and washer system: Fill with Windscreen Clear - G 052  
164-  
⇒ page 34  
⇒ page 57  
⇒ page 76  
– Cooling system: Check coolant level and frost protection, add coolant if  
necessary  
– Camshaft drive toothed belt: check condition  
•
Only valid for vehicles with TDI/SDI engines ►2000 with engine codes  
AKU, AMF and ANY  
– Fuel filter: drain water  
Only valid for vehicles with diesel engine and distributor injection pump  
⇒ page 75  
•
– Brake fluid level (dependent upon brake pad/lining wear): check.  
⇒ page 100  
Documentation/final checks  
Page  
– “Your next service” sticker: Enter next due date and attach sticker to driver  
side door pillar (B-pillar)  
⇒ page 19  
– Carry out road test  
⇒ page 111  
10  
2. Service work  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
2.4  
Inspection service every 30,000 km  
Note  
Inform the customer if faults are found during service and repair  
measures are necessary.  
Caution  
♦ If RME fuel (biodiesel) is used, always note the information  
on RME fuel (biodiesel) ⇒ page 22 .  
♦ When using RME (biodiesel) according to “EN 14214”, the  
fuel filter must be renewed every 15,000 km.  
Caution  
♦ In countries where diesel has a high sulphur content,  
change oil every 7,500 km. Affected countries with a high  
sulphur content ⇒ page 21 .  
– Ask the customer if he requires:  
•
•
New wiper blades  
Replenish Windscreen Clear G 052 164 (cleanser and anti-  
freeze).  
– Check if storage life date of first aid box has been exceeded  
and if warning triangle is fitted.  
– Removing and installing engine compartment cover -bottom-  
(noise insulation) ⇒ page 25  
The sequence of the individual service tasks has been tested and  
optimised. Therefore, it should be followed to avoid unnecessary  
interruptions in the work.  
Scope of work in conjunction with inspection every 30,000 km  
Electrics  
Page  
– Front and tail lights, turn signals, hazard warning lights: Check function  
– Interior light, cigarette lighter, sockets, warning lamps and horn: Check  
function  
– Driver's and passenger airbag: Visual check of airbag units for external  
damage  
⇒ page 33  
– Carry out vehicle system test  
⇒ page 40  
⇒ page 43  
1
–
Automated manual gearbox (DSG): Carry out basic setting  
– Service interval display: Reset  
⇒ page 43  
1
Only valid for vehicles type “6E” with gearbox type 085  
Vehicle exterior  
Page  
– Window wash/wipe system and headlight washer system: Check function  
and settings  
⇒ page 34  
2. Service work  
11  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
Vehicle exterior  
Page  
– Wiper blades: Check for damage; check park position, adjust if necessary;  
only if wiper blades “judder”: Check setting angle, adjust if necessary  
⇒ page 38  
•
Do not adjust setting angle on aero wipers  
– Door arrester: grease.  
⇒ page 55  
⇒ page 55  
– Sunroof: Check function, clean guide rails and lubricate with special grease  
- G 000 450 02-  
– Folding fabric sunroof: Lubricate guide rails  
⇒ page 56  
Tyres  
Page  
1
–
–
–
⇒ page 94  
⇒ page 95  
⇒ page 95  
⇒ page 94  
Tyres (including spare wheel) : Check condition and wear pattern  
1
Tyre tread depth (including spare) : Check and enter  
1
Tyre pressures (including spare) : Check, correct if necessary  
– Check expiry date of tyre sealant in breakdown set (if fitted), renew if nec‐  
essary  
1
Vehicles type “6E” are not fitted with spare wheel  
Underside of vehicle  
Page  
– Engine oil: Drain or extract; renew oil filter  
⇒ page 79  
⇒ page 56  
– Engine and components in engine compartment: inspect for leaks and  
damage (from below).  
– Gearbox, final drive and drive shaft boots: inspect for leaks and damage.  
– Brake system: inspect for leaks and damage.  
– Front and rear brake pads/linings: Check thickness  
– Underbody protection: Carry out visual check for damage  
– Exhaust system: inspect for leaks, firm seating and damage.  
– Track rod ends: checking clearance, firm seating and boots  
– Swivel joints: Visual check of swivel joint boots for leaks and damage  
⇒ page 83  
⇒ page 89  
⇒ page 90  
⇒ page 92  
⇒ page 92  
⇒ page 93  
⇒ page 83  
– Manual gearbox/final drive: checking oil level  
1
–
Automated manual gearbox (DSG) : Check gear selector boots (on gear‐  
box) for leaks and damage  
1
Only valid for vehicles type “6E” with gearbox type 085  
Engine compartment  
– Engine oil: Replenish  
– Battery: Check  
Page  
⇒ page 79  
⇒ page 28  
⇒ page 56  
– Engine and components in engine compartment: visual check for leaks and  
damage (from above)  
– Window wiper and washer system: Fill with Windscreen Clear - G 052 164-  
– Cooling system: Check coolant level and frost protection  
– Fuel filter: drain water  
⇒ page 34  
⇒ page 57  
⇒ page 75  
•
Only valid for vehicles with diesel engine and distributor injection pump  
12  
2. Service work  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
Engine compartment  
Page  
– Camshaft drive toothed belt: Check condition  
⇒ page 76  
•
Only valid for vehicles with TDI/SDI engines ►2000 with engine codes AKU,  
AMF and ANY  
– Brake fluid level (dependent upon brake pad/lining wear): check.  
⇒ page 100  
Documentation/final checks  
Page  
– Headlight adjustment: checking  
⇒ page 100  
⇒ page 19  
– “Your next service” sticker: Enter next due date and attach sticker to driver  
side door pillar (B-pillar)  
– Carry out road test  
⇒ page 111  
2.5  
Additional work based on time or distance  
Every 30,000 km  
Additional work  
Page  
– Dust and pollen filter: renew filter element  
⇒ page 75  
•
Only valid for vehicles driving more than 30,000 km in 2 years  
– Fuel filter: Renew  
⇒ page 72  
•
•
Only valid for vehicles with diesel engine using biodiesel according to EN  
14214  
Only valid for vehicles using diesel not conforming to EN 590  
Every 60,000 km  
Additional work  
Page  
– Fuel filter: Renew  
⇒ page 72  
•
Only valid for vehicles using diesel not conforming to EN 590  
– Air filter: Clean housing and renew filter element  
– Poly V-belt: Check condition  
– Spark plugs: Renew  
⇒ page 59  
⇒ page 83  
⇒ page 65  
⇒ page 71  
– Power assisted steering: Check fluid level  
•
Not valid for Lupo 3L and FSI  
– Toothed belt: Renew  
⇒ page 79  
⇒ page 79  
•
•
Only valid for vehicles with diesel engine and engine code AKU ►2000  
Additional work as a separate charge!  
– Camshaft drive toothed belt: renew.  
•
Only valid for vehicles with diesel engine and engine codes AMF, ANY and  
AYZ ►2000  
•
Additional work as a separate charge!  
2. Service work  
13  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
Additional work  
– Camshaft drive toothed belt tensioning roller: Renew  
Page  
⇒ page 79  
•
Only valid for vehicles with diesel engine and engine codes AMF, ANY and  
AYZ ►2000  
•
Additional work as a separate charge!  
– Automatic gearbox: Check ATF level  
⇒ page 98  
⇒ page 86  
1
–
Automated manual gearbox (DSG) : Check oil level  
1
Only valid for vehicles type “6E” with gearbox type 085  
Every 90,000 km  
Additional work  
Page  
– Toothed belt: Renew  
⇒ page 79  
•
•
Only valid for vehicles with diesel engine and engine code AKU 2001►  
Additional work as a separate charge!  
– Camshaft drive toothed belt: renew.  
⇒ page 79  
⇒ page 79  
•
Only valid for vehicles with diesel engine and engine codes AMF, ANY or  
AYZ 2001►  
•
Additional work as a separate charge!  
– Camshaft drive toothed belt tensioning roller: Renew  
•
Only valid for vehicles with diesel engine and engine codes AMF, ANY or  
AYZ 2001►  
•
Additional work as a separate charge!  
At 90,000 km then every 30,000 km  
Additional work  
Page  
– Camshaft drive toothed belt: check.  
⇒ page 78  
•
Only valid for 4-cylinder petrol engines without prescribed change interval  
Every 120,000 km  
Additional work  
Page  
– Camshaft drive toothed belt: renew.  
⇒ page 79  
•
•
Only valid for vehicles with engine code AMF 2004►  
Additional work as a separate charge!  
14  
2. Service work  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
Every 240,000 km  
Additional work  
Page  
– Camshaft drive toothed belt tensioning roller: Renew  
⇒ page 79  
•
Only valid for vehicles with diesel engine and engine codes AMF, ANY or  
AYZ  
•
•
Valid for vehicles with engine code AMF 2004►  
Additional work as a separate charge!  
Every 2 years  
Additional work  
Page  
– Brake and clutch system: change brake fluid.  
⇒ page 98  
•
Additional work as a separate charge!  
– Dust and pollen filter: renew filter element  
Only valid for vehicles driving less than 30,000 km in 2 years  
⇒ page 75  
•
3 years after initial registration and then every 2 years/applicable  
for Germany only  
Additional work  
Page  
– Carry out exhaust emissions test  
⇒ page 113  
•
Additional work as a separate charge!  
Every 4 years  
Additional work  
Page  
– Air filter: Clean housing and renew filter element  
⇒ page 59  
•
Valid for all engines except engine codes AKU, AMF, ANY, ARR and AYZ  
– Spark plugs: Renew  
⇒ page 65  
Every 6 years  
Additional work  
Page  
– Air filter: Clean housing and renew filter element  
⇒ page 59  
•
Only valid for engines with engine codes AKU, AMF, ANY, ARR and AYZ  
2.6  
Delivery inspection  
Notes on performing service work  
♦ The sequence of the individual service tasks has been tested  
and optimised. Therefore, it should be followed to avoid un‐  
necessary interruptions in the work.  
2. Service work  
15  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
♦ For stock vehicles and vehicles in storage perform measures  
according to ⇒ ElsaWin - “Maintenance tables” !  
Scope of work  
Page  
– Battery: Check battery terminals by hand for tightness  
– Battery: Check  
⇒ page 26  
⇒ page 28  
– Fuse(s) (in ashtray): Fit  
– Wheel bolts: tightening to specified torque  
⇒ page 28  
– Fit all equipment which has been packed inside vehicle (if part  
of original equipment): Mats, wiper arms, spoilers, roof aerial,  
wheel trims/hub caps, tyre valve extensions  
– All switches, electrical consumers, sockets, gauges and other  
controls: Check function  
– Clock: setting to correct time  
– Service interval display: Reset  
⇒ page 29  
⇒ page 43  
⇒ page 30  
– Radio: Activate anti-theft coding, store local radio stations to sta‐  
tion buttons  
– Windscreen wipe/wash system and headlight washer system:  
Check function and spray jet settings; replenish with Windscreen  
Clear - G 052 164- to maximum  
⇒ page 34  
– Engine oil level: checking  
⇒ page 32  
⇒ page 56  
– Engine and components in engine compartment: visual check for  
leaks and damage (from above)  
– Coolant level: Check it is at maximum  
– Power assisted steering: Check fluid level  
– Brake fluid level: Check level is at maximum  
⇒ page 57  
⇒ page 71  
⇒ page 100  
⇒ page 31  
– Transportation devices: removing blocking pieces from springs  
on front axle  
– Vehicle from below (without removing engine cover for noise in‐  
sulation): inspect engine and components in engine compart‐  
ment, protective bellows, brake system, steering, axles, gearbox,  
final drive, hoses and fluid reservoirs for leaks and damage  
⇒ page 56  
– Vehicle underside (floor pan): Visual check for damage  
⇒ page 92  
– Edge protection on doors (plastic film): remove.  
1
–
⇒ page 94  
⇒ page 95  
Tyres (including spare) : Check  
1
–
Tyre pressures (including spare) : Check, correct if necessary  
– Check vehicle interior for cleanliness: Front and rear seats, in‐  
terior trim, carpets/mats, windows  
– Check vehicle exterior for cleanliness: Paintwork, decorative  
parts, windows, wiper blades  
– Seat and carpet protective coverings: remove.  
– “Your first service” sticker: Apply sticker on door pillar (B-pillar);  
the sticker can be found on an instruction attached at front of  
vehicle wallet. Destroy the instruction after attaching the sticker!  
⇒ page 18  
– Service schedule: enter delivery inspection.  
– Owner's literature: check that literature is complete and prepare  
for delivery to customer.  
– Carry out road test  
⇒ page 111  
1
Vehicles type “6E” are not fitted with spare wheel  
16  
2. Service work  

Related Topics

Service tables Oil change service Inspection service every 12 months Inspection service every 30,000 km Additional work based on time or distance Delivery inspection

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