Volkswagen Lupo 1999 Maintenance Manual
  1. Manuals
  2. Brands
  3. Volkswagen Manuals
  4. Automobile
  5. Lupo 1999
  6. Maintenance manual
Volkswagen Lupo 1999 Maintenance Manual

Volkswagen Lupo 1999 Maintenance Manual

Hide thumbs Also See for Lupo 1999:
Table of Contents

Advertisement

Quick Links

Download this manual
Service
Maintenance
Lupo 1999 ➤
Lupo 3L 1999 ➤
Edition 03.2018
Service Department. Technical Information

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Lupo 1999 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Volkswagen Lupo 1999

Summary of Contents for Volkswagen Lupo 1999

  • Page 1 Service Maintenance Lupo 1999 ➤ Lupo 3L 1999 ➤ Edition 03.2018 Service Department. Technical Information...

  • Page 2: Maintenance

    Service Maintenance H e a d i n g 1. Engine list 2. Service work 3. General information 4. Descriptions of work: 5. Exhaust emissions test 6. Glossary Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety.

  • Page 3: Table Of Contents

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Contents Engine list ............. .
  • Page 4 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 4.33 Manual gearbox/final drive: Checking oil level, filling oil as required ....

  • Page 5: Engine List

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Engine list (VIGG001136; Edition 03.2018) 1) Under exceptional circumstances unleaded, at least 91 RON permitted, but with reduced output. 2) In exceptional circumstances at least 95 RON, but with reduced output 3) Only for vehicles with gearbox code letters for the Japanese market 4) Only for vehicles with gearbox codes EHE and FMC (►2001)
  • Page 6 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Engines → Petrol engine Petrol engine Petrol engine Displace‐ ment Engine code Exhaust gas recirculation Turbocharged Engines → Petrol engine Petrol engine Petrol engine Displacement Engine code No. of cylinders/valves per cylinder...
  • Page 7 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Engines → Petrol engine Petrol engine Petrol engine 6E Displace‐ ment Engine code ARR (FSI) Turbocharged Engines → Petrol engine Petrol engine Petrol engine Displace‐ ment Engine code No.
  • Page 8 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Engines → Petrol engine 6E Petrol engine Displace‐ ment Engine code AVY (GTI) Lambda control Exhaust gas recirculation Turbocharged Engines → Diesel engine Diesel engine Diesel engine 6E...
  • Page 9 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Engines → Diesel engine 6E Displacement Engine code AYZ (3L) Turbocharged 1. Engine list...

  • Page 10: Service Work

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Service work This chapter provides information on the following subjects: ♦ Service tables ⇒ page 6 ♦ Oil change service ⇒ page 7 ♦ Inspection every 12 months ⇒...

  • Page 11: Service Intervals

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 LUPO FILTER CHANGE INTERVALS Every Every Every Every Every Every 60,000 30,000 30,000 15,000 30,000 15,000 km DUST AND POLLEN FILTER All engine types Every 30,000 km or 2 years 2.1.3...

  • Page 12: Inspection Service Every 12 Months

    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.
  • Page 13 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.
  • Page 14 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Tyres Page – Tyre tread depth (including spare) ⇒ page 95 : Check and enter – Tyre pressures (including spare) ⇒ page 95 : Check, correct if necessary –...

  • Page 15: Inspection Service Every 30,000 Km

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 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 16 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Vehicle exterior Page – Wiper blades: Check for damage; check park position, adjust if necessary; ⇒ page 38 only if wiper blades “judder”: Check setting angle, adjust if necessary •...

  • Page 17: Additional Work Based On Time Or Distance

    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 –...
  • Page 18 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Additional work Page – Camshaft drive toothed belt tensioning roller: Renew ⇒ page 79 • Only valid for vehicles with diesel engine and engine codes AMF, ANY and AYZ ►2000...

  • Page 19: Delivery Inspection

    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 •...
  • Page 20 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 ⇒...

  • Page 21: General Information

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 General information This chapter provides information on the following subjects: ♦ Raising vehicle with lifting platform and trolley jack ⇒ page 17 ♦ Service sticker ⇒ page 18 ♦...

  • Page 22: Service Sticker

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Position support plate on vertical reinforcement of side member at area marked -arrow-. Note Ensure that the side member reinforcement -arrow- seats cen‐ trally on support plate of hoist mounting and the side member is not damaged.

  • Page 23: Connecting Vehicle Diagnostic Tester

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 3.2.2 Attaching “Your next service” sticker – “Your next service” sticker: Enter a cross in position for next oil change service or inspection service (next service due) and enter date and mileage –...
  • Page 24 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‐...

  • Page 25: Vehicle Identification Number

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – 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.

  • Page 26: Engine Code And Engine Number

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Armenia Yugoslavia Moldova Surinam Bahrain Cambodia Mozambique Tajikistan Bangladesh Kazakhstan Myanmar Tanzania Chile Kenya New Caledonia Turkey Dominican Republic Columbia Nigeria Ukraine El Salvador Cuba Oman Uruguay Ecuador...

  • Page 27: Type Plate

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 ♦ At ambient temperatures below -10°C we recommend using winter diesel fuel. Note When using biodiesel observe the changed intervals for drain‐ ♦ ing and changing the fuel filter .

  • Page 28: Descriptions Of Work

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Descriptions of work: ♦ Removing and installing engine compartment cover (noise in‐ sulation) ⇒ page 25 ♦ Battery: checking battery terminal clamps for secure seating ⇒ page 26 ♦...

  • Page 29: Removing And Installing Engine Compartment Cover (Noise Insulation)

    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 ♦...

  • Page 30: Battery: Checking Battery Terminal Clamps For Secure Seating

    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.
  • Page 31 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.

  • Page 32: Battery: Check

    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.

  • Page 33: Clock: Setting To Correct Time

    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.

  • Page 34: Radio: Activating Anti-Theft Coding

    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.

  • Page 35: Transportation Devices: Removing Blocking Pieces From Springs On Front Axle

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 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-.

  • Page 36: Engine Oil Level: Check, Replenish If Necessary

    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. 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.

  • Page 37: Driver And Front Passenger Airbags: Visual Check Of Airbag Units

    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-.

  • Page 38: Front Passenger Airbag

    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.
  • Page 39 ♦ 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.
  • Page 40 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‐...
  • Page 41 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‐...

  • Page 42: Wiper Blades: Checking For Damage; Checking Park Position, Adjusting If Necessary; If Wiper Blades "Judder": Checking Setting Angle, Adjusting If Necessary

    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.
  • Page 43 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.

  • Page 44: Carry Out Vehicle System Test

    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...
  • Page 45 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‐...
  • Page 46 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 ⇒...

  • Page 47: Automated Manual Gearbox (Dsg): Carrying Out Basic Setting

    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‐...
  • Page 48 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 Mileage and service INSP Inspection service every 12 months or every 30,000 km...
  • Page 49 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.
  • Page 50 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‐...
  • Page 51 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Indicated on display: Select operating mode: – Press button for on display Vehicle self-diagnosis -arrow-. Note If the display is not as shown in the procedure: ⇒ Operating in‐...
  • Page 52 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 ♦...
  • Page 53 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 ♦...
  • Page 54 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 ♦...
  • Page 55 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press buttons on display number block -arrow-. – Confirm entry with 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).
  • Page 56 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 ♦...
  • Page 57 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press buttons on display number block -arrow-. – Confirm entry with 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).
  • Page 58 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press “10 - Adaption” on display -arrow-. Indicated on display: – Press buttons on display number block -arrow-. – Confirm entry with key on display number block.

  • Page 59: Door Arrester: Grease

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press button on display -arrow-. GoTo Indicated on display: – Press the button on display -arrow-. – Press button in End menu. – Switch off ignition and separate diagnosis connections.

  • Page 60: Folding Fabric Sunroof: Cleaning And Greasing Guide Rails

    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- .

  • Page 61: Cooling System: Checking Frost Protection And Coolant Level

    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‐...
  • Page 62 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.

  • Page 63: Mixing Ratio

    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...
  • Page 64 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-.
  • Page 65 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...
  • Page 66 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-.
  • Page 67 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-.
  • Page 68 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.

  • Page 69: Spark Plugs: Renewing

    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.
  • Page 70 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«...
  • Page 71 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«...
  • Page 72 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«...
  • Page 73 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-.
  • Page 74 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.

  • Page 75: Power Assisted Steering: Check Fluid Level

    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.

  • Page 76: Fuel Filter: Renewing (Diesel Engine)

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ 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 –...
  • Page 77 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-.
  • Page 78 Lupo 1999 ➤ , Lupo 3L 1999 ➤ 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‐...

  • Page 79: Fuel Filter: Draining Water (Diesel Engine)

    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.

  • Page 80: Toothed Belt: Checking For Wear (Diesel Engine ►2000)

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ 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-.
  • Page 81 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.

  • Page 82: Camshaft Drive Toothed Belt: Checking (4-Cylinder Petrol Engine)

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ 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.

  • Page 83: Toothed Belt: Renewing (Diesel Engine With Engine Code Aku)

    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: •...
  • Page 84 Lupo 1999 ➤ , Lupo 3L 1999 ➤ 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- ♦...

  • Page 85: Checking Oil Level

    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‐...
  • Page 86 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.

  • Page 87: Poly V-Belt: Checking Condition

    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.
  • Page 88 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 ⇒ page 85 4.33.1...
  • Page 89 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)”...

  • Page 90: Automated Manual Gearbox (Dsg): Checking Oil Level, Filling Hydraulic Oil As Required

    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.
  • Page 91 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‐...
  • Page 92 Lupo 1999 ➤ , Lupo 3L 1999 ➤ 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 ♦...

  • Page 93: Brake System: Inspect For Leaks And Damage

    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-;...

  • Page 94: Front And Rear Brake Pads/Linings: Check Thickness

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ 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...

  • Page 95: Rear Brake Pads

    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.

  • Page 96: Underbody Protection: Carry Out Visual Check For Damage

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ 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 •...

  • Page 97: Swivel Joints: Inspecting

    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.

  • Page 98: Checking Breakdown Set

    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 –...

  • Page 99: Tyre Tread Depth (Including Spare Wheel): Checking

    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.
  • Page 100 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...
  • Page 101 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...

  • Page 102: Automatic Gearbox: Checking Atf Level, Filling Atf As Required

    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«...
  • Page 103 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- .

  • Page 104: Brake Fluid Level (Dependent Upon Brake Pad/Lining Wear): Check

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Sequence: Brake fluid quantity which must flow out of wheel brake cylinders or brake Wheel brake cylinders, calipers: brake calipers Front left 200-250 cm Total quantity: approx. 1.1 litres –...
  • Page 105 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.
  • Page 106 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.

  • Page 107: Adjusting Headlights

    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.
  • Page 108 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.
  • Page 109 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.
  • Page 110 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 ♦...
  • Page 111 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Switch on ignition. Indicated on display: Select operating mode: – Press button for on display Vehicle self-diagnosis -arrow-. Note If the display is not as shown in the procedure: ⇒ Operating in‐...
  • Page 112 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 button on display number block. After “Wait” is indicated on display, the following message ap‐...
  • Page 113 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.
  • Page 114 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Indicated on display: – Press the button on display -arrow-. – Press button in End menu. – Switch off ignition and separate diagnosis connections. – Install ashtray insert.

  • Page 115: Carry Out Road Test

    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.
  • Page 116 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 ♦ Wheel bearings: noises ♦ Engine: hot starting behaviour 4. Descriptions of work:...

  • Page 117: Exhaust Emissions Test

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Exhaust emissions test Note Please observe the country specific legal regulations. ♦ The exhaust emissions test described below has been created ♦ according to the legal regulations valid in Germany.
  • Page 118 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 ♦ Engine speed adapter - VAS 5087- ♦ ⇒ Data sheets for exhaust emissions test Note It is only possible to carry out an exhaust emissions test when ♦...
  • Page 119 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 An overview is displayed to select the respective EET type. – Select “EET petrol” -arrow-. The display for warm-up phase appears. – Continue exhaust emissions test according to instructions on display.
  • Page 120 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Enter vehicle data from vehicle identification card at positions -1...7-. ♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ♦ -2- Vehicle type: “e.g. Lupo” ♦ -3- Key number for 1: “e.g. 11 11”...
  • Page 121 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Enter displayed values on EET data sheet in column “Test values for exhaust emissions test” on display as follows: Test speed (idling speed) Warm-up phase for catalytic converter...
  • Page 122 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Visual inspection: – Follow instructions on display. – Perform visual check. – If visual check is OK press “OK” button -arrow-. Note When "not OK" button is pressed a check will be carried out The visual check is displayed with the request to connect the ca‐...
  • Page 123 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Follow instructions on display. Measurement starts when the engine speed has reached the re‐ quired level. – Maintain engine speed in required engine speed range. The remaining time to perform the warm-up phase is displayed -arrow A-.
  • Page 124 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Measuring idling speed and CO content: It is automatically switched to display for measuring the idling speed and CO content. Measurement starts when the engine speed has reached the re‐...
  • Page 125 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Pull 4-pin connector off coolant temperature sender - G62- to‐ gether with coolant temperature sender - G2- -arrow-. The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.
  • Page 126 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Pull 4-pin connector -arrow- off coolant temperature sender. The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds. Note The throttle valve must not be operated during the test, otherwise the disconnected connector will be recognised as fault by the self- diagnosis and stored in the fault memory.
  • Page 127 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Pull 4-pin connector off coolant temperature sender - G62- with coolant temperature sender - G2- -arrow-. The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.
  • Page 128 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Pull 4-pin connector off coolant temperature sender - G62- with coolant temperature sender - G2- -arrow-. The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.

  • Page 129: Exhaust Emissions Test For Petrol Engines With Obd

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Pull 4-pin connector off coolant temperature sender - G62- with coolant temperature sender - G2- -1-. The control unit must recognise the disturbance variable and eliminate through regulation within 60 seconds.
  • Page 130 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Note The following description refers to vehicles fitted with “On‐ ♦ board diagnosis” OBD. The OBD monitors all components and part systems influenc‐ ♦ ing the exhaust emissions quality.

  • Page 131: Exhaust Emissions Test For Diesel Engines Without Obd

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Note To use the ELSA web service, the exhaust gas testing station ♦ L which is used for the exhaust emissions test must be inte‐ grated in the workshop network.
  • Page 132 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 5.3.1 Exhaust emissions test for diesel en‐ gines without OBD with diesel tester V.A.G 1743 Special tools and workshop equipment required ♦ Test equipment trolley - V.A.G 1700- ♦...
  • Page 133 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Connecting test units – Connect diesel tester - V.A.G 1743- according to operating instructions. Description, measuring process, tester functions, setting up and operating ⇒ operating instructions diesel tester - V.A.G 1743-...
  • Page 134 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Enter vehicle identification data from vehicle identification document using keyboard as follows (press button Return after each entry): Registration number • -A- Vehicle manufacturer • -B- Key number •...
  • Page 135 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Note The idling speed and maximum speed can be checked but not adjusted. – If the values are not within specified range, a repair must be made. – Continue test sequence by pressing the button.
  • Page 136 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 If this message appears on the display: Data transfer to diesel tester Depress accelerator quickly – Depress accelerator pedal fully and hold. Indicated on display: Data transfer to diesel tester Neutral accel.
  • Page 137 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 If this message appears on the display: Opacity band width -> ACT. x.xx rpm SPEC. x...x.xx rpm – Press button. → If this message appears on the display:...
  • Page 138 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 ♦ Exhaust emissions station - VAS 6300- ♦ OBD adapter cable - VAS 5052/16- Note ♦ It is only possible to carry out an exhaust emissions test when all units of the exhaust emissions station - VAS 6300- are con‐...
  • Page 139 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Select “EET diesel” -arrow-. The display for warm-up phase appears. – Continue exhaust emissions test according to instructions on display. – If the EET specification selection is displayed, select respec‐...
  • Page 140 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 ♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ♦ -2- Vehicle type: “e.g. Lupo” ♦ -3- Key number for 1: “e.g. 11 11” ♦ -4- Key number for 2: “e.g. 0603” (vehicle registration docu‐...
  • Page 141 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Perform manual data input according to instructions on dis‐ play. – Enter displayed values on EET data sheet in column “Test values for exhaust emissions test” on display as follows:...
  • Page 142 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 The visual check is displayed with the request to connect the di‐ agnostic connector -arrow A- – Follow instructions on display -arrow A- and -arrow B-. – Connect diagnosis cable connector to EOBD connection.
  • Page 143 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 It is automatically switched to display for measuring engine tem‐ perature. – Follow instructions on display. Note This is only indicated on display if engine temperature has not ♦...
  • Page 144 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 It is automatically switched to display for measuring rev limit. Measurement starts when the engine speed has reached the re‐ quired level. – Operate throttle until the measurement is carried out. To do this, immediately depress accelerator pedal.
  • Page 145 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Follow instructions on display -arrow B-. – Depress accelerator pedal fully when prompted and hold until the prompt for idling is shown on display. Free acceleration - phase 3: –...
  • Page 146 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 – Press button “Close” -arrow B- to close the menu “Print pre‐ view ”. – Follow instructions on display. – Take emission probe out of exhaust tail pipe.

  • Page 147: Glossary

    Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Glossary These explanations only apply to “Maintenance Manual”. They are not necessarily generally valid! Term Explanation (Anti-lock brake system); the ABS is a regulating system in the brake system, that pre‐...
  • Page 148 Lupo 1999 ➤ , Lupo 3L 1999 ➤ Maintenance - Edition 03.2018 Term Explanation (Society of Automotive Engineers); society which creates proposals/guidelines for im‐ plementing legal requirements (e.g. standards). Naturally aspirated diesel engine Naturally aspirated diesel engine - direct injection...

This manual is also suitable for:

Lupo 3l 1999

Table of Contents