VOLKSWAGEN POLO 2002 (01) PDF Document

When converting wheels and tyres on your VOLKSWAGEN POLO 2002, you must observe certain legislative and technical conditions.

Legislative Conditions:

• If the wheel and tyre size, including load index and speed symbol, is listed in the vehicle’s General Type Approval (GTA) or EU operating permit/type approval, it can be fitted without issue.

• It is not mandatory to fit the specific wheel and tyre combination listed in the registration certificate. Any combination approved in the vehicle’s GTA or EU type approval may be fitted.

• For conversions recommended by Volkswagen, there are no general operating permits. If the wheels or tyres are not included in the vehicle’s type approval, the vehicle may no longer meet road traffic regulations.

Technical Conditions:

• The combinations and conversions listed refer exclusively to Volkswagen genuine disc-type wheels.

• Tubeless radial tyres may only be fitted to rims with a safety hump feature on the shoulder.

• When using listed wheel and tyre combinations, you must adhere to the associated tyre inflation pressures found on the sticker inside the fuel tank flap or in the vehicle’s tables.

• Ensure sufficient clearance between the wheels/tyres and the wheel housing, suspension, and braking system in all operating conditions.

• Unless stated otherwise, snow chains may only be fitted to the drive wheels. On all-wheel drive vehicles, only the front wheels may be fitted with snow chains (with the exception of the Touareg).

• Some vehicles may require wheel housing extensions (flaps) on the wing or bumper when using certain wheel and tyre combinations.

The sidewall of a tyre contains numerous markings that provide important information. Here is a breakdown of what they mean:

1. Size code: e.g., 205/55 R 16. This indicates tyre width, aspect ratio, construction type, and rim diameter.

2. Position of TWIs: Tread Wear Indicators show when the tyre tread has reached its minimum legal depth.

3. Manufacturer (trade name): The brand of the tyre.

4. Construction: “Radial” indicates radial cord direction; “Tubeless” indicates it’s a tubeless tyre.

5. Load capacity index / speed rating: e.g., 91 H. “91” is the load index, and “H” is the speed rating.

6. Specified direction of rotation/installation for tyre: Indicates the direction the tyre must rotate when the vehicle moves forward.

7. Maximum permissible load: Data for North America.

8. Maximum permissible tyre pressure: Data for North America.

9. Number of plies: Information on the number of plies in the tread and sidewalls and the material used.

10. E number: Approval number indicating the tyre meets European guidelines.

11. Manufacturer code / date of manufacture (DOT): An identification number for the manufacturer’s plant, tyre size, model, and the date of manufacture.

12. DOT: Department of Transportation, indicating the tyre meets US standards.

13. Marking for Brazil

14. Marking for China

15. Country of origin: e.g., Made in Germany.

16. Safety reference: For use or fitting of the tyre.

17. Abrasion resistance: Relative expected service life based on a US standard test.

18. Wet-braking traction rating: A, B, or C, according to a US test.

19. Temperature resistance rating: A, B, or C, according to a US test.

20. Identifying tyres with run-flat properties: e.g., self-supporting run-flat.

21. Tread pattern: The model name of the tyre tread, e.g., ContiPremiumContact.

Understanding the codes on your tyres is crucial for safety and performance.

Tyre Size Explanation (Example: 195/65 R 15 91 V)

• 195: Tyre width in millimeters.

• 65: Aspect ratio (height as a percentage of width).

• R: Code for tyre construction, “R” indicates Radial.

• 15: Rim diameter in inches.

• 91: Load rating code/load index (LI).

• V: Speed rating code.

Speed Rating / Maximum Speed

The speed rating code indicates the maximum speed the tyre can sustain.

Load Rating Code / Load Index (LI)

The load rating indicates the maximum load in kilograms that the tyre can bear.

Proper tyre storage is essential to maintain their condition and extend their life.

Storage Room Conditions:

The storage room should be:

• dark

• dry

• cool

• ventilated

Storage of Complete Wheels (Tyres on Rims):

• Tyres mounted on wheels can be stored flat, stacked on top of each other.

• Ensure the tyres are clean and dry before storing.

• The inflation pressure should be increased to a maximum of 3 bar.

Storage of Tyres without Wheels:

• Tyres without wheels are best stored standing vertically.

• If tyres are stacked for long periods, they can be pressed together, making them difficult to fit later.

• If storing vertically, it is recommended to turn them every 14 days to avoid flat spots.

WARNING: Stored tyres must not come in contact with fuel, oil, grease, or chemicals under any circumstances. The tyre material can be damaged by chemical reactions that are not always visible, leading to dangerous situations when driving.

Tyres age due to physical and chemical processes, which can impair their function. Tyres stored for long periods can harden and become brittle faster than tyres in constant use.

Determining Tyre Age:

You can determine the tyre’s age from the DOT number on the sidewall.

• Until 31.12.1999: A number like “509” means the 50th week of 1999.

• From 01.01.2000: A number like “0100” means the 1st week of 2000. The last two digits indicate the year.

Recommendations:

• It is recommended not to use summer or winter tyres that are older than 6 years. Their original properties deteriorate over time.

• A spare tyre may be used if it is in flawless condition and not more than 6 years old.

• All VW vehicles are factory-fitted with four identical tyres and wheels.

Renewing Tyres:

Tyres must always be renewed when:

• The legal minimum tread depth of 1.6 mm is reached.

• There is visible mechanical damage.

Several factors influence a tyre’s service life:

Driving Style:

• Speed: Higher speeds cause more wear. Driving at 180 km/h can cause 9 times more wear than at 100 km/h.

• Braking: Most wear occurs during braking. Heavy braking causes significantly more wear than coasting to a stop.

• Acceleration: Driving off with spinning wheels can cause 100-200 times more wear than driving off gently.

• Cornering: Sporty driving through curves causes greater wear. Doubling the cornering speed can increase wear 16-fold.

Maintenance:

• Tyre Pressure: Low tyre pressure causes greater deformation, heat, and wear. A pressure of 1.0 bar instead of the specified 2.3 bar can reduce tyre life to just 25%.

Environment:

• Road surface

• Ambient temperature and climate

Vehicle:

• Weight

• Dynamic toe and camber settings

To measure the tyre tread depth correctly:

1. Measure the depth in the main tread channels, at the points where the tyre is most heavily worn.

2. Do not measure at the Tread Wear Indicators (TWIs). The TWIs are small raised bars in the grooves that indicate the minimum legal tread depth (1.6 mm in Germany).

3. The position of the TWIs can be identified by a “TWI”, a triangle symbol (Δ), or the manufacturer’s logo on the shoulder of the tyre.

4. Always measure at the deepest point of the tread channel, away from the TWI bars.

Tyre noise is caused by air vibrations transmitted from the tyre.

General Causes:

• Road Surface: The structure and material of the road greatly affect noise. A wet road is much louder than a dry road.

• Tread Pattern: Tyres with transverse grooves are louder than those with diagonal grooves. Wider tyres are generally louder as they displace more air.

• Tyre Vibration: Caused by the agitation of air columns in the tread channels.

• Air Pumping: The compression and expansion of air caused by the deformation of tread blocks as they contact the road.

Saw-Tooth Wear:

This is a stepped wear pattern on individual tread blocks that can cause increased noise. It is more pronounced on non-driven wheels.

Remedies for Saw-Tooth Wear:

• Non-directional tyres: The direction of rotation must be reversed. If wear is pronounced, interchange the tyres diagonally. The noise will be louder initially but should normalize after 500-1,000 km.

• Directional tyres: Interchange the front and rear tyres. If wear is severe on the outer edges, turn both tyres around on their rims and swap them to the opposite sides of the vehicle.

Flat Spots:

Flat spots from hard braking (locking the wheels) also cause noise and vibration. Tyres with this type of damage must be renewed.

Properly balancing the wheels is essential for smooth running and even tyre wear. It is recommended to balance wheels at least twice during a tyre’s service life.

Pre-Balancing Checks:

• Conduct a road test to determine the speed range where vibration occurs.

• Check that tyre pressure is correct.

• The tyre tread must not have one-sided wear and should be at least 4 mm deep.

• The tyre must not show any signs of damage (cuts, foreign bodies, etc.).

• The wheel suspension, steering, and shock absorbers must be in perfect condition.

Balancing Procedure on a Stationary Machine:

1. Remove the wheels from the vehicle.

2. Clean the contact surfaces, the center of the wheel, and the recess on the inside of the wheel.

3. Mount the wheel on the balancer, preferably using a centering system like VAS 5271 for 100% accurate centering.

4. Rotate the wheel on the balancer and check for even running of the tyre sidewall and body. If there is lateral or radial runout, check the tolerances.

5. If runout is within tolerance, balance the wheel until the display reads 0 grams. Do not use more than 60 grams of weight per tyre.

6. If more weight is needed, perform a match mounting procedure by rotating the tyre on the rim.

7. Reinstall the wheel on the vehicle, tightening the bolts diagonally to the specified torque.

8. Perform a final road test.

A vehicle pulling to one side is often caused by the tyres, a phenomenon known as “conicity” or “tyre pull”. This is due to a slight offset of the tyre’s internal belts relative to its geometric center, creating a lateral force as the tyre rolls. While the running gear can be a cause, experience shows tyres are responsible in about 90% of cases.

Troubleshooting Steps:

1. Initial Checks: Before a road test, check all suspension components for damage, ensure tyre pressures are correct, and inspect tyres for uneven wear or damage.

2. Road Test: Perform a road test on a level, straight road with no crosswind to confirm the vehicle pulls and to which side.

3. Strategic Wheel Rotation: The goal is to counteract the lateral forces of the tyres. The following is a systematic approach for non-directional tyres.

• Step 1: If the vehicle pulls to one side, interchange the front wheels. Perform another road test.

• Step 2A (If it pulls to the other side): Interchange the front and rear wheels. Perform a road test. If it still does not travel straight, reverse one of the front tyres on its rim and test again. If the issue persists, check wheel alignment.

• Step 2B (If it still pulls to the same side): Reverse one front tyre on its rim (the one on the side it pulls towards). Perform a road test. If it travels straight, the issue is resolved. If not, proceed to check front and rear wheel alignment.

• Step 2C (If it now travels straight): The problem is solved.

For vehicles with unidirectional tyres, the options are more limited. You can interchange the front and back wheels on the same side. If this doesn’t work, you may need to renew one or both front tyres and check wheel alignment.

The approved wheel and tyre combinations for the VOLKSWAGEN POLO 2002 vary by engine and equipment. Below is a summary of standard, modification, and winter tyre options.

Note: Combinations with 205/45 R 16 tyres are also listed, which may require widened wheel housings (flaps).

The wheels for the VOLKSWAGEN POLO 2002 (Type 9N) have a pitch circle diameter of 100 mm and use 5 wheel bolt holes. Below are the specifications for various wheel sizes.

5 J x 13 Wheel

• Size: 5 J x 13

• Wheel offset in mm: 35

• Wheel load in kg: 400

5 J x 14 Wheels

• Size: 5 J x 14

• Wheel offset in mm: 35

• Wheel load in kg: 455 (For models up to 110 kW) or 435 (For vehicles up to max. axle load of 870 kg)

6 J x 14 Wheels

• Size: 6 J x 14

• Wheel offset in mm: 43

• Wheel load in kg: 465

6 J x 15 Wheels

• Size: 6 J x 15

• Wheel offset in mm: 43

• Wheel load in kg: 480 or 500 (depending on part number)

6 1/2 J x 16 Wheels

• Size: 6 1/2 J x 16

• Wheel offset in mm: 38 or 43 (depending on part number)

• Wheel load in kg: 480

The following tables list the recommended makes and tread patterns for summer tyres on the VOLKSWAGEN POLO 2002.

The following table lists the recommended makes and tread patterns for all-season tyres on the VOLKSWAGEN POLO 2002.

The following tables list the recommended makes and tread patterns for winter tyres on the VOLKSWAGEN POLO 2002.