Volkswagen Lupo User Manual
The Lupo
Design and function
Self-Study Programme No. 201
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The Lupo, a new addition to the
subcompact family, extends the
Volkswagen product range.
In spite of its compact dimensions, the Lupo
boasts a specification which stands comparison
with any saloon and is rounded off by a
distinctive design.
Environmental pollution kept to a minimum by
using fuel-efficient, low-emission and quiet
engines as well as recycleable and recycled
plastic parts.
The Lupo conforms to all internationally
recognised safety standards for head-on
collision, side impact, offset collision and rear
collision as well as for rollover.
The small and highly manoeuvrable vehicle
is simply likeable, chic and natural.
The Self-Study Programme
is no Workshop Manual.
2
SSP 201_130
Please always refer to the relevant
Service Literature for all inspection,
adjustment and repair instructions.
SSP 201_134
SSP 201_131
New Important
Note
At a glance
The Lupo .......................................................................
Vehicle dimensions, aerodynamics
The car and the environment
Environmental protection, recycling
Body ..............................................................................
Safety bodyshell,
paintwork structure and corrosion protection, high-strength body panels
Soundproofing, Isofix, fabric sliding roof
Front and rear bumpers
Restraint system, airbags
Engines ..........................................................................
Engine-gearbox combination
Engines, roller cam follower,
Power transmission ......................................................
Manual gearbox 085 and gear selection
Manual gearbox 002 and gear selection
Automatic gearbox and gate selection
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10
18
26
Fuel system ................................................................... 29
Running gear ................................................................
Steering
Front axle/rear axle
Brake system
Front and rear brakes
ESBS
Electrical system ..........................................................
Vehicle electrical system/components
Fitting locations of control units,
Dash panel insert, central locking
Radio generation ’99
Heating, air conditioning system ...............................
Heating, air conditioning system,
Radiator fan control unit,
high pressure sender, system overview, functional diagram
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48
Service ...........................................................................
Special tools
55
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The Lupo
The small LUPO achieves great things in terms
of safety, quality, performance, running gear
and equipment.
• Safety
The safety bodyshell, belt
tensioners, front airbags
and side airbags mean that the
little Lupo is no baby when it
comes to safety.
SSP 201_174
SSP 201_133
• The running gear
The suspension strut front axle with
wishbones, as well as the torsion beam
rear axle are a winning team and place
the LUPO firmly on the road.
SSP 201_080
4
• Equipment level
A 4-seater or 5-seater version can
be specified. Easy Entry seats are
standard for the driver and front
passenger. They exceed the
standard specification.
Also available for the LUPO is a
complete range of extras ranging
from the electric fabric sliding roof
and the air conditioning system to
the navigation system.
• Quality
The Lupo also meets
Volkswagen's recognised
quality standard:
• Narrow body joints
• High-quality materials
SSP 201_168
SSP 201_132
SSP 201_131
• Engines and gearboxes
A choice of four petrol engines and
one
diesel engine in combination with
a 5-speed manual gearbox and a
4-speed automatic gearbox will be
available when the LUPO is
launched on the market.
5
The Lupo
Vehicle dimensions
Width: 1639 mm
Front track width: Rear track width:
1387 mm (4 1/2 J x 13)
1371 mm (5 1/2 J x 13, 6 J x 14)
With a maximum
length of 3527 mm, the
LUPO belongs to the
subcompact class.
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SSP 201_010
Tank capacity
34 litres
1400 mm (4 1/2 J x 13)
1384 mm (5 1/2 J x 13, 6 J x 14)
SSP 201_011
The Lupo offers space
for 4 or 5 persons,
depending on the
equipment level.
729
mm
Wheelbase: 2323 mm
Length: 3527 mm
The luggage compartment has a capacity of
139 or 792 litres. The rear seat backrest can be
folded down. The inclination of the rear seat
backrest can be adjusted in two stages in order
475
mm
SSP 201_012
to enlarge the luggage compartment.
SSP 201_007
6
Aerodynamics
cd = 0.32
Aerodynamic
drag
D = 0.62 m
2
A = 1.94 m
SSP 201_018 SSP 201_130
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One of the main goals in the
development of the LUPO's
aerodynamics was to
streamline the bodyshell in
such a way as to eliminate
additional measures to
improve the vehicle’s
aerodynamics, measures
which involve higher costs
and weight.
SSP 201_020
A streamlined bumper with integral front spoiler,
optimised door mirror, small gap and joint
dimensions as well as flush-fitting windows and
headlights minimise aerodynamic drag and wind
noise.
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The car and the environment
In addition to households, industry,
power stations, heating stations and
industrial agriculture, the car is one
of the principal sources of air
pollution.
Global annual CO2 emissions caused by man
Source: Technical University of Vienna
Other modes of transport
Ocean-going ships
Air traffic
Trucks and buses
Passenger cars
Industry
Power stations and heating
stations
Combustion of biomass
House fires and small
consumers
SSP 201_005
CO2 emissions constitute
approx. 50 percent of the
greenhouse gases which are
responsible for the "manmade" phenomenon of
global warming. Industry,
power stations, households
and small consumers are
responsible a good two thirds
of CO
emissions. Road traffic
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worldwide accounts for
approx. 12 percent of CO
2
emissions, whereas cars
contribute less than 6 percent.
For Volkswagen, reducing fuel consumption, and
Fuel consumption of cars
supplied by Volkswagen in Germany
along with it CO2 emissions, is one of its main
goals in the development of new automobiles. We
have agreed to reduce the fuel consumption of our
new vehicles by 25 percent between 1990 and
2005. During the period from 1990 to 1995, we
achieved a 10 percent reduction. We plan to
achieve another 15 percent reduction within the
next ten years. The so-called "3-litre car" (a car
Polo SDI
3-litre car
Source: VOLKSWAGEN AG
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SSP 201_006
which consumes 3 litres of fuel per 100 km) is a
major step towards low-CO
-emission vehicles,
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both for production and during operation.
Recycling
Volkswagen, in association with
disposal firms, runs a Workshop
Disposal Programme. This process
is co-ordinated through the
distribution centre or the importer
in charge in accordance with
prevailing national legislation.
These components can be disposed of
without posing a burden on the environment:
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Starter batteries
•
Laminated glass windscreens
•
Airbags and belt tensioner
(not fired)
Brake fluid
•
Coolant
•
Shock absorbers
•
Plastic bumpers
•
Radiator grilles
•
Plastic fuel tanks
•
Wheel housing liners
•
Wheel covers
•
Lock carriers/subframes
•
Old tyres
•
SSP 201_013
SSP 201_009
9
Body
Development
of the safety bodyshell
The blueprint for development of the
LUPO's body was the Polo ‘95.
A key development goal was to design a body
whose occupant cell offers a high level of
dimensional stability in crash situations.
During a head-on collision,
the impact energy is absorbed
via 2 crash planes:
SSP 201_021
In the 1st crash plane, the side re-inforcement in
the doors located directly behind the bumper
cover, transmits the impact energy to the side
members. The energy is then distributed evenly
to the centre tunnel and re-inforced side
members.
In the 2nd crash plane, the wheelhouse side
members transfer the impact energy via the door
re-inforcements to the rear end.
In the event of a rear collision,
the side re-inforcement in the doors behind the
bumper cover transmits the force to the side
members.
The body side panel which is almost fully
enclosed on the inside helps to absorb more
energy.
= 1st crash plane
= 2nd crash plane
SSP 201_046
10
= 1st crash plane
= 2nd crash plane
SSP 201_046
In the event of a side impact,
the re-inforced A- and B-pillars, the strong side
members and the almost fully integrated inner
panel of the door minimise deformation of the
occupant cell.
The side impact re-inforcement in
the door, the door-glass channel reinforcement and the intermediate
padding produce an optimal barrier
against the force of impact.
Door-glass
channel re-
inforcement
SSP 201_024
The closed door is securely
anchored to the side member by
means of a bracket on the
underside. During a side impact, it
prevent the door from intruding into
the occupant cell.
Padding
Side
impact
reinforce
ment in
the door
Bolt-on
bracket
Plastic guide
SSP 201_026
SSP 201_025
11
Body
The body of the
LUPO has
features which surpass the norm for this class:
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Long-term corrosion protection
-
Fully-galvanised body
Crash performance in acordance with VW's
-
safety standard
Modular design
-
Narrow ioints
-
Paintwork structure
and corrosion protection
Environmentally friendly, waterdilutable paints are:
The cathodic cataphoresis,
-
filler, top coat (met. base
coat,
solid base coat )
Galvanised sheet steelLegend:
Zinc phosphatisation
Water based
Cathodic
immersion
cataphoresis
Filler coat
All outer panel are
-
electroplated.
All inner panels are hot-dip
-
galvanised.
SSP 201_027
High-strength body panels
are also used in the LUPO.
They are not as thick as conventional body panels and, as a
result, weigh less but are stronger.
High-strength body panels have the task of absorbing and
distributing energy during a crash in a more controlled
manner.
They absorb vibrations at the rear axle mount.
You can find detailed information regarding
high-strength sheet-metal panels in Self-Study
Programme No. 200.
Top coat
Clear coat
High-strength body
panels
SSP 201_028
12
F
Bitumen-based heat-shrinkable and adhesive
foils of various thickness as well as felt parts and
carpeting are used for soundproofing purposes.
The adhesive foils absorb the vibrations which
occur in various areas of the body. Felt parts
absorb noise by interrupting the sound wave.
The Isofix child safety seat fastening
is fitted in the LUPO as standard.
There are 4 retaining eyelets below the rear
seats, which make it possible to install two child
safety seats with the Isofix fastening system. The
retaining eyelets are welded to the floorpan
assembly and hold the child safety seat securely
during a crash.
F
B
FBFelt parts
Heat-shrinkable/
adhesive foils
B
B
F
SSP 201_029
The electric fabric sliding roof
In addition to the electrically-operated glass
sliding/tilting roof, an electrically-operated
fabric sliding roof is also available for the LUPO.
The roof spoiler allows the vehicle to be driven
without any draught and quietly with the sunroof
open, even at high speed.
The electric fabric sliding roof is identical
to the sunroof used in Polo model ‘95.
SSP 201_030
Fabric sliding roof
Sunroof opening
Roof spoiler
SSP 201_031
13
Body
The front and rear bumpers
comprise a side re-inforcement in the doors and
a bumper cover.
Front
The front bumper cover
comprises 2 components
The front and rear bumper covers are capable of
absorbing impact energy at speeds of up to 4
kph without damage.
Higher impact speeds of up to approx. 15 kph
are absorbed by the side re-inforcement in the
doors without deformation of the side members.
The side members only become deformed as a
result of a severe impact.
Side re-inforcement in
the doors
The upper section is painted
in the body
colour
Rear
Side re-
inforcement in the
doors
SSP 201_032
Bumper
cover
14
SSP 201_034
The restraint system
and the airbags
Seat belts
Front:
They have ball-type
tensioners which are
fired both
mechanically and
pyrotechnically.
SSP 201_171
SSP 201_170
For more detailled information on the belt
tensioners, please refer to
Self-Study Programme No. 192.
3-point seat belt concepts for the rear seats
Standard equipment The 5-seater version is also equipped with a lap
belt for the middle seat.
SSP 201_173SSP 201_172
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Body
The front airbags
have a volume of 57 litres for male/female
drivers
and a volume of 95 litres for the front passenger.
At production launch, a 120-litre front
passenger's airbag will be used. It will be
identical to the airbag used in the Golf ’98.
The 120-ltr. front passenger's airbag cannot be
replaced by the 95-ltr. airbag, therefore it can
only be replaced in accordance with the original
equipment level.
The side airbags
SSP 201_174
have a volume of 12 litres.
All gas generators contain acid-free propellant.
The function of the restraint system
during severe accidents
The restraint system prevents
contact occurring between the
shoulder and head area with
the steering wheel or dash
panel insert.
SSP 201_175
16
Once the firing threshold
is attained, the airbag
control unit transmits the
"Open central locking (CLS)" signal
to the CLS control unit.
SSP 201_176
The airbag system
As of a defined degree of accident severity and
the
the associated delay period, the appropriate
airbags are triggered depending on the impact
side and the angle of impact.
Head-on collision
The driver's and front
passenger's airbags
are triggered.
Side/head-on
collision
SSP 201_102
The driver's, front
passenger's and side
airbags are triggered.
Side impact
Only the side airbag
which is actually
required to protection
the vehicle's
occupants is triggered.
This considerably
reduces repair costs
after an accident.
SSP 201_103
SSP 201_104
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