Recalls: Volkswagen Mk.5 Polo
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Volkswagen Mk.5 Polo
2010-11 Volkswagen Mk.5 Polo: DQ200 DSG recall
In June 2013, a recall was issued for Volkswagen Mk.5 Polo vehicles that were fitted with seven-speed DQ200 Direct Shift Gearboxes (DSGs) and manufactured prior to September 2011. In these vehicles, sulphur in the gear oil and an inorganic heat stabiliser in the plastic parts (iodine) of the mechatronic unit could cause metallic surfaces to suffer from electrolytic corrosion, particularly in conditions with high temperatures and humidity. Conducting particles could then settle between the circuit paths of the control unit and cause a short circuit and blow the gearbox fuse. If the fuse were to blow, the clutch would open and freewheel, resulting in a sudden and total loss of power to the wheels. Although other vehicle systems such as steering and braking would continue to function, the loss of power may pose a hazard to the vehicle and other road users (PRA 2013/13626).
‘2013 model year’ Volkswagen Mk.5 Polo: DQ200 DSG recall
In November 2013, a recall was issued for 2013 model year Volkswagen Polo vehicles with seven-speed DQ200 DSG transmissions. In these vehicles, electrolysis of sulphur constituents in the synthetic oil could cause them to separate and accumulate between electrical conductor paths. In turn, this could create a short circuit and blow the gearbox fuse, causing the clutch to fully open. While the majority of failures occurred on start-up when the vehicle was stationary, a failure when the vehicle was in motion would result in a sudden loss of power at the wheels. All other functions of the vehicle, however, would remain active. As part of the recall, the synthetic transmission oil was to be replaced with mineral oil (PRA 2013/13835).
Volkswagen Mk.5 Polo: airbag may not deploy as designed
In December 2014, a recall was issued for Volkswagen Mk.5 Polo vehicles due to a fault in the production of an internal airbag acceleration sensor. The airbag control unit could generate ‘faulty signals’ and, as a result, the airbag may not deploy as designed in the event of a collision (PRA 2014/14476).
2015 model year Volkswagen Mk.5 Polo 1.2 TSI: engine failure
In April 2015, a recall was issued for ‘2015 model year’ Volkswagen 6C Polo vehicles with 1.2-litre TSI (EA211) engines because the pulley on the camshaft adjuster could break. If this occurred, the belt drive of the engine may be damaged, oil may leak and, at worst, the valves may contact the pistons and cause serious engine damage (PRA 2015/14676).
2015 model year Volkswagen Mk.5 Polo: backrest could fail in collision
In June 2015, a recall was issued for ‘model year 2015’ Volkswagen Polo vehicles. In these vehicles, incorrect welding on the front seats could cause noises; at worst, the backrest may fail in the event of a collision and cause injury to the front seat passengers (PRA 2015/14777).
2009-15 Volkswagen Polo 1.6 TDI: excess NOx emissions
In October 2015, a recall was issued for 2009-15 Volkswagen Mk.5 Polo vehicles with 1.6-litre EA189 diesel engines. According to the recall notice, ‘the emissions levels may not meet regulatory requirements when the affected vehicle is driven under normal conditions’ (see ‘Diesel engines: NOx emissions “defeat device”‘, below). For the 1.6-litre EA189 engine, a ‘flow transformer’ will be fitted directly in front of the air mass sensor and a software update will be introduced. The flow transformer is a mesh screen that reduces the swirl of the air flow upstream of the air mass sensor so that the sensor can more accurately measure intake air volume. Owners could determine if their vehicles were part of the recall by visiting volkswagendieselinfo.com.au (PRA 2015/14950).
2016 model year Volkswagen 6C Polo: child lock
In June 2016, a recall was issued for certain 2016 ‘model year’ Volkswagen 6C Polo vehicles because the detent lever of the child lock was damaged during the production process and could break. As a result, an active child lock could be unnoticeably switched off – this could enable a child to open a rear door from the inside when the child lock appeared to be on. As such, this condition could increase the risk of injury to vehicle occupants (PRA 2016/15463).
2017-18 model year Volkswagen 6C Polo: welding on towing eye could fail
In January 2018, a recall was issued for 2017 and 2018 model year Volkswagen 6C Polo vehicles. For certain 6R Polo vehicles, the welding on the towing eye in the vehicle tool kit could tear as a result of forces exerted on it. In the event that the towing eye was torn, the towrope could sling back and cause an injury. For the VINs of the recalled Volkswagen 6C Polo vehicles, please see PRA 2018/16563.
2010-15 Volkswagen 6R Polo: Takata airbag recall #1
In May 2019, recall campaign 69Q7 was issued for Volkswagen 6R Polo vehicles that were supplied between 1 January 2010 and 1 January 2015 in Queensland, Western Australia and the Northern Territory. These vehicles had Takata driver’s airbags and propellant wafers inside these airbags could absorb moisture over time. In the event of airbag deployment, excessive pressure in the airbag inflator housing could cause it to rupture and metal fragments could be projected through the airbag cushion and into the vehicle’s cabin. These metal fragments posed a risk of serious injury and fatality. For the VINs of the recalled vehicles, please see PRA 2019/17531.
2010-15 Volkswagen 6R/A5 Polo: Takata airbag recall #2
In July 2019, recall campaign 69Q7 was issued for Volkswagen 6R/A5 Polo vehicles that were available for sale from 1 December 2010 to 1 January 2015. These vehicles had Takata driver’s airbags and propellant wafers inside these airbags could absorb moisture over time. In the event of airbag deployment, excessive pressure in the airbag inflator housing could cause it to rupture and metal fragments could be projected through the airbag cushion and into the vehicle’s cabin. These metal fragments posed a risk of serious injury and fatality. For the VINs of the recalled vehicles, please see PRA 2019/17687.
2010-15 Volkswagen 6R/A5 Polo: Takata airbag recall #3
In September 2019, recall campaign 69Q7 was issued for 2010-15 Volkswagen 6R/A5 Polo vehicles. These recalled vehicles had Takata driver airbags and propellant wafers inside these airbags could absorb moisture over time. In the event of airbag deployment, excessive pressure in the airbag inflator housing could cause it to rupture and metal fragments could be projected through the airbag cushion into the vehicle’s cabin. These metal fragments posed a risk of serious injury and fatality. For the VINs of the recalled vehicles, please see PRA 2019/11797.
2011-15 model year Volkswagen Mk.5 Polo DSG: pressure accumulator crack and loss of power
In October 2019, recall campaign 35D8 was issued for 2011-15 model year Volkswagen Mk.5 Polo vehicles. Due to a production fault, a crack in the transmission’s pressure accumulator (within the mechatronics housing) could occur. If the pressure accumulator cracked, oil and pressure would be lost in the hydraulic system of the gearbox. If this occurred, the transmission of engine power would be interrupted, similar to depressing the clutch in a vehicle with a manual transmission – this increased the risk of a collision and injury to vehicle occupants. For the VINs of the recalled vehicles, please see PRA 2019/17886. AustralianCar.Reviews understands that the recalled vehicles had seven-speed DQ200 DSG transmissions.
2011-15 Volkswagen Mk.5 Polo with 7sp DSG: loss of drive
In April 2020, recall campaign 34J5 was issued for Volkswagen Mk.5 Polo vehicles that had seven-speed dual clutch (‘DSG’) transmissions. In these vehicles, a fluid leak could lead to a loss of pressure in the gearbox. This pressure loss could interrupt the transmission of power between the engine and gearbox, causing a loss of drive – this increased the risk of a collision and posed a hazard to both vehicle occupants and other road users. For the VINs of the recalled vehicles, please see PRA 2020/18258.
Problems and faults: Volkswagen Mk.5 Polo
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
VW Polo with 1.4 Twincharger (TSI) engine: stretched timing chain
In an autobild.de article published in April 2012, a Volkswagen employee admitted that its 1.4 ‘Twincharger’ TSI engine was susceptible to stretched timing chains. According to Volkswagen, worn stamping tools caused:
- The holes in the chain links to miss the targeted manufacturing tolerances; and,
- Small burrs on the chain links that would cause abrasive wear to the timing chain.
If the timing chain stretched, the change in the engine’s camshaft timing could cause the valves and pistons to collide such that the engine would have to be re-built or replaced. A common symptom of a stretched timing chain is a rattling noise from the engine bay (see video below).
It is understood that the manufacturing defect was rectified for post-2012 1.4 TSI ‘Twincharger’ engines, though Volkswagen has not identified the production dates or engine codes of affected engines. As such, the 132 kW 1.4 TSI CAVE engine in the Volkswagen 6R Polo GTi may be susceptible to this problem. According to Volkswagen, the number of poorly manufactured chains was in the ‘low hundreds’.
2010-11 VW Polo 1.2 TSI: stretched timing chains (CBZ engines)
Models and engines affected
For Volkswagen Polo 1.2 TSI vehicles with CBZA, CBZB and CBZC engines that were manufactured prior to 18 June 2011, the timing chain was susceptible to elongation (or stretching). In Australia, however, the only affected model was the VW Polo 77TSI. Symptoms of a stretched timing chain include:
- A rattling noise from the engine bay; and,
- If the timing chain skips teeth on its sprocket, the valve timing may be disturbed. This could cause rough running, illumination of the ‘check engine’ light and, at worst, contact between the valves and pistons which causes serious engine damage.
If the engine warning light illuminates, the vehicle should not be driven.
Repair kit
Since the original timing chain (part no. 03F 109 158B) was susceptible to elongation, Volkswagen released a repair kit (part no. 03F 198 229 A) which included:
- A reinforced chain (part no. 03F 109 158 K); and,
- A new chain guard with anti-jump teeth (initially, part no. 03F 109 210 C and, subsequently, part no. 03F 109 210 D).
Whilethe 03F 198 229A repair kit prevented the timing chain from stretching, there may still be a rattling noise heard in the first five seconds after start up from the hydraulic chain tensioner since it takes time to accumulate oil pressure. Since the spring inside the chain tensioner loosens over time, this rattling noise is more likely to be heard on older, higher mileage 1.2 TSI engines.
June 2011 production changes
This revised chain and chain guard were incorporated into production from 18 June 2011 – this corresponds to engines numbers after:
- CBZ* 462774 (for Mlada Boleslav production); and,
- CBZ* 714253 (for Salzgitter production).
The production location can be determined by inspecting the sticker on the boost pressure pipe or on the intercooler (‘M’ for Mlada Boleslav or ‘S’ for Salzgitter).
November 2011 production changes
On 7 November 2011, new versions of the CBZ engines were introduced (part no. 03F 103 101 B). For the post-November 2011 CBZ engines, changes included:
- A wider timing chain (part no. 03F 109 158 G);
- New chain guides (03F 109 509 and 03F 109 469 E);
- A black chain tensioner (changed material and size); and,
- An improved upper sprocket (changed materials and tooth design).
As such, the post-November 2011 1.2 TSI are not susceptible to the start-up rattle noise of the earlier engines. For reference purposes, however, the timing chain repair kit for these engines has the part no. 03F 198 158 B.
Pre-2012 VW Polo 1.2 TSI (CBZ): shim and ECU update
For pre-2012 Volkswagen 6R Polo vehicles with the 1.2 TSI engine (engine codes CBZA, CBZB and CBZC), the Mahle Rotary Electronic Actuator (REA) may malfunction due to the variable nozzle turbine (VNT) sticking as a result of carbon build-up. This may cause the following symptoms:
- The Electronic Power Control (‘EPC’) warning light would illuminate and the vehicle would enter ‘limp home’ mode;
- When slowing down in second gear (for example, prior to cornering or entering a roundabout), the driver may experience delayed power delivery when trying to subsequently accelerate; and,
- Error code P334B (Charge Pressure Control Actuator – Mechanical Malfunction) may be logged when driving, particularly when lifting off after heavy acceleration.
For Australia, potentially affected vehicles were limited to the Polo 77TSI (CBZB).
To fix,
- A 2 mm shim was to be fitted between the wastegate actuator and the turbo body; and,
- The engine control unit (ECU) was to be updated to calibrate the new actuator position.
It is understood that the ECU re-programming also provided more progressive power delivery.
Some owners experienced rough running subsequent to these measures being implemented. While dealers advised that this should resolve itself within 800 kilometres (500 miles), owners have reported that this has not always been the case.
Pre-2011 VW Polo 1.2 TSI: #3 cylinder HT lead failure
For pre-2011 VW Polo 1.2 TSI models, the high tension (HT) lead for cylinder three passes close to the exhaust manifold. Due to the heat of the exhaust manifold and the lack of insulating material for the HT lead, the lead can be damaged and cause the following symptoms:
- The Electronic Power Control (‘EPC’) warning light illuminates and the vehicle enters ‘limp home’ mode;
- Rough running; and/or,
- Loss of power.
It is understood that the HT leads on post-2012 1.2 TSI engines had heat-resistant sleeves at the coil end to protect against heat radiated from the exhaust manifold.
VW Polo with diesel engines: NOx emissions “defeat device”
Australian-delivered Volkswagen Mk.5 Polo vehicles powered by 1.6-litre diesel engines that were available for sale from 2009 to 2014 had software in the electronic control module (ECM) that could sense – via sensors measuring the position of the steering wheel, vehicle speed, the duration of the engine’s operation and barometric pressure – when the vehicle was undergoing emissions testing. The ECM would then run a ‘dyno calibration’ to produce lower nitrous oxide emissions during testing. At all other times, the ECM would run a separate ‘road calibration’ which reduced the effectiveness of the emission control system, specifically the selective catalytic reduction (SCR) or the lean NOx trap.
Based on testing conducted by the EPA and the California Air Resources Board (CARB), NOx emissions for the ‘road calibration’ were 10 to 40 times higher than US standards – this led the United States Environmental Protection Agency (EPA) to issue a notice of violation under the Clean Air Act.As a result, these vehicles did not meet the environmental standards claimed by Volkswagen.
Volkswagen 6R Polo: delayed deployment of rear head airbag
In 2011, Volkswagen UK issued a ‘non-code action’ for Volkswagen Polo vehicles due to potentially delayed deployment of the rear head airbag (NCA/2011/019); no further details were provided.
