John Evans is a long-time motoring journalist and editor from titles such as What Car?, AutoCar and Practical Caravan.
The third generation of the VW Polo, launched in 1994, had brought real class and sophistication to the supermini class. Its successor, the Mk4, seized the baton and ran with it.
In fact, if anything, this Polo felt tougher and even better made. It was certainly well equipped with all versions having power steering and anti-lock brakes, and most a height-adjustable driver’s seat and multi-adjustable steering wheel.
A facelift in 2005 ushered in some new engines and trims, and a powerful petrol GTI version. A fun choice, if you can find one, is the Polo Dune of 2006. It’s a kind of crossover, with mini 4x4 looks. There’s a very economical BlueMotion 1.4 TDI version worth looking out for from this era, too.
Regardless of the year, the Polo Mk4 is available in three and five-door forms, and powered by a choice of petrol and diesel engines. The three-cylinder 1.2 petrol is nippy and economical; the 1.4 longer legged for more relaxed motorway driving.
Avoid the early 1.4 SDI diesel – it’s slow. Instead, go for a 1.4 TDI. The 1.9 TDI PD is the biggest surprise. It’s badged a GT and lives up to the name.
All versions are tidy handlers. Steering is accurate and well weighted, and there’s plenty of grip. The suspension is on the firm side but the pay-off is good body control in corners, and it’s mostly supple and forgiving.
There are many used Polos out there but prices are strong, even at this age. Don’t give up without a fight. The Ford Fiesta Mk5 is just as plentiful and good to drive, but cheaper and, as you’ll see, less troublesome.
How reliable is a VW Polo Mk 4?
Tough and classy it may be, but underneath that richly painted exterior the Polo is fragile, with the same problems reported across the entire range and at all years. Pre-facelift (2002-05) 1.2s suffered timing chain stretch (feel for lumpy running) and occasional snapping.
EGR (exhaust gas recirculation) valves and coils are another problem area.
Plastic timing belt tensioners on 1.4 and 1.6 petrols prone to breaking, and ECUs to faults. All this and corrosion under the window sealing strips at the bottom of the windscreen, as well as rust perforation in the front wheelarches caused by the liners rubbing.
For information on official safety recalls, check the DVSA recall website here. Examples include:
- Bolts of the tandem fuel pump cover may break (cars built 01/03/04 – 31/08/04)
- Seat may catch fire (01/05/05 – 28/02/07)
Engine
Problems here are legion and on pre-facelift 1.2s include fuel leakage (most versions built in 2004 were recalled to check the tandem fuel pump cover), a difficult engine start accompanied by a fluctuating idle (a faulty coil or EGR malfunction) and a misfire (faulty injector).
Others include engine surge when accelerating (believe it or not, a melted tail light bulb carrier plate), a fuel level indicator fault (damaged solders in the instrument cluster) and the engine going to limp home mode, with a jerky motion (damaged oxygen sensor wiring).
Power loss accompanied by rattling is possibly an incorrectly fitted or failing timing chain.
The 1.4 of the same era can suffer even more faults including running on three cylinders (a faulty coil) and regular illumination of the engine warning light (everything from contamination of the throttle body, in which case the electronic power control warning light may also come on, to a clogged catalytic converter).
On the 1.4 TDI of 2005-10, vibration from the engine compartment at low speeds in third or fourth gear could be a faulty engine damper (if fitted).
If the glowplug warning illuminates on the 1.9 TDI DPF of 2007-10 it could be that an oil plug is missing at the top of the engine, requiring replacement of the rocker shafts.
Transmission
Fewer problems here but on 1.2s from launch to 2007, an oil leak from the transmission rears its head from time to time. Check the tightening torque and if necessary, renew the seals.
The 1.6 with the DSG semi-automatic transmission from 2007 onwards may display the transmission warning light owing to lost adaptation values due to power supply fluctuations.
Steering and suspension
Increased steering effort can affect all versions and at all years. If no fault code is displayed, check the steering rack for a clogged union bolt.
Brakes
Loss of braking assistance was the subject of a recall affecting pre and post-facelift cars. The brake servo vacuum supply pipe could crack and leak.
Meanwhile, the ABS light illuminating could be a faulty ABS controller (check fault codes P04B1 and P012D). Not a problem confined to the Polo but certainly one it was known for was the handbrake seizing after being engaged for an extended period.
It’s caused by corrosion build-up between the brake linings and the drums.
Exterior and interior
Versions with heated seats were recalled over a risk of fire in the front seats. An incorrectly installed tension wire strap for the front seat backrest cover was suspected. The tension wire contacts the seat heating elements. The fix was to insulate the front seat tension wires.
The electric windows can play up on most versions and at all years. Check passenger or driver door for damaged wiring to control unit. If you have the equipment, check the CAN-Bus signal, too.
Electronics
Problems here are common. A fault with the air conditioning where no fault codes are displayed could be a damaged lock plate on the compressor. Faulty left-turn indicators could be damaged wiring.
If the brake pad wear indicator warning light illuminates, there’s a fuel level indicator malfunction and an incorrect ambient temperature reading, all occurring randomly, check for damaged solders in the instrument cluster.