The New Polo - Engines and transmissions

Seven engines will be offered on the new Polo during its first year of production – four gasoline and three diesels. Five of these engines are either brand new or new to the Polo; three of them can be paired with the innovative 7-speed dual clutch transmission (DSG) as an option instead of the manual 5-speed or 6-speed transmission. All engines satisfy limits of the new Euro-5 emissions standard.

The gasoline engines, two three-cylinder and two four-cylinder engines, sport a power range extending from 44 kW / 60 PS to 77 kW / 105 PS. New to the lineup are the two most powerful gasoline engines, the 1.4 liter with 63 kW / 85 PS and the 1.2 TSI with the noted 105 PS that is shifted by a standard 6-speed transmission.

Also new to the Polo are all three common rail turbo-diesels. These high-torque four-cylinder engines produce between 55 kW / 75 PS and 77 kW / 105 PS. A BlueMotion Technology version based on the mid-range power level of 66 kW / 90 PS will also debut in 2009; this Polo will consume just 3.6 liters of fuel per 100 kilometers and emit only 96 g/km CO₂. A summary of all engines being offered on the Polo in 2009:

Gasoline engines

Diesel engines

* Optional with 7-speed dual clutch transmission
Forecast value
* Values for TDI with BlueMotion package

Gasoline engines in detail

1.2 MPI with 44 kW / 60 PS and 51 kW / 70 PS

Entry into the world of Polo engines is offered by two proven three-cylinder engines with 60 PS or optional 70 PS and a multi point injection (MPI) engine. The 1.2-liter engines were further perfected in terms of weight, acoustics and attainment of the Euro-5 emissions standard for use in the new generation of the Polo. One example of a technical modification exhibited by the agile and economical three-cylinders is an optimized reduced-noise chain for the timing and oil pump drives. Engine management was also reconfigured. Technical modifications made in the engine area and body-related improvements have resulted in fuel consumption savings of an average of 0.3 liters per 100 kilometers relative to comparable versions of the previous model. CO₂ emissions were similarly reduced from 138 to 128 g/km.

Both 1.2-liter engines aboard the Polo, each with four valves per cylinder, consume 5.5 liters of super or normal gasoline in combined mode. This contrasts with a respectable top speed of 157 km/h and 16.1 seconds for the sprint from 0 to 100 km/h for the lightweight 1067 kilogram* 60-PS version. The 70-PS version reaches a top speed of 165 km/h and can sprint to 100 km/h in 14.1 seconds if necessary.
(* includes driver weighing 68 kg, 7 kg of luggage and fuel tank 90 % full)

The 60-PS 1.2 MPI engine delivers its maximum power at 5,200 rpm; its maximum torque of 108 Newton-meter is available at 3,000 rpm. The Polo with 70 PS develops its maximum power at 5,400 rpm; its 112 Newton-meter maximum torque is available at an identical 3,000 rpm. While the 60-PS engine is paired with the base "Trendline" version, the 70-PS engine may also be ordered as an option on the higher "Comfortline" equipment line.

1.4 MPI with 63 kW / 85 PS

The most powerful gasoline engine in the Polo lineup at the time of market launch is the 1.4 MPI that is equipped with new engine electronics and a new injection system as well. The four-cylinder aluminum block engine outputs 85 PS (at 5,000 rpm). Its maximum torque of 132 Newton-meter is available at 3,800 rpm. For the first time on a Polo, this engine will be available with an optional 7-speed dual clutch transmission over the mid-term.

Besides offering good comfort and dynamic performance, the just 95 kilogram heavy – or rather light – engine is distinguished above all by its excellent economy. The Polo 1.4 MPI, when paired with standard 5-speed transmission, consumes 5.9 liters fuel per 100 kilometers on average. This puts its CO₂ value at 139 g/km. With this engine too, it was possible to significantly reduce fuel consumption and emissions compared to the previous model. And indeed by 0.4 liter and 11 g/km CO₂. As on the three-cylinder engines, the three-way catalytic converter of the four-cylinder is equipped with an optimized noble metal coating with the goal of impressively fulfilling Euro-5 emissions limits.

When it comes to dynamic performance, the Polo 1.4 MPI scores points with a top speed of 177 km/h and a 0-100 km/h sprint time of 12.1 seconds. In this case, the engine's elasticity is also very good: in fifth gear this Polo accelerates from 80 to 120 km/h in just 18 seconds. The 1.4-liter engine can be ordered with either the "Comfortline" or "Highline" version.

1.2 TSI with 77 kW / 105 PS

A new Volkswagen highlight in drive technology is the 1.2 TSI of the Polo. It is debuting sometime this year. The turbocharged four-cylinder engine was completely redeveloped, and it follows the downsizing philosophy of the internationally successful 1.4 TSI and 2.0 TSI. This expresses itself as maximum power with minimal fuel consumption. The latest TSI is characterized by sensational performance data. For example, the 105 PS Polo 1.2 TSI accelerates from a standstill to 100 km/h after just 9.7 seconds and can move at 190 km/h if necessary. This contrasts with fuel consumption and emissions values on the level of the already very good 60-PS base version: 5.5 liter consumption and 129 g/km CO₂. Compared to the retired 1.6-liter engine of the previous model, average fuel consumption was lowered by 1.2 liter (!). This corresponds to a 30 g/km reduction in CO₂ emissions.

The 1.2 TSI reaches its peak power at 5,000 rpm. The maximum torque of 175 Newton-meter – from 1.2 liters of displacement – is available between 1,500 and 3,500 rpm. The Polo 1.2 TSI is delivered with a standard 6-speed manual transmission. As an option, this engine may also be paired with the 7-speed DSG developed by Volkswagen. Plans call for offering the TSI together with the "Comfortline" and "Highline" equipment lines.

Diesel engines in detail

1.6 TDI with 55 kW / 75 PS, 66 kW / 90 PS and 77 kW / 105 PS

The common rail diesels of the fifth generation Polo are entirely new developments. They output 75 PS, 90 PS and 105 PS. A version of the 90-PS TDI with BlueMotion package is also being offered; it consumes just 3.6 liters of diesel per 100 kilometers. All Polo TDIs come with a standard diesel particulate filter (DPF).

Like the 2.0-liter TDIs with common rail direct injection, the 1.6-liter four-cylinder, 16-valve engines exhibit ideal acoustic properties, a high level of agility and – a crucial factor here – extremely low fuel consumption and emissions. Of course, all variants of the Polo 1.6 TDI fulfill limits of the new Euro-5 emissions standard.

Technically, the 1,598 cm3 displacement TDI in this segment sets the highest standard on the market. Using a common rail system, the diesel fuel is sprayed directly into the combustion chamber at a pressure of 1,600 bar. Piezo actuators control multiple injections with highly precise fuel quantities and timing.

In an effort to reduce internal engine friction, crankshaft, valve and oil pump drives were optimized. A square stroke/bore ratio minimizes friction losses at the cylinder liners. Furthermore, flow energy losses were reduced in oil and coolant loops as well as air induction and charge air flows. This has resulted in a lineup of TDI engines that offers uncompromisingly low fuel consumption and emissions without lacking in comfort or dynamic performance in the least.

1.6 TDI with 55 kW / 75 PS

The 75-PS version already outputs a maximum torque of 195 Newton-meter between 1,500 and 2,000 rpm. Fuel consumption: 4.2 liters. CO₂ emissions: 109 g/km. Its maximum power is output at 4,000 rpm. In this version, the Polo 1.6 TDI can move at 170 km/h and accelerates to 100 km/h in 13.9 seconds. When shifted by the standard 5-speed transmission, the car takes exactly 18.0 seconds for the elastic sprint from 80 to 120 km/h in top gear.

1.6 TDI with 66 kW / 90 PS

Those wishing to reduce costs of ownership, fuel consumption and emissions even further will want to order the new Polo 1.6 TDI with the BlueMotion package. Here the car's power is 90 PS, and thanks to the innovative array of Volkswagen fuel-saving measures – including an automatic start-stop system – fuel consumption is just 3.6 liters of diesel per 100 kilometers. And that corresponds to a CO₂ value of just 96 g/km. In the standard version without BlueMotion package the 90-PS TDI consumes 4.2 liters. The 90-PS TDI engines provide their maximum torque of 230 Newton-meter between 1,500 and 2,500 rpm.

1.6 TDI with 77 kW / 105 PS

The most dynamic engine, the 105-PS version, goes to work with 250 Newton-meters of torque (1,500 to 2,500 rpm). It accelerates to 100 km/h in 10.4 seconds and reaches a top speed of 189 km/h. Average fuel consumption: 4.2 liters diesel per 100 kilometers. Economizing with the Polo is fun too.

DSG dual clutch transmission 

7-speed DSG

The new Polos are delivered with standard, precise-shifting and well staged 5-speed transmissions. In the case of the 1.2 TSI, a 6-speed transmission is also used. The 7-speed dual clutch transmission (DSG) on the Polo delivers a new maximum of efficiency, dynamic response and comfort. It is offered as an option on the 1.4 MPI with 85 PS, 1.6 TDI with 90 PS and 1.2 TSI with 105 PS. The transmission can be individually tuned for the use of different engines by calibrating various individual parameters, characteristic curves and maps.

Layout and operation of the 7-speed-DSG

The world's first 7-speed DSG for large-scale production has – as its most prominent design characteristics – two dry clutches whose pressure is regulated hydraulically. Engine power is transmitted to the dual clutch via the crankshaft and a dual-mass flywheel. Clutch I handles the odd-numbered gears, and clutch II the even gears plus reverse gear. The results of this sophisticated clutch management: when shifting, there are no gaps in propulsive power. Comfort and convenience are excellent, and the driver experiences an incomparably dynamic yet comfortable shifting feeling.

Responsible for this – along with an intelligent mechatronic system (electro-hydraulic transmission control) – are two clutches as well as two drive shafts and three final drive shafts. This networked system makes it possible to continually "lie in wait", ready to go into action at the next higher driving level. And indeed it is lightning-fast. Example: while the Polo is driven in sixth gear, the seventh gear is already engaged, but is not yet "active". As soon as the ideal shifting point has been reached, the clutch responsible for sixth gear automatically opens, while the other one closes and "pre-activates" seventh gear. This produces an overlap between opening and closing of the two clutches, and this leads to the comfortable shifting described above. The entire shifting process is completed within a few hundredths of a second, which is much faster than even the most highly trained professional driver could achieve.

Some exciting numbers on the 7-speed DSG

• 1.7 liters of oil operate in the 7-speed DSG
• 70 kilograms is the weight of the 7-speed DSG
• 250 Newton-meter is the maximum torque of engines that can be paired with the 7-speed DSG
• 2003 was the year in which the first DSG was introduced (6-speed DSG in the Golf R32)
• 2005 was the year in which the powerful 1001 PS Bugatti Veyron 16.4 was launched with DSG
• 2007 (end of the year) is when series production began for the 7-speed DSG (first used in the Golf TSI with 90 kW)
• 2009 is when the 7-speed DSG first appears in the Polo

Note:
All data and equipment contained in this press release apply to models offered in Germany. They may differ in other countries. All information is subject to change or correction.
TDI, TSI, DSG and Twincharger are registered trademarks of Volkswagen AG or other companies of the Volkswagen Group in Germany and other countries.