Update (Long post)
The car is finally back with me. Had been to the workshop and after a long TD was satisfied the car is temporarily 'ok'. I handed over a letter mentioning all the breakdowns and replacements till date. Initially they refused to give any acknowledgement, but agreed to it finally and put their seal and Senior Service Manager's signature on our office copy.
He's promised he'll reply to it by mail, so will have to follow up on that.
Post 6k i notice changes in the engine. Its a lot smoother at lower revs and the lugging ability has certainly improved. I can now take big speed breakers with 4 on-board in the 2nd gear. I don't see any change in how the car surges. The steering noise has been taken care of, the gearbox is still hard but notice it is hard in other diesel polo's too,one with 11k on the odo.
Hope there are no breakdowns in future. Fingers crossed!
I drove the new-gen i20 a week ago (30 kms TD), here's a small comparison with my Polo.
Looks: I like how the i20 looks, especially from the front but the rear spoils the overall looks and is quite quirky. I'm a fan of german design and like simple,understated looks. So Polo is my pick.
Build Quality: i20 is built well, better than Swift for sure.But Polo is in a different league altogether, certain parts like the drivers door handle feel really very durable and overall Polo feels better built.
Engine: A full 5/5 for the i20. Excellent engine really! NVH is comparable to some 20 lakh rupee sedans, the cabin is well insulated and you don't hear the typical diesel clatter. It sounds nothing like a diesel, more like an unrefined petrol.
The throttle response even below 2k rpm is far better than in the Polo, you never feel that the car is under-powered with the i20, once the turbo kicks in at 2k rpm (no push back feeling) it only gets better. Power delivery is linear and mature.
Turbo-lag is there, but its much less than in the Polo and one can live with it within the city. On the highway this car can easily do 150+ without too much of an effort, it pulls like a locomotive even at 100+ km/hr.
However i didn't like the in-gear acceleration at all. If your stuck in the wrong gear, it takes quite sometime before the car gets moving and can lead to dangerous situations on the highway.But downshift, get back in the power-band and she flies!
Polo TDI in comparison is noisy,unrefined and lethargic below 2k rpm.Its pretty good post 2k rpm an you'll be happy with the power on hand and the throttle response. Polo cries for a 4cyl refined engine! VW are you listening ? Also you feel a lot of drivetrain movement on the pedals and the steering also to an extent.
Gearbox: The i20 gearbox is very smooth and not hard like in the Polo. The gears slot in well, but its not as sure slotting as in my Polo. Even though its slightly hard, i prefer the Polo's gearbox for the overall feel. The clutch in the i20 is smooth with short play, Polo's also smooth but with a long play. Pick what you want.
Suspension & Ride Quality: If the i20 owns the Polo when it comes to the engine, the Polo simply owns the i20 both in the city and highway when it comes to the Supension and the ride quality.
Polo has a slightly stiff ride at low speeds but it settles down at high speeds, the suspension makes a noise when you go over potholes but not much is felt in the cabin. On the open road the the ride is FLAT and the vertical movements are well controlled (by hatchback standards). Thanks to the higher GC you won't be scraping anywhere.
I drove the i20 where i usually drive my Polo and i found myself slowing down more than usual for familiar bumps and potholes. On the highways if your at speed the excessive vertical movement will scare the driver and the passenger. Its even worse if your mid corner and encounter such bumps. In the city, the low speed ride is pretty good but the suspension doesn't handle potholes as well as the Polo and you're better off slowing down.
Interiors are pretty good in the i20 too, but i prefer the Polo's dash, somehow it feels more upmarket and big-car like. i20 has more space and the front seats are a tad bit better, but Polo has more usable cup-holders in the front seat pockets. Boot space is more or less same.
Handling: Polo wins again, hands down! Polo also has an EPS and i hated it when compared to the Skoda's HPS, but its good enough and feels 'connected'. The handling at high speeds is big-car like, it masks speeds well and. You'll enjoy the handling and dynamics on the open road, only the engine will let you down if you're the kind who drives at 120+ all the time.
i20 in comparison is a total disaster. I had no idea that the steering could be so 'disconnected'. Its probably the worst in the segment and is devoid of ANY feel and is 'video game like'. Very scary at high speeds as you have no idea what the front wheels are upto. The speed masking ability is not as good as in the Polo and it makes you aware of what speeds you're doing. Dynamics made me chuck the old i20, and i'm disappointed nothing has changed since then.
I liked the brakes on my Polo as they have better bite and it cuts down speed MUCH quicker than the i20 which has disc brakes all around.
Equipment: i20 wins here, hands down! You get SO much for what you pay. Polo feels like daylight robbery at the same price with 50% equipment compared to the i20.
All in all the i20 is an awesome package, but I'd still buy the Polo as I like to drive car with sorted ride and handling whether I use it in the city or on the highway. Plus Polo with a re-map or a tuning box will help get rid of the dollops of turbo lag and improve drivability to be on par with i20.
So Polo it is for me now,due to lack of options (Punto ruled out by dad). Lets see in future (2014) if the New Polo comes with a 4cyl engine and 90+bhp i'll swap my car for that and still buy one in black only. Until then, its a remapped Polo or Polo with a tuning box. I want more power, so will wait for 6 months and if there are no breakdowns i'll go ahead with my plans.