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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Polo (from 1994 to 2001, the year of issue)

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Volkswagen Polo
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Volkswagen
Polo
General Information
Engine
Removing and installing engine
Disassembly and assembly of the engine
Cylinder head and valves
The pistons and connecting rods
Cylinder block
Crankshaft and main bearings
Timing
Exhaust system (OG)
Greasing system
Cooling
Fuel-injection systems
Ignition system
Coupling
Manual transmission
The drive wheels
A steering without the amplifier
A steering with the hydraulic booster
Front suspension
Rear suspension
Brakes
Electrical
Heating and ventilation system
Automatic Transmission
Applications
 


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Cylinder block



If complete disassembly carefully clean the cylinder block and remove from cavities and channels lubricating all deposits. Particular attention should be paid to the complete removal of cleaning fluids used for cleaning. If possible, use compressed air for drying.
To measure the working air gap of the piston to measure the diameters of the pistons (see. Fig. 67) and fix the values obtained.

Measurement of piston diameter (10 mm from the bottom edge of the piston skirt)
Fig. 67. Measurement of piston diameter (10 mm from the bottom edge of the piston skirt)




To determine the working gap inner diameter of the cylinder shall be measured as follows:
- Using the indicator bore gauge, measure the diameter of 10 mm from the top edge and then at the same distance from the bottom edge of the cylinder;
- Perform additional one dimension in the middle;
- Said measurements are carried out in the longitudinal direction, and then again with the same values of the depth in the transverse direction of the block. Record the results of all six dimensions. We recommend to make a drawing, similar to Fig. 74, and it indicates the measurement results. The difference between the upper and lower measurement determines the taper, the difference between the values of measuring the longitudinal and transverse directions gives roundness. None spot diameter must not deviate from the nominal size of more than 0.04 mm. In Fig. 74 (right) shows the values of wear during normal operation, (a) and with inadequate lubrication (b).

Measurement of Bore
Fig. 74. Measurement of Bore




Pistons are available in three sizes of repair, if necessary, the unit should be in addition to chisel and hone to the next size.
The surface of the cylinder checked for deformation as well as the cylinder head. Measure unit locksmith ruler and probe in the longitudinal, transverse and diagonal directions. Probe thickness greater than 0.10 mm should not enter into the gaps.




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Installation of pistons and rods
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Crankshaft and main bearings

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