Polo Mk5
| Assembly overview |
| 1 - | Piston |
| q | Checking → Chapter |
| q | Mark installation position and cylinder number |
| q | Arrow on piston crown points to pulley end |
| q | Install using piston ring clamp |
| 2 - | Piston pin |
| q | If difficult to remove, heat piston to 60 °C |
| q | Remove and install with drift -10-14- |
| 3 - | Circlip |
| 4 - | Conrod |
| q | Renew as set only |
| q | Mark with cylinder number -A- |
| q | Installation position: Marking -B- faces towards belt pulley end |
| q | Guided axially by piston |
| 5 - | Bearing shell |
| q | Do not interchange used bearing shells |
| q | Insert bearing shells centrally |
| Check radial clearance with Plastigage: |
| q | New: 0.020...0.060 mm |
| q | Wear limit: 0.090 mm |
| q | Do not rotate crankshaft when checking radial clearance |
| 6 - | Cylinder block |
| q | Checking cylinder bores → Chapter |
| q | Piston and cylinder dimensions → Chapter |
| 7 - | Conrod bearing cap |
| q | Caps fit only in one position and only on the corresponding con-rod due to breaking procedure (cracking) for separating cap from con-rod |
| 8 - | Conrod bolt |
| q | M7×0.75: 20 Nm + 1/4 turn (90°) further |
| q | M8×1: 30 Nm + 1/4 turn (90°) further |
| q | Renew |
| q | Oil threads and contact surface |
| q | To measure radial clearance, tighten to corresponding specified torque but not further |
| 9 - | Oil scraper rings |
| q | Carefully remove and install 3-part oil scraper rings by hand |
| q | Checking ring gap → Fig. |
| q | Ring-to-groove clearance cannot be measured |
| 10 - | Compression rings |
| q | Offset gaps by 120° |
| q | Remove and install compression rings with piston ring pliers |
| q | “TOP” faces towards piston crown |
| q | Checking ring gap → Fig. |
| q | Checking ring-to-groove clearance → Fig. |
