Volkswagen Workshop Service and Repair Manuals > Polo Mk5 > Power unit | 4-cylinder diesel engine (1.6 l engine, common rail) | Enginecrankshaft group, pistons | Pistons and conrods

Measuring piston projection at „TDC“

Note

t	Piston projection at „TDC“ must be measured when installing new pistons or a short engine.

t	If you have measured the piston projection and it is not same for all pistons, use the highest value to determine the correct gasket size.

t	Install the appropriate cylinder head gasket depending upon piston projection, according to following table:

Special tools and workshop equipment required

t	Measuring bridge -VW 382/7- from measuring tool -VW 382-

t	Measuring plate -VW 385/17- from universal measuring tool -VW 385-

t	Dial gauge -VAS 6079-

Procedure

–	Secure dial gauge -VAS 6079- with measuring bridge -VW 382/7- and measuring plate -VW 385/17- to cylinder block as shown in the illustration.

–	Measure the projection of each piston at the two points marked with -arrows- (at the rear side and front side of the piston seen in the longitudinal direction of the engine).

–	Install the appropriate cylinder head gasket depending upon piston projection, according to following table:

Piston projection over upper edge of cylinder block mm	Identification (No. of holes)
0.91 … 1.00	1
1.01 … 1.10	2
1.11 … 1.20	3

Cylinder head gasket identification

1 -	Part number

2 -

Holes

3 -

Ignore

Note

If the measured values for piston projection are not the same for all pistons, use the highest value to determine the correct gasket size.

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