Table Of Contentv w
POLO
1994 to 1999 (M to S registration) Petrol & Diesel
aynes Service and Repair Manual
expert22 fl/m http://rutracker.org
Includes Roadside Repairs and MOT Test Checks
Contents
REPAIRS & OVERHAUL
Engine and associated systems
Petrol engine in-car repair procedures Page 2A»1
Diesel engine in-car repair procedures Page 2B»1
Engine removal and overhaul procedures Page 2C»1
Cooling, heating and ventilation systems Page 3»1
Fuel system - single-point petrol injection Page 4A«1
Fuel system - multi-point petrol injection Page 4B»1
Fuel system - diesel Page 4C«1
Emission control and exhaust systems Page 4D»1
Starting and charging systems Page 5A»1
Ignition system - petrol models Page 5B«1
Preheating system - diesel models Page 501
Transmission
Clutch Page 6»1
Manual transmission Page 7A*1
Automatic transmission Page 7B»1
Driveshafts Page 8*1
Brakes and suspension
Braking system Page 9»1
Suspension and steering Page 10*1
Body equipment
Bodywork and fittings Page 11*1
Body electrical systems Page 12*1
Wiring diagrams
Page 12*20
REFERENCE
Dimensions and weights Page REF*1
Conversion factors Page REF»2
Buying spare parts and vehicle identification Page REF»3
General repair procedures Page REF»4
Jacking and vehicle support Page REF«5
Radio/cassette anti-theft system - precaution Page REF»5
Tools and working facilities Page REF*6
MOT test checks Page REF»8
Fault finding Page REF»12
Glossary of technical terms Page REF»19
Index
Page REF»23
B*1
1
Chapter 1 Part B:
Routine maintenance & servicing - diesel models
Contents
Air filter renewal...................................................................................30 Lights and horn operation check......................................................... 7
Airbag unit check................................................................................. 8 Lubricate folding fabric sunroof guide rail...........................................22
Auxiliary drivebett check and renewal................................................25 Pollen fitter renewal...............................................................................24
Battery etee\to*y\e \eve& chcck..............................................................^2 Rear Vxake shoe tihecto..........................................................................>6
Brake fluid renewal ..............................................................................34 Regular maintenance............................................................................ 2
Braking system check..........................................................................15 Resetting service interval display ....................................................... 6
Coolant renewal....................................................................................33 Road test...............................................................................................20
Engine oil and filter renewal................................................................. 3 Steering and suspension check ..........................................................18
Exhaust emissions check ....................................................................35 Timing belt and belt tensioner renewal - engine codes AEF
Exhaust system check..........................................................................17 and AQD ...........................................................................................32
Fault code check...................................................................................11 Timing belt and belt tensioner renewal - engine codes AHG
Front brake pad check......................................................................... 4 and AKU..............................................................................................31
Fuel filter renewal..................................................................................23 Timing bolt condition and tension check - engine code AEF only .. 26
Fuel filter water draining ..................................................................... 5 Timing belt condition and wear check - engine codes AGD. AHG
Headlight beam alignment check ........................................................19 and AKU.............................................................................................27
Hinge and lock lubrication....................................................................10 Transmission and driveshaft gaiter check............................................14
Hose and fluid leak check....................................................................13 Transmission oil level check ................................................................28
Idle speed check - engine code AEF only...........................................21 Underbody protection check................................................................29
Introduction.......................................................................................... 1 Washer system(s) check..................................................................... 9
Degrees of difficulty
Easy, suitable for Fairly easy, suitable Fairly difficult. Difficult, suitable for Very difficult,
novice with Sttte (or beginner with suitable for competent ^ experienced DIY suitable for expert D(Y
experience some experience DIYmechanic mechanc or professional
Roadside repairs 09
Identifying leaks
Puddles on the garage floor or drive, or A Warning: Most automotive oils
The smell of a fluid leaking
obvious wetness under the bonnet or and fluids aro poisonous. Wash HAYNES
. from the car may provide a
underneath the car, suggest a leak that needs them off skin, and change out of
IH lN T j due to what's leaking. Some
investigating. It can somotimes be difficult to contaminatod clothing, without
' fluids are distinctively
decide where the leak is coming from, dolay.
coloured. It may help to ciean the car
especially if the engine bay is very dirty
carefully and to park it over some dean
already. Leaking oil or fluid can also be blown
paper overnight as an aid to locating the
rearwards by the passage of air under the car.
source of the leak.
giving a false impression of where the
problem lies. Remember that some leaks may only
occur while the engine is running.
Sump oil Oil from filter Gearbox oil
Engine oil may leak from the drain plug... ...or from the base of the oil filter. Gearbox oil can leak from the seals at the
inboard ends of the driveshafts.
Antifreeze Brake fluid Power steering fluid
Leaking antifreeze often leaves a crystalline A leak occurring at a wheel is almost Power stoering fluid may leak from the pipe
deposit like this. certainly brake fluid. connectors on the steering rack.
Towing
When all else fails, you may find yourself direction indicator and brake lights will work. □ The driver of tho car being towed must
having to get a tow home - or of course you □ A rear towing eye is provided below the keep the tow-rope taut at all times to avoid
may be helping somebody else. Long-distance rear bumper. The front towing eye is provided snatching.
recovery should only be done by a garage or in the vehicle tool kit. and is screwed into tho □ Make sure that both drivers know the route
breakdown service. For shorter distances. DIY front bumper after prising out the trim cover .
before setting off.
towing using another car is easy enough, but □ Before being towed, release tho handbrake
□ Only drive at moderate speeds and keep
observe the following points: and select neutral on tho transmission.
the distance towed to a minimum. Drive
□ Use a proper tow-rope - they are not □ Note that greater-than-usual pedal
expensive. The vehiclo being towed must pressure will be required to operato the smoothly and aHow plenty of time for slowing
display an 'ON TOW' sign in its rear window. brakes, since the vacuum servo unit is only down at junctions.
□ Always turn the ignition key to tho 'on' operational with the engine running. □ On models with automatic transmission,
position when the vehicle is being towed. 30 C On models with power stoering. greater- special precautions apply. If in doubt, do not
that the steering lock is released, and that the than-usual steering effort will also be required. tow, or transmission damage may result.
Engine removal and overhaul procedures 2013
^nlikoty to be confined to any one component,
so renewal of the camshaft, cylinder head and
bearing caps must be considered; seek the
advice of a cylinder head rebuilding specialist.
30 The difference between the outside
-ameters of the camshaft bearing surfaces
and the internal diameters formed by the
Gearing caps and the cylinder head must now
be measured, this dimension is known as the
camshaft running clearance.
31 The dimensions of the camshaft bearing
journals are not quoted by the manufacturer,
so running clearance measurement by means
of a micrometer and a bore gauge or internal 4.41 Measure the diameter of a valve stem 4.45 Measure the maximum deflection of
vernier calipers cannot be recommended in with a micrometer the valve in Its guide, using a DTI gauge
this case.
tolerance, tho camshaft and cylinder head valve end face flush with the top of the valve
32 Another (more accurate) method of
should be renewed. Note that undersize guide, measure the maximum side-to-sido
measuring the running clearance involves the
camshafts with bearing shells may be deflection of the valve In its guide (see
jse of Plastlgauge. This is a soft, plastic
obtained from VAG dealers, but only as part of illustration).
material supplied in thin sticks of about the
an exchange cylinder head package. 46 If the measurement is out of tolerance, the
same diameter as a sewing needle. Lengths of
40 On completion, remove the beanng caps valve and valve guide should be renewed as a
Plastigauge are cut to length as required, laid
and camshaft, and clean of all remaining pa*. Note: Valve guides are an interference fit
on the camshaft bearing journals and crushed
traces of Plastigauge and silicone release in the cylinder head, and their removal
as the bearing caps aro temporarily fitted and
agent. requires access to a hydraulic press. For this
tghtenod. The Plastigauge spreads
reason, it would be wise to entrust the job to
widthways as it is crushed; the running
Valves and associated components an engineering workshop or head rebuilding
c:earanco can then be determined by
Note: On alt engines, the valve heads cannot specialist.
measuring the increase In width using the
card gauge supplied with the Plastigauge kit. bo re-cut (although thoy may be lapped in): 47 Using vernier calipers, measure the free
new or exchange units must be obtained. length of each of the valve springs (seo
33 Tho following paragraphs describe this
41 Examine each valve closely for signs of Illustration). As a manufacturer's figure is not
measurement procedure step by step, but
wear. Inspect the valve stems for wear ridges, quoted, the only way to check the length of
note that a similar method is used to measure
scoring or variations in diameter; measure tho springs is by comparison with a new
rhe crankshaft running clearances; refer to
their diameters at several points along their component. Note that valvo springs are
:he illustrations In Section 11 for further
lengths with a micrometer (see illustration). usually renewed during a major engine
guidance.
42 The valve heads should not be cracked, overhaul.
34 Ensure that tho cylinder head, bearing cap
bactty pitted or charred Note that light pitting 48 Stand each spring on its end on a flat
and camshaft bearing surfaces are completely
of the valve head can be rectified by grinding- surface, against an engineer's square (see
dean and dry. Lay the camshaft in position in
in the valves during reassembly, as described illustration). Check the squareness of the
the cylinder head.
later in this Section. spring visually: if it appears distorted, renew
35 Lay a length of Plastigauge on top of each
43 Check that the valve stem ond face is free the spring. No squareness limits are specified
of the camshaft bearing journals.
from excessive pitting or indentation; this by the manufacturers.
36 Lubricate each bearing cap with a little
would be caused by defective hydraulic 49 Measuring valve spring pre-load involves
silicone release agent, then place them in
tappets. compressing the valve by applying a specified
oosition over the camshaft and tighten the
44 Place the valves in a V-block and usmg a weight and measuring the reduction In length.
retaining nuts down to the specified torque •
DTI gauge, measure the runout at the valve This may be a difficult operation to conduct in
refer to Reassembly later in this Section for
head. A maximum figure is not quoted by the the home workshop, so it would be wise to
guidance. Note: Where the torque setting is
manufacturer, but the valve should be approach your local garage or engineering
expressed in several stages, tighten the cap
renewed if the runout appears excessive. workshop for assistance. Weakened valve
fixings to the first stage only. Do not rotate the
45 Insert each valve into Its respective guide springs will at best, increase engine running
camshaft whilst tho bearing caps are in place,
in the cylinder head, and set up a DTI gauge noise and at worst, cause poor compression,
as the measurements wiM bo affected.
against the edge of the valve hoad. With the so defective items should be renewed.
37 Carefully removo the bearing caps again,
lifting thorn vertically away from the camshaft
:o avoid disturbing the Plastigauge. The
Plastigauge should remain on tho camshaft
bearing surface, squashed into a uniform
sausage shape. If it disintegrates as the
bearing caps are removed, re-clean the
components and repeat the exercise, using a
ittle more release agent on the bearing cap.
38 Hold the scale card supplied with the kit
against each beanng journal, and match the
width of the crushed Plastigauge with the
graduated markings on the card: use this to
determine the running clearances.
39 Compare the camshaft running clearance
measurements with those listed in the 4.47 Measure the free length of each of 4.48 Checking the squareness of a valve
Specifications: if any are outside the specified the valve springs spring
2014 Engine removal and overhaul procedures
4.51 Grinding-in a valve 4.56a Fitting a swirl chamber 4.56b Swirl chambor locating recess
(diesel engine code AEF)
Reassembly Attach the grinding tool to the valve head and of wood to protect the face of the swirl
using a backward/forward rotary action, grind chamber. Note tho locating recess on the side
Caution: Unloss all now components are to
the valve head into its scat (see illustration). of the chamber and the corresponding groove
be usod, maintain groups when refitting
Periodically lift the valvo and rotate it to in the housing (see illustrations).
valve train components - do not mix
rodistnbute tho grinding paste. 57 On completion, the projection of tho swirl
components between cylinders, and
ensure that components are refitted in 52 Continue this process until the contact chamber from the face of the cylinder head
between valve and soat produces an must be measured using a DTI gaugo and
their original positions.
50 To achieve a gas-tight seal between the unbroken, matt grey ring of uniform width, on compared with the limit quoted in the
valves and their seats, it will be necessary to both faces. Repeat the operation for the Specifications (see illustration). If this limit is
grind, or lap', the valves in. To complete this remaining valves. exceeded, there is a risk that the chamber
process, you will need a quantity of 53 If the valves and seats are so badly pittod may be struck by the piston, and in this case
fine/coarse grinding paste and a grinding tool that coarse grinding paste must be used, the advice of a professional cylinder head
• this can either be ot the dowel and rubber check first that there is enough material left on rebuildor or machine shop should be sought.
sucker type, or the automatic type which are both components to make this operation 58 Turn the head over and place it on a
driven by a rotary power tool. worthwhile - if too little material is left stand, or wooden blocks. Where applicable,
51 Smear a small quantity of fino grinding remaining, the valvo stems may protrude too fit the first lower spring seat into place, with
paste on the scaling face of the valve hoad. far above their guides, impeding the correct the convex side facing the cylinder head (see
Turn the cylinder head over so that the operation of the hydraulic tappets. Refer to a illustration).
combustion chambers are facing upwards, machine shop or cylinder head rebuilding 59 Working on one valve at a time, lubricate
and insert the valve into the correct guide. specialist for advice. the valve stem with clean engine oil. and
54 Assuming the repair is feasible, work as insert it into the guide. Fit one of tho
described in the previous paragraph but use protoctivo plastic sleeves suppliod with the
tho coarse grinding paste initially, to achtovo a new valve stem oil seals over the valve end
dull finish on the valvo face and seat. Then, face - this will protect the oil seal whilst it is
wash off coarse paste with solvent and repeat being fitted (see illustrations).
the process using fine grinding paste to obtain 60 Dip a new valve stem seal in clean engine
the correct finish. oil. and carefully push it over tho valve and
55 When all the valves have been ground in, onto the top of the valve guide - take care not
remove all traces ot grinding paste from tho to damage the stem seal as it passes over the
cylinder head and valves with solvent, and valve end face. Use a suitable long-reach
allow them to dry completely. socket to press it firmly into position (see
56 Where necessary on engine code AEF. fit illustrations).
new swirl chambers by driving them squarely 61 Locate the valve spring over the valve
into their housings with a mallet - use a block stem (see illustration).
4.57 Measuring swirl chamber projection
using a OT) gauge
4.58 Fit the lower spring seat in place, with 4.59a Lubricate the valve stem with clean 4.59b Fit one of the protective plastic
the convex face facing the cylinder head engine oil and insert It Into the guide sleeves over the valvo end face
Engine removal and overhaul procedures 2015
4.60a Fit a new valve stem seal over the 4.60b Use a long-reach socket to press on 4.61 Fitting a valve spring
v8lve the oil seal
62 Fit the upper seat over the top of Check before progressing any further that the illustration). Slide the seal along the camshaft
:ne spring, then using a valve spring spilt collets remain firmly held in the end of the until it locates in the lower half of its housing
rompressor. compress the spring until the valve stem by the upper spring seat. in the cylinder head.
jPPer seat is pushed beyond the collet 64 Smear some clean engine oil onto the 67 Oil the upper surfaces of the camshaft
grooves in the valve stem. Refit the split sides of the hydraulic tappets, and fit them bearing journals, then fit the bearing caps in
collet, using a dab of grease to hold the two into position in their bores in the cylinder head ptace. Ensure that they aro fitted tho right way
-alves in the grooves (see illustrations). (see illustration). Push them down until they around and in the correct locations, then fit
Gradually release the spring compressor, contact the valves, then lubricate the and tighten the retaining nuts, as follows:
checking that the collet remains correctly camshaft lobe contact surfaces.
Petrol engines
seated as the spring extends. When correctly 65 Lubricate the camshaft and cylinder head
seated, the upper seat should force the two bearing journals with clean engine oil, then 68 Note the fitted orientation of the camshaft
r%a!ves of the collet together, and hold them carefully lower the camshaft into position on bearing caps. The wider cast lugs must be
securely in the grooves in the end of the the cylinder head (see illustrations). Support positioned on the inlet side of tho head, and
valve. the ends of the shaft as it is inserted, to avoid the bearing cap identification numbers must
63 Repeat this process for the remaining sets damaging the lobes and journals. be readable from the exhaust side (see
of valvo components. To settle the 66 On diesel engines, with reference to illustration).
components after installation, stnke the end Chapter 2B, lubricate the lip of a new 69 Fit caps Nos 2 and 4 over the camshaft,
c' each valve stem with a mallet, using a block camshaft oil seal with clean engine oil. and and tighten the retaining nuts alternately and
of wood to protect the stem from damage. locate it over tho end of the camshaft (seo diagonally to the specified Stage 1 torque.
w m m
/ O k
4.62a Fit the uppor seat over the top of the 4.62b Use grease to hold the two halves of 4.64 Fit the tappets into their bores in the
valve spring the split collet in the groove cylinder head
4.65a Lubricate the camshaft bearings 4.65b ... then lower the camshaft into 4.66 Fitting the camshaft oil seal
with clean engino oil... position on the cylinder head (diesel engines)
2016 Engine removal and overhaul procedures
4.68 Petrol engine camshaft bearing cap 4.70 Smear the mating surfaces of cap No 4.73 Fitting a new camshaft oil seal
orientation 1 with sealant
A Cast lug 78 Refit the coolant outlet elbow, using a 2 With the pistons sitting halfway down the r
B Identification number new gasket/0-ring as necessary. bores, carefully feel around the tops of the
79 Refit the fuel injectors and glow plugs, cylinder bores. Any wear ridges found at the
70 Smear the mating surfaces of caps Nos 1
with reference to Chapters 4C and 5C. point whero the pistons reach top dead centre
and 5 with sealant (see illustration). Locate
caps Nos 1.3 and 5 over the camshaft, then fit All engines must be removed, otherwise the pistons may
bo damaged whon they are pushed out of
and tighten the nuts to the specified Stage 1 80 Refit the coolant temperature sensor and
their bores. This can be accomplished with a
torque. oil pressure switch.
scraper or ridge reamer.
71 Working in a diagonal sequence, tighten 81 With reference to Chapter 2A or 8 as
3 Scribe the number of each piston on its
all the beanng cap nuts to the specified Stage applicable, carry out the following:
crown, to allow identification later; note that
2 angle - use an angle gauge, if available, to a) Refit the timing belt sprocket to the
No 1 is at the timing belt end of the engine.
ensure accuracy. camshaft.
4 Using a set of feeler blados. measure the
72 Fit the nuts to bearing cap No S, and b) Refit the inlet and exhaust manifolds,
big-end to crankpin web thrust clearance at
tighten to the specified torque. completo with now gaskets.
each connecting rod. and record the
73 With reference to Chapter 2A, lubricate 82 Refer to Chapter 2A or B as applicable
measurements for later reference.
the lip of a new camshaft oil seal with clean and refit the cylinder head to tho cylinder
5 On diesel engines, remove the retaining
engine oil. and locate it over the end of the block.
screw and withdraw the piston cooling jets
camshaft (see illustration). Using a mallet
from their mounting holes (see illustrations).
and a long-reach socket of an appropriate
diameter, drive the seal squarely into its 5 Pistons and connecting rods 6 Rotate the crankshaft until pistons Nos 1
housing until it bears against the Inner stop - - removal and inspection and 4 are at bottom dead centre. Unless they
are already identified, mark the big-end
do not attempt to force it in any further.
bearing caps and connecting rods with their
Diesel engines respective piston numbers, using a centre-
A Warning: Petrol engine codes
74 The bearing cap mounting holes are punch or a scribe (see illustration). Note the
AER and ALL havo an aluminium
drilled off-centre; onsuro that they are fitted orientation of tho bearing caps in relation to
cylinder block, and the crankshaft
the correct way around (see illustration). the connecting rod; it may be difficult to see
on these engines must not bo
75 When fitting the bearing caps, the the manufacturer's markings at this stage, so
removed, or the block main bearings will
camshaft lobes for No 1 cylinder must be distort. Even loosening the main bearing scribe alignment arrows on them both to
facing upwards. caps will hove this effect. Take care, ensure correct reassembly. Note: On engine
76 Fit caps Nos 2 and 4 over the camshaft, therefore, that only the big-end cap bolts are codes AER end ALL. the caps will only fit the
and tighten the retaining nuts alternately and loosened during the following procedures. correct way round on the correct connecting
diagonally to tho specified torque. rod, as the caps are cracked off the rods
Removal
77 Now fit caps Nos 1. 3 and 5 over the during production. It is still advisable to mark
camshaft and tighten tho nuts to tho specified 1 Refor to Part A or B of this Chapter and the caps and rods for location and orientation,
torque. Ensure that cap No 5 is correctly remove the cylinder head, flywheel, sump and however, to save time when reassembling.
located by lightly tapping the end of the baffle plate, oil pump and pickup, as 7 Note the fitted orientation of the connecting
camshaft. applicable. rods and caps in relation to the timing belt end
engines are drilled off-centro, to ensure 5.5a Remove the piston cooling jet 5.5b ... and withdraw the jet from its
they are refitted the correct way round retaining screw (arrowed)... mounting hole
Engine removal and overhaul procedures 2017
5.6 Mark the big-end caps and connecting 5.9 Pad the bolt threads with tape 5.12a Insert a small screwdriver Into the
rods with their piston numbers (arrowod) slot and prise off the gudgeon pin circlips
3f the engine. Depending on engine code, there reassembly. If the pin proves difficult to 17 Examine the piston for signs of terminal
aril be some form of marking on the side of rod remove, heat the piston to 60*0 with hot wear or damage. Some normal wear will bo
and cap which faces the timing belt end - this water - the resulting expansion will then allow apparont, in the form of a vertical ‘grain’ on
ray be a punch mark, cut-out. raised dot or a the two components to be separated. the piston thrust surfaces and a slight
afferent profile in the casting. Make your own looseness of the top compression ring in its
Inspection
-arks on tho timing belt side of the rod and cap groove. Abnormal woar should bo carofully
t me manufacturer's marks are unclear. 13 Before an inspection of the pistons can be examined, to assess whether the component
8 Unbolt the bearing cap bolts/nuts, half a carried out. the existing piston rings must be is still serviceable and what the cause of the
•jn at a time, until they can be removed by removed, using a removal/installation tool, or wear might be.
•and. Recover the bottom shell bearing, and an old fooler blade if such a tool is not 18 Scuffing or scoring of tho piston skirt may
tape it to the cap for safo keeping. Note that if available (seo illustration). Always remove indicate that the engine has been overheating,
tr.e shell bearings are to be re-used, they the upper piston rings first, expanding them to through inadequate cooling, lubrication or
-~ust be refitted to tho same connecting rod. clear the piston crown. The rings are very abnormal combustion temperatures. Scorch
9 On engine code AEV, the beanng cap bolts brittle and will snap if they are stretched too marks on tho skirt indicate that btow • by has
remain in the connecting rod: in this case, much - sharp edges are produced when this occurred, perhaps caused by worn bores or
tne threads of the bolts should be padded happens, so protect your eyes and hands. piston rings. Burnt areas on the piston crown
*ith insulating tape, to prevent them from Discard the rings on removal, as new items are usually an indication of pre-ignition, pinking
scratching the crankpins when the pistons are must be fitted when the engine is or detonation. In extreme cases, the piston
amoved from their bores (see illustration). reassembled. crown may be melted by operating under these
tO Drive the pistons out of the top of their 14 Use a section of old piston ring to scrape conditions. Corrosion pit marks in the piston
bores by pushing on the underside of the the carbon deposits out of the ring grooves, crown indicate that coolant has seeped into tho
piston crown with a piece of dowel or a taking care not to score or gouge the edges of combustion chamber and/or the crankcase.
rammer handle. As the piston and connecting the groove. The faults causing those symptoms must be
rod emerge, recover the top shell bearing and 15 Carefully scrape away all traces of carbon corrected before tho engine is brought back
tape it to the connecting rod for safekeeping. from the top of the piston. A hand-held wire into service, or the same damage will recur.
11 Turn tho crankshaft through half a turn brush (or a piece of fine emery doth) can be 19 Check the pistons, connecting rods,
and working as descrtbod above, remove Nos used, once the majority of the deposits havo gudgeon pins and beanng caps for cracks.
2 and 3 pistons and connecting rods. boen scraped away. Be caroful not to remove Lay the connecting rods on a flat surface, and
Remember to maintain the components In any metal from tho piston, as it is relatively look along the length to see if it appears bent
•.heir cylinder groups, whilst they are in a soft. Note: Take care to preserve the piston or twisted. If you have doubts about their
dismantled state. number markings that were made during condition, get them measured at an
12 Insert a small flat-bladed screwdhver into removal. engineering workshop. Inspect the small-end
the removal slot, and prise the gudgeon pin 16 Once the deposits have been removed, bush bearing for signs of woar or cracking.
circlips from each piston. Push out the clean the pistons and connecting rods with 20 Using a micrometer, measure the
gudgeon pin. and separate the piston and paraffin or a suitable solvent, and dry diameter of all four pistons at a point 10 mm
connecting rod (see Illustrations). Discard thoroughly. Make sure that the oil return holes from the bottom of the skirt, at right-angles to
the circlips. as new itoms must be fitted on in the ring grooves are clear. the gudgeon pin axis (see illustration).
5.12b Push out the gudgeon pin and 5.13 Piston rings can be removed using on 5.20 Using a micromotor, measure the
separate tho piston and connecting rod old feeler blade diameter of all four pistons
2018 Engine removal and overhaul procedures
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5.21 Measuring the piston ring-to-groove 6.4 Measuring crankshaft endftoat using a 6.5 Measuring crankshaft endftoat using
clearance using a feeler blade OTI gauge feeler blades
Compare the measurements with those listed in rod and its bearing cap both have recesses pushed far enough up the bores so that they
the Specifications. If the piston diameter is out machined into them, close to their mating are positioned clear of the crankpins. The use
of the tolerance band listed for its particular surfaces - these recesses must both face the of an engine stand is strongly recommended
sizo. then it must be renewed. Note: If the same way as the arrow on the piston crown (ie 2 With reference to Chapter 2A or B as
cylinder block was re-bored during a previous towards the timing belt end of the engine) applicable, carry out the following:
overhaul, oversize pistons may have been fitted. when correctly installed. Reassemble the two a) Remove the crankshaft timing belt
Record the measurements and use them to components to satisfy this requirement. sprocket.
check the piston clearances when the cylinder 24 Lubricate the gudgeon pin and small-end b) Remove the clutch components, where
bores are measured, later in this Chapter. bush with clean engine oil. Slide the pin into applicable, and the ffywheel/driveplate.
21 Hold a new piston ring in the appropriate the piston, engaging the connecting rod c) Remove tho sump, baffle plate (where
groovo and measure the ring-to-groove small-end. Fit two new circlips to the piston at applicable), oil pump and pickup.
clearance using a feeler blade (see either end of the gudgeon pin. such that their d) Remove the front and rear crankshaft oil
illustration). Note that the rings are of open ends are facing 180* away from the seals and their housings.
different widths, so use the correct ring for the removal slot in the piston. Repeat this 3 Flemove the pistons and connecting rods. 3S
groove. Compare the measurements with operation for the remaining pistons. described in Section 5 (refer to the Note above
those listed; if the clearances are outside of 4 Carry out a check of the crankshaft endfloa*
the tolerance band, then the piston must be v\ as follows. Note: This can only be accom
Crankshaft -
renewed. Confirm this by checking the width plished when the crankshaft is still installed f
removal and inspection
of the piston ring with a micrometer. the cylinder block/crankcase, but is free to
22 Using internal/external vernier calipers, move. Set up a DTI gauge so that the probe <s
measure the connecting rod small-end internal in line with the crankshaft axis and is in contact
diameter and tho gudgeon pin external A Warning: Petrol engine codes with a fixed point on end of the crankshaft (see
diameter. Subtract the gudgeon pin diameter AER and ALL have an aluminium illustration). Push the crankshaft along its axts
from the small-end diamoter to obtain the cylinder block, and tho to the ond of its travol, and thon zero the
clearance. If this measurement is outside its crankshaft on these engines gauge. Push the crankshaft fully the other wa>
specification (where given), then the piston must not be removed, or the block main and record the endftoat indicated on the dial
and connecting rod bush will have to be bearings will distort. Even loosening tho Compare the result with the figure given in the
resized and a new gudgeon pin installed. An main bearing caps will have this effect. For Specifications and establish whether new
engineering workshop wil have the equipment this reason, If crankshaft or main bearing thrustwashers are required.
needed to undertake a job of this nature. wear is suspectod, the crankshaft and 5 If a dial gauge is not available, feeler blades
23 The orientation of the piston with respect cylinder block must bo renewed complete. can bo used. First push the crankshaft fully
to the connecting rod must be correct when towards the flywheel end of the engine, then
the two are reassembled. The piston crown is Removal use a feeler blade to measure the gap
marked with an arrow (which may be 1 Note: If no work is to be done on the between cylinder No 2 crankpin web and the
obscured by carbon deposits): this must point pistons and connecting rods, then removal of main bearing thrustwasher (see illustration)
towards the timing belt end of the engine the cylinder head and pistons will not be Compare the results with the Specifications.
when the piston is installed. The connecting necessary. Instead, the pistons need only be 6 Observe the manufacturer's identification
marks on the main bearing caps. The number
relatos to the position in the crankcase, as
counted from the timing belt end of the engine
(sco illustration).
7 Loosen the main bearing cap bolts one
quarter of a turn at a time, until they can be
removed by hand. Using a soft-faced mallet
strike the caps lightly to free them from the
crankcase. Recover the lower main bearing
shells, taping them to the cap for safekeeping.
Mark them with indelible ink to aid
identification, but do not score or scratch
them in any way.
8 Carefully lift the crankshaft out. taking care
I 6.6 Manufacturer’s identification markings 6.8 Lifting the crankshaft from the not to dislodge the upper main bearing sheiis
on the main bearing caps (arrowed) crankcase (see illustration). It would be wise to get ar
