VW Golf manuals

Volkswagen Golf Service & Repair Manual: Assembly overview - pistons and conrods

Assembly overview - pistons and conrods

1 -  Bolts
Renew
Oil threads and contact surface
30 Nm + 90°
2 -  Conrod bearing cap
The conrod bearing cap only fits in one position and only on the appropriate conrod due to the breaking procedure (cracking) separating the cap from the conrod.
Mark allocation to cylinder and conrod in colour -B-.
Installation position: Lug -A- on conrod bearing cap faces towards pulley end
3 -  Bearing shells
Installation position → Fig.
Renew worn bearing shells
Ensure secure seating
4 -  Conrod
With industrially cracked conrod bearing cap
Renew as set only.
Mark allocation to cylinder and conrod bearing cap in colour -B-.
Measuring radial clearance → Chapter
Separate new conrod → Fig..
Installation position: Lug -A- on conrod bearing cap faces towards pulley end
5 -  Circlip
Qty. 2
Renew
6 -  Piston pin
Removing and installing → Chapter „Removing and installing pistons“
7 -  Piston
Mark installation position and cylinder number → Fig..
Removing and installing → Chapter
Checking piston and cylinder bore → Chapter
8 -  Piston rings
Compression rings
Measuring ring gap → Fig.
Measuring ring-to-groove clearance → Fig.
Use commercially available piston ring pliers to remove and install.
Installation position: marking “TOP” or side with lettering towards piston crown
Offset gaps by 120°.
9 -  Piston ring
Oil scraper ring
Measuring ring gap → Fig.
Measuring ring-to-groove clearance → Fig.
Use piston ring pliers to remove and install.
Installation position: marking “TOP” or side with lettering towards piston crown
Offset gap 120° relative to lower compression ring

 
     
Installation position and allocation of piston to cylinder
Arrow on piston crown points to pulley end -arrow-.
 

Assembly overview - pistons and conrods

Bearing shells - installation position
–  Centre bearing shells on conrod and on conrod bearing cap.
Dimension -a- = 2.5 mm.
 

Assembly overview - pistons and conrods

Separating new conrods
On new conrods it is possible that the breaking point is not fully separated. When the conrod bearing cap cannot be removed by hand, proceed as follows:
–  To avoid damage, gently clamp conrod in a vice with protection jaws, as shown in illustration.
Clamp conrod below dashed line.
–  Unscrew bolts -arrows- around 5 turns.
 

Assembly overview - pistons and conrods

–  Using a plastic hammer, carefully knock against conrod bearing cap -arrow- until it is loose.
 

Assembly overview - pistons and conrods

Pistons and conrods
...

Removing and installing pistons
Special tools and workshop equipment required     Drift -VW 222 A- Piston ring ...

Other materials:

Removing and installing front air distribution flap actuation unit, Climatronic
Removing –  Remove dash panel → General body repairs, interior; Rep. gr.70. –  Remove the air duct for the defroster vent → Chapter. –  ...

Assembly overview - long noise insulation
  Note The removal and installation procedures may have to be modified slightly depending on engine fitted. 1 -  Short noise insulation Removing –  Remove bolts -2-, -3- and -4-. –  Pull out ...

Checking inner constant velocity joint
Removing The joint is to be dismantled when following work is done: Replacement of grease if very contaminated Check of running surfaces for wear Check of balls for wea ...

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