Volkswagen Golf Service & Repair Manual: Removing and installing pistons

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Enginecrankshaft group, pistons / Pistons and conrods / Removing and installing pistons

Special tools and workshop equipment required

Drift -VW 222 A-

Piston ring clamp, commercially available

Removing

–	Removing cylinder head → Chapter

–	Remove sump upper part → Chapter.

–	Mark piston installation position and corresponding cylinder number.

–	Mark installation position and matching of cylinder and conrod bearing cap to conrod → Item.

–	Remove conrod bearing cap and withdraw piston and conrod upwards.

Note

If the piston pin is difficult to move, heat the piston to approx. 60°C.

–	Remove circlip from piston pin eye.

–	Drive out piston pin using drift -VW 222 A-.

Installing

Installation is carried out in the reverse order; note the following:

Note

Renew bolts that are tightened with specified tightening angle.

–	Oil running surfaces of bearing shells.

–	Install piston with commercially available piston ring clamp, noting installation position → Fig..

–	Install conrod bearing cap, noting installation position → Item.

–	Installing cylinder head → Chapter.

–	Remove upper part of sump → Chapter.

Specified torques

→ Chapter „Assembly overview - pistons and conrods“

Removing and installing pistons

Assembly overview - pistons and conrods

1 - Bolts Renew Oil threads and contact surface 30 Nm + 90° 2 - Conrod bearing ...

Removing and installing oil spray jets

Special tools and workshop equipment required Socket -T10545- Removing – Remove noi ...

Other materials:

Safety precautions when using testers and measuring instruments during a road test
Risk of injury through insecure testing and measuring instruments When the front passenger airbag is triggered in an accident, insufficiently secured testing and measuring instruments become dangerous projectiles. – Secure testing and measuring in ...

Assembly overview - cylinder block, gearbox end
Note For assembly work, secure engine to engine and gearbox support → Chapter. 1 - Bolt Renew 60 Nm + 90° 2 - Flywheel Removing and installin ...

Side view
Fig. 1 Overview of the driver side Key for : Roof aerial Tank flap Exterior door release lever Exterior mirrors Additional turn signal Surround lighting Jacking points ...