Volkswagen Golf Service & Repair Manual: Assembly overview - pistons and conrods
| Oil threads and contact surface |
| 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 |
| Installation position → Fig. |
| Renew worn bearing shells |
| With industrially cracked conrod bearing cap |
| 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 |
| Removing and installing
→ Chapter „Removing and installing pistons“ |
| Mark installation position and cylinder number
→ Fig.. |
| Removing and installing
→ Chapter |
| Checking piston and cylinder bore
→ Chapter |
| 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 |
| 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-. |
|
|
|
| Bearing shells - installation position |
| – |
Centre bearing shells on conrod and on conrod bearing cap. |
|
|
|
| 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. |
|
|
|
| – |
Using a plastic hammer, carefully knock against conrod
bearing cap -arrow- until it is
loose. |
|
|
|
Special tools and workshop equipment
required
Drift -VW 222 A-
Piston ring ...
Other materials:
Removing and installing upper rear lid trim
Special tools and workshop equipment
required
Wedges -T10383
Removing
–
Detach retaining straps for rear shelf on left and right from window
...
Paint thickness tester -VAS 6197
Designation:
Paint thickness tester -VAS 6197-
Product description
Fully electronic paint thickness tester with 2 independently
functioning probes and liquid crystal display. Measurements are
...
Removing and installing hinges
Special tools and workshop equipment
required
Note
Removal and installation are described for the right
hinge only. Removal and installation of the left hinge are
similar.
...
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Removing and installing pistons