Volkswagen Golf Service & Repair Manual: Checking pistons and cylinder bores
| – |
Using a micrometre, measure approx. 10 mm from the lower
edge, perpendicular to the piston pin axis. |
| Maximum deviation from nominal dimension: 0.04 mm |
|
|
|
|
Piston diameter mm |
|
Specification |
74.42
1) |
| 1) Dimensions without coating |
| Piston manufacturer Federal Mogul (thickness of 0.018 mm per
side) |
| Piston manufacturer Mahle (thickness of 0.015 mm per side) |
|
| Measuring piston ring gap |
| – |
Push piston ring at right angles to cylinder wall from above
down into cylinder bore to approx. 15 mm from bottom end of
cylinder. |
| – |
Push in using a piston without piston rings. |
|
|
|
| Piston
ring |
New
mm |
Wear
limit
mm |
| Compression
ring |
0.20
+ 0.15 |
1.0 |
| Oil scraper ring (2
parts) |
0.20
+ 0.20 |
3.0 |
| Oil scraper ring
(3 parts) |
0.50
+/- 0.25 |
3.0 |
| Measuring ring-to-groove clearance |
| – |
Clean annular groove of piston before check. |
|
|
|
| Piston ring |
New
mm |
Wear limit
mm |
| 1st compression ring
(piston ring manufacturer Federal Mogul) |
0.050 … 0.090 |
0.15 |
| 1st compression ring
(piston ring manufacturer Mahle) |
0.035 … 0.085 |
0.15 |
| 2nd compression ring |
0.030 … 0.070 |
0.15 |
| Oil scraper rings (3
parts) |
Not
measurable |
| Oil scraper rings (2 parts) |
0.04 … 0.08 |
Risk of damage to the surface of the cylinder bore caused by incorrect
machining.Do not machine cylinder bore (reboring, honing, grinding) with
workshop equipment.
| – |
Using cylinder gauge -VAS 6078- take measurements at 3
positions diagonally in lateral direction
-A- and longitudinal direction -B-. |
| Maximum deviation from nominal dimension: 0.08 mm |
|
|
|
|
Cylinder bore diameter mm |
| Specification |
74.5 + 0.015
1)
+0.005 |
 Note
| Cylinder bores must not be measured when cylinder block is
mounted on engine and gearbox support -VAS 6095-, as
measurements may be incorrect. |
|
|
|
Special tools and workshop equipment
required
Socket -T10545-
Removing
–
Remove noi ...
Special tools and workshop equipment
required
Plastigage
Procedure
–
Remove conrod ...
Other materials:
Paintwork structure of factory finish, cathodic dip primer
Cathodic dip primer, 2-door version
-
Electrophoretic finish
Cathodic dip primer, 4-door
-
Electrophoretic finish
...
Electronic parking brake
Fig. 141 In lower part of centre console:
button for the electronic parking brake
First read and observe the introductory information
and safety warnings The electronic parking brake replaces the handbrake.
Switching on the electronic parking brake
The electronic parking brake can be swit ...
Removing and installing trim panel
Note
Removal and installation are described for the trim panel on
driver side. Follow same instructions for the front passenger
side as appropriate.
Removing
–
Remove rear door trim
...
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Removing and installing oil spray jets
Checking radial clearance of conrods