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:
Silicone remover
Designation:
Aqueous silicone remover -LSW 019 000 A5-
Silicone remover -LVM 020 000 A5-
Slow-drying silicone remover -LVM 020 100 A5-
Issued 02.2012
...
Removing and installing rear underbody cover – petrol/diesel
Note
The removal and installation procedures may have to be modified
slightly depending on engine fitted.
–
Loosen lock washer -3-.
–
Unclip spreader rivet -2- and remove
bolt -4-.
–
Remove rea ...
Rodent proofing
First read and observe the introductory information
and safety warnings Rodent proofing equipment is made up of special brushes
and casings and impedes entry to the engine compartment by rodents when the bonnet
is shut. This prevents damage caused to components by rodent bites.
NOTICE
If ...
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Removing and installing oil spray jets
Checking radial clearance of conrods