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:

Assembly overview - radiator cowl and radiator fan
1 - Bolt 5 Nm 2 - Radiator cowl Removing and installing → Chapter 3 - Radiator fan -V7- Removing and installing → Chapter ...

Hot air blower, 220 V / 50 Hz -VAS 1978/14-
Caution When shrink-fitting, take care not to damage any other wiring, plastic parts or insulating material with the hot air blower. Observe the operating instructions of the hot ai ...

Removing and installing water drain hoses
Note In models for “NAR” market, the left rear water drain hose ends in the left wheel housing. Removing front water drain hose – Remove A-pillar trim → General body repairs, interior; Rep. gr.70. ...