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:

Balancing wheel, balancing wheel with finish balancer
Note Before working with a finish balancer, the mechanic needs to have been instructed by the manufacturer of the balancer. To balance the wheels, set the wheels of the driven axle on the sensor platforms. On front-w ...

Switching lights on and off
Fig. 82 Next to the steering wheel: examples of the various light switches First read and observe the introductory information and safety warnings Observe any country-specific regulations when using vehicle lighting. In vehicles with a factory-fitted towing bracket, the vehicle's re ...

Assembly overview - window regulator
1 - Front door 2 - Hexagon nut Qty. 5 6 Nm 3 - Window regulator Removing and installing → Chapter. 4 - Bolt Qty. 3 3 Nm 5&n ...