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-. |
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| Bearing shells - installation position |
| – |
Centre bearing shells on conrod and on conrod bearing cap. |
|
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| 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. |
|
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|
Special tools and workshop equipment
required
Drift -VW 222 A-
Piston ring ...
Other materials:
Windscreen and rear window washer system
Pull the two coupling sections apart (no securing device) to
loosen the connection.
–
To secure the connection, push the two coupling sections
together, until you hear and feel them engage.
...
Removing and installing rain and light sensor, vehicles with front camera
for driver assist systems
Note
The rain and light sensor has a silicon layer (coupling pad)
which forms the contact surface to the windscreen.
The rain and light sensor has been designed so that it can
be used again. A prerequisite for re-use ...
Switching TCS or TCS with ESC on and off
Fig. 142 In the centre console: button
for switching the traction control system (TCS) or electronic stability control
(ESC) on and off manually
Fig. 143 In the centre console: button
for switching the traction control system (TCS) on and off manually (vehicles without
ESC)
First read an ...
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Removing and installing pistons