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:
Fitting control unit to hydraulic unit
Special tools and workshop equipment
required
ESD workplace -VAS 6613-
Torque screwdriver -V.A.G 1624-
Torx bit T25
Severe ...
Components of reversing camera system
The reversing camera system supports the driver during
reversing by providing the driver with an image of the traffic
situation behind the vehicle via display unit for control device
of front display and information control panel -J685-.
...
High-pressure safety valve
The high-pressure safety valve is fitted to the air
conditioner compressor or the receiver.
The valve opens at a pressure above approx. 38 bar and
closes again when the pressure has dropped (approx. 30 bar).
Not all the ...
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Removing and installing pistons