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-. |
|
|
|
| Bearing shells - installation position |
| – |
Centre bearing shells on conrod and on conrod bearing cap. |
|
|
|
| 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. |
|
|
|
Special tools and workshop equipment
required
Drift -VW 222 A-
Piston ring ...
Other materials:
Checklist
Never carry out any work on the engine or in the engine compartment
if you are not familiar with the requisite procedures and general safety requirements,
or if you only have access to incorrect operating equipment, service fluids,
and unsuitable tools . The work should be carried ou ...
Checking metering pump -V54- with end sealing valve
–
If you are uncertain as to whether the metering pump -V54--C-
has an end sealing valve or not, connect e.g. hand vacuum pump
-VAS 6213- to connection -A-.
–
Use hand-operated vacuum pump to a generate a vacuum of ...
2-pack HS clear coat
Designation:
2-pack HS clear coat -L2K 769 500 A5-
Issued 10.2012
Product description
2-pack HS clear coat is a VOC compliant, high-grade
high-solid clear coat.
...
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Removing and installing pistons