Volkswagen Workshop Service and Repair Manuals

Assembly overview

1 -	Piston rings

q	Offset gaps by 120°.

q	Remove and install using piston ring pliers.

q	The 3 part oil scraper ring must be installed without piston ring pliers.

q	Removing and installing oil scraper ring → Chapter

q	“TOP” faces towards piston crown.

q	Checking ring gap → Fig..

q	Checking ring-to-groove clearance → Fig..

2 -

Piston

q	Checking → Fig..

q	Mark installation position and cylinder number.

q	Arrow on piston crown points to pulley end.

q	Install using piston ring clamp.

3 -	Piston pin

q	If difficult to remove, heat piston to 60 °C.

q	Remove and install with drift -VW 222 A-.

4 -

Circlip

5 -

Conrod

q	With industrially cracked bearing caps.

q	Renew as set only.

q	Mark cylinder number -B-.

q	Installation position: marking -A- faces towards pulley end.

6 -	Bearing shell

q	Note installation position → Fig..

q	Insert bearing shells centrally.

q	Do not interchange used bearing shells.

q	Check for secure seating.

Axial clearance

q	New: 0.10...0.35 mm

q	Wear limit: 0.4 mm

Check radial clearance with Plastigage.

q	New: 0.01...0.05 mm

q	Wear limit: 0.09 mm

q	Do not rotate crankshaft when checking radial clearance.

7 -	Cylinder block

q	Checking cylinder bores → Fig..

q	Piston and cylinder dimensions → Chapter.

8 -	Conrod bearing cap

q	Note installation position.

q	The caps only fit in one position and only on the appropriate conrod due to the breaking procedure (cracking) separating the cap from the conrod.

9 -	30 Nm + 1/4 turn (90°) further

q

Renew.

q	Oil threads and contact surface.

q	To measure radial clearance, tighten to 30 Nm but not further.

Checking piston ring gap Special tools and workshop equipment required t  Feeler gauges Test procedure –  Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.

Piston ring		Gap
		New	Wear limit
Compression rings	mm	0.20...0.40	0.8
Oil scraper ring	mm	0.25...0.50	0.8

Checking ring-to-groove clearance Special tools and workshop equipment required t  Feeler gauges Test procedure Clean groove before check.

Piston ring		Clearance
		New	Wear limit
Compression rings	mm	0.06...0.09	0.20
Oil scraper ring	mm	0.03...0.06	0.15

Checking piston Special tools and workshop equipment required t  External micrometer 75...100 mm Test procedure Measure pistons approx. 10 mm from the lower edge of skirt, at 90° to the piston pin axis. Deviation from nominal dimension max. 0.04 mm

Bearing shells - installation position Bearing shell -1- with oil hole -arrow- for conrod. Bearing shell -2- without oil hole for conrod bearing cap. –  Fit bearing shells in centre of conrod and conrod cap. Dimension -a- must be the same on the left and right.

Checking cylinder bores Special tools and workshop equipment required t  Dial test indicator 50...100 mm Test procedure –  Measure at 3 positions both across -A- and in-line with engine -B-. Deviation from nominal dimension max. 0.08 mm   Note Cylinder bores must not be measured when the cylinder block is secured to engine and gearbox support -VAS 6095-, as measurements may be incorrect.