Volkswagen Workshop Service and Repair Manuals

Assembly overview   Note All bearing and running surfaces must be oiled before assembly.

1 -

Circlip

2 -	Piston pin

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

q	Remove and install with drift -10-14-.

3 -

Piston

q	Check → Fig..

q	Mark installation position and cylinder number.

q	Arrow on piston crown points to belt pulley end.

q	Install using piston ring clamp.

4 -	Compression rings

q	Offset gaps by 120°.

q	Remove and install compression rings with piston ring pliers.

q	„TOP“ faces towards piston crown.

q	Checking ring gap → Fig..

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

5 -	Oil scraper rings

q	Carefully remove and install 3-part oil scraper rings by hand.

q	Checking ring gap → Fig..

q	Ring-to-groove clearance not measurable.

6 -

Conrod

q	Renew as set only.

q	Mark with cylinder number -A-.

q	Installation position: Marking -B- faces towards pulley end.

q	Guided axially by piston.

7 -	Conrod bearing cap

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.

8 -	Conrod bolt

q	M7×0.75: 20 Nm + 1/4 turn (90°) further.

q	M8×1: 30 Nm + 1/4 turn (90°) further.

q

Renew.

q	Oil threads and contact surface.

q	To measure radial clearance, tighten to corresponding specified torque but not further.

9 -	Cylinder block

q	Checking cylinder bores → Fig..

q	Piston and cylinder dimensions → Chapter.

10 -	Bearing shell

q	Do not interchange used bearing shells.

q	Insert bearing shells centrally.

Check radial clearance with Plastigage.

Do not rotate crankshaft when checking radial clearance.

q	New: 0.020…0.061 mm.

q	Wear limit: 0.091 mm

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

Piston ring dimensions in mm	New	Wear limit
1st compression ring	0.20...0.50	1.0
2nd compression ring	0.40...0.70	1.0
Oil scraper ring	0.40...1.40	--- → Remark

1)  No wear limit details available

Checking ring-to-groove clearance Special tools and workshop equipment required t  Feeler gauges –  Clean ring groove before checking.

Piston ring dimensions in mm	New	Wear limit
1st compression ring	0.04...0.08	0.15
2nd compression ring	0.04...0.08	0.15
Oil scraper ring	Not measurable

Checking piston Special tools and workshop equipment required t  External micrometer 75…100 mm –  Measure pistons approx. 10 mm from the lower edge of skirt, at 90° to the piston pin axis. Difference between actual and nominal diameter: not more than 0.04 mm. Nominal dimension → Chapter

Checking cylinder bores Special tools and workshop equipment required t  Cylinder gauge 50…100 mm –  Take measurements at 3 positions in both lateral direction -A- and longitudinal direction -B-. Difference between actual and nominal diameter max. 0.08 mm. Nominal dimension → Chapter   Note Cylinder bores must not be measured when cylinder block is mounted on engine and gearbox support -VAS 6095-, as measurements may be incorrect.