Volkswagen Golf Mk1 Workshop Service and Repair Manuals

• Piston rings
• ◆ Offset gaps by 120°
• ◆ Remove and install with piston ring pliers
• ◆ "TOP" towards piston crown
• ◆ Checking piston ring gap =>Fig. 1
• ◆ Checking piston ring groove clearance => Fig. 2
• Piston
• ◆ Checking => Fig. 3
• ◆ Mark installation position and cylinder number.
• ◆ Arrow on piston crown faces pulley end
• ◆ Install using piston ring clamp
• ◆ Identification => Fig. 4
• Conrod
• ◆ Renew in sets only
• ◆ Mark with respect to cylinder -A-
• ◆ Installation position: Marks -B- face pulley end
• ◆ Identification => Fig. 5

• Conrod nut
• ◆ Identification and tightening torque => Fig. 6
• ◆ Lubricate thread and the support surface
• ◆ To measure radial clearance tighten to 30 Nm, but do not turn further
• Conrod cap
• ◆ Installation position: Marks -B- face pulley end
• Bearing shell
• ◆ Watch position
• ◆ Do not interchange used bearing shells
• ◆ Ensure tight fit in the retaining lugs
• ◆ Axial clearance Wear limit: 0.37 mm
• ◆ Check radial clearance with Plastigage Wear limit: 0.12 mm
• ◆ Do not rotate crankshaft when measuring the radial clearance

• Cylinder block
• ◆ Checking cylinder bore => Fig. 7
• ◆ Piston and cylinder dimensions =>page 13-43
• Conrod bolt
• ◆ Identification => Fig. 8
• Circlip
• Piston pin
• ◆ Heat piston to 60 °C if stiff
• ◆ Removing and installing:
  dia. 22 mm with VW 207 c
  dia. 20 mm with VW 222 a
• ◆ Identification => Fig. 9
• ◆ Piston with short piston pin => Fig. 10

→ Fig.1     Checking piston ring gap

Push ring squarely from above into lower end of cylinder approx. 15 mm away from edge of the cylinder.

→ Fig.2     Checking piston ring groove clearance

Clean groove before checking.

→ Fig.3     Checking pistons

Check approx. 10 mm from bottom of skirt offset by 90° with respect to piston pin axis.

Deviation from specified dimension: max. 0.04 mm.

→ Fig.4     Piston distinguishing features

     1)     Flat piston

Bore ø= 76.5 mm

Bore ø= 76.5 mm

Note:

When performing repairs, an engine may only be fitted with pistons and piston rings of the same desin and pistons from the same weight category.

→ Fig.5     Connecting rod distiguishing features

→ Fig.6     Conrod nut distinguishing features

→ Fig.7     Checking cylinder bore

• ◆ Measure bore at 3 locations crosswise in tranverse -A- and axial direction -B-.
• ◆ Use 50 ... 100 mm internal precision dial gauge.
• ◆ Deviations from specified dimension: max. 0.08 mm.

Note:

Measuring the cylinder bore must not be done when the cylinder block is attached to repair stand with adapter VW 540 as incorrect measurements may then result.

→ Fig.8     Conrod bolt distinguishing features

→ Fig.9     Piston pin distinguishing features

→ Fig.10     Piston with short piston pin

With a = 55 m piston pin the piston was flattened off in the area of the piston pin bore -arrow-.

Note:

When performing repairs, an engine may only be fitted with pistons and piston rings of the same desing and piston from the same weight class.