Volkswagen Workshop Service and Repair Manuals

Note:

Do not rotate crankshaft when measuring radial clearance.

• Piston rings
• ◆ Ring gap offset 120°
• ◆ Use piston ring pliers for removing and installing
• ◆ Checking ring gap =>fig.1
• ◆ Checking vertical groove clearance =>fig.2
• ◆ Marking "TOP" points toward crown of piston
• ◆ Oil ring

• Piston
• ◆ Checking =>fig.3
• ◆ Mark installation position and cylinder No.
• ◆ Install using piston crown points toward pulley end
• ◆ Arrow on piston crown points toward pulley end
• ◆ Identifying version =>fig.5
• Conrod
• ◆ Always renew in sets
• ◆ Mark cylinder No. -A-
• ◆ Installation position: Marking -B- is toward the pulley end.
• ◆ Identifying version =>fig.8

• Bearing cap nuts
• ◆ Identification and tightening torque =>fig.7
• ◆ Oil contact surfaces
• ◆ Tighten to 30 Nm for radial clearance measurement, do not turn further
• Conrod cap
• ◆ Install in correct position
• Bearing shell
• ◆ Install in correct position
• ◆ Do not interchange
• ◆ Ensure proper fit in retaining grooves
• ◆ Axial clearance. Wear limit: 0.37 mm
• ◆ Measure radial clearance with Plastigage. Wear limit: 0.12 mm

• Cylinder block
• ◆ Check cylinder bores =>fig.4
• ◆ Pistons and cylinder dimensions
• Conrod bolt
• ◆ Identifying version
• Circlip
• Piston pin
• ◆ When dificult to move, heat piston to approx.60°C
• ◆ Removing and installing:
  Engine Code EG with VW 207c
  Engine Codes DX, JH, JJ, KT, 2H,with VW 222a
• ◆ Identifying version =>fig.6

→ Fig.1     Piston rings - Checking ring gap

• ‒ From the crankcase side, press ring evenly into cylinder bore to approx. 15mm from the cylinderm edge.

Engine Code: EG

Engine codes: DX, JH, JJ, KT, 2H

→ Fig.2     Piston rings - Checking ring groove clearance

New: 0.02...0.05 mm

Wear limit: 1.50 mm

→ Fig.3     Checking piston

Measure approx. 10 mm the lower edge at an angle of 90° to the piston axis.

Maximum deviation from specification =
     0.04 mm

→ Fig.4     Checking cylinder bore

• ‒ Take three measurements at right angles to one another both laterally -A- and longitudinally -B- .

Use internal dial guage 50...100 mm.

Maximum deviation from specifications is 0.08 mm

Note:

Measurements of cylinder bore should not be performed when cylinder block is attached to engine stand with VW 540, as incorrect measurements could result.

→ Fig.5     Pistons identification characteristics

Only pistons and pistons rings of the same version and pistons of the same weight rating should be installed the engine.

→ Fig.6     Pistons pins-Identification characteristics

→ Fig.7     Bearing cap bolts - Identification charateristics

→ Fig.8     Conrod - identification characteristics

→ Fig.9     Conrod bolts - Identification characteristics