Golf Mk4
| Dismantling and assembling pistons and conrods |
| 1 - | Piston rings |
| q | Offset gaps by 120°. |
| q | Remove and install using piston ring pliers. |
| q | Marking “TOP” in relation to piston crown |
| q | Check ring gap → Fig.. |
| q | Check ring-to-groove clearance → Fig.. |
| 2 - | Piston |
| q | Check → 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 in centre. |
| q | Do not interchange used bearing shells. |
| q | Check for secure seating. |
| q | Axial clearance new: 0.10...0.35 mm, wear limit: 0.4 mm. |
| q | Check radial clearance with Plastigage: new: 0.01...0.05 mm, wear limit: 0.09 mm. Do not rotate crankshaft when checking radial clearance. |
| 7 - | Cylinder block |
| q | Check 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 | Torx E 10 |
| q | Renew. |
| q | Oil threads and contact surface. |
| q | To measure radial clearance, tighten to 30 Nm but not further. |
