Volkswagen Workshop Service and Repair Manuals

• Piston rings
• ◆ Offset gaps by 120 °
• ◆ Use piston ring pliers to remove and install
• ◆ Manufacturer's mark faces towards piston crown
• ◆ Checking ring gap=> fig. 1
• ◆ Checking ring to groove clearance => fig. 2
• Piston
• ◆ Checking => fig. 3
• ◆ Mark installation position and cylinder number
• ◆ Arrow on piston crown points to belt pulley end
• ◆ Install using piston ring clamp
• Piston pin
• ◆ If difficult to remove, heat piston to 60 °C
• ◆ Remove and install with VW 222a

• Circlip
• Conrod
• ◆ with cracked bearing cap
• ◆ Only renew as a set
• ◆ Mark allocation to cylinder -B-
• ◆ Installation position:
  Marking -B- faces towards belt pulley end
• Bearing shell
• ◆ Observe installation position=>
  Fig. 4
• ◆ Insert bearing shells centrally
• ◆ Do not interchange used bearing shells
• ◆ Check seated securely
• ◆ Axial clearance
  New: 0.10 ... 0.35 mm
  Wear limit: 0.4 mm
• ◆ Check radial clearance with Plastigage:
  New: 0.01 ... 0.05 mm
  Wear limit: 0.09 mm
  Do not rotate crankshaft when checking radial clearance

• Cylinder block
• ◆ Checking cylinder bore
  =>Fig. 5
• ◆ Piston and cylinder dimensions
  =>Page 13-44
• Conrod bearing cap
• ◆ Observe installing position
• ◆ The caps only fit in one position and only on the appropriate conrod, this is due to the breaking procedure (industrially cracking) separating the cap from the conrod
• 30 Nm + 1/4 turn (90 °) further
• ◆ Torx E 10
• ◆ Renew
• ◆ Oil thread and contact surface
• ◆ To measure radial clearance tighten to 30 Nm, but do not turn further

→ Fig. 1    Checking piston ring gap

Special tools, testers, measuring instruments and auxiliary items required

• ◆ Feeler gauge

Test sequence

• ‒ Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.

→ Fig. 2    Checking ring to groove clearance

Special tools, testers, measuring instruments and auxiliary items required

• ◆ Feeler gauge

Test sequence

Clean groove before checking.

→ Fig. 3    Checking piston

Special tools, testers, measuring instruments and auxiliary items required

• ◆ External micrometer 75 ... 100 mm

Test sequence

Measure pistons approx. 10 mm from the lower edge of skirt, 90 ° offset to the axis of the piston pin.

Deviation from nominal dimension
    max. 0.04 mm

→ Fig. 4    Installation position of bearing shells

Bearing shell-1- with oil channel-arrow- for conrod.

Bearing shell-2- without oil channel conrod bearing cap.

• ‒ Insert bearing shells and conrod bearing cap centrally.

The dimension -a- must be the same on both the left and the right side.

→ Fig. 5    Checking cylinder bores

Special tools, testers, measuring instruments and auxiliary items required

• ◆ Internal dial gauge 50 ... 100 mm
• ◆ Measure bores at 3 locations in both directions -A- across the engine and -B- in line with crankshaft.
• ◆ Deviation from nominal dimension
      max. 0.08 mm

Note:

Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with adapter bracket VW 540, as incorrect measurements would then be possible.