Golf Mk4
Assembly overview |
1 - | Piston rings |
q | Offset gaps by 120°. |
q | Remove and install using piston ring pliers. |
q | The 3 part oil scraper ring must be installed without piston ring pliers. |
q | Removing and installing oil scraper ring → Chapter |
q | “TOP” faces towards piston crown. |
q | Checking ring gap → Fig.. |
q | Checking ring-to-groove clearance → Fig.. |
2 - | Piston |
q | Checking → 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 centrally. |
q | Do not interchange used bearing shells. |
q | Check for secure seating. |
Axial clearance |
q | New: 0.10...0.35 mm |
q | Wear limit: 0.4 mm |
Check radial clearance with Plastigage. |
q | New: 0.01...0.05 mm |
q | Wear limit: 0.09 mm |
q | Do not rotate crankshaft when checking radial clearance. |
7 - | Cylinder block |
q | Checking 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 | Renew. |
q | Oil threads and contact surface. |
q | To measure radial clearance, tighten to 30 Nm but not further. |
|
Piston ring | Gap | ||
New | Wear limit | ||
Compression rings | mm | 0.20...0.40 | 0.8 |
Oil scraper ring | mm | 0.25...0.50 | 0.8 |
|
Piston ring | Clearance | ||
New | Wear limit | ||
Compression rings | mm | 0.06...0.09 | 0.20 |
Oil scraper ring | mm | 0.03...0.06 | 0.15 |
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Note
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