Golf Mk5
| Assembly overview - pistons and conrods |
| 1 - | Piston rings |
| q | Offset gaps by 120°. |
| q | Use piston ring pliers to remove and install. |
| q | „TOP“ faces towards piston crown. |
| q | Checking ring gap → Fig.. |
| q | Checking ring-to-groove clearance → Fig.. |
| 2 - | Piston |
| q | With combustion chamber. |
| q | Mark installation position and cylinder number. |
| q | Installation position and allocation of piston to cylinder → Fig.. |
| q | Arrow on piston crown points to belt pulley end. |
| q | Install using piston ring clamp. |
| q | If piston skirt is cracked, renew piston. |
| q | Checking piston projection at TDC → Chapter. |
| 3 - | Piston pin |
| q | If difficult to remove, heat piston to 60 °C. |
| q | Remove and install using drift -VW 222-. |
| 4 - | Circlip |
| 5 - | Conrod |
| q | Mark cylinder allocation -A- with coloured pen. |
| q | Installation position: Marking -B- faces towards pulley end. |
| q | With industrially cracked conrod cap. |
| 6 - | Bearing shell |
| q | Note installation position. |
| q | Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identification: Black line on bearing surface in area of joint. |
| q | Do not interchange used bearing shells. |
| q | Insert bearing shells centrally. |
| q | Check for secure seating. |
| q | Axial clearance, wear limit: 0.37 mm. |
| q | Check radial clearance with Plastigage: Wear limit: 0.08 mm, 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 - | Oil spray jet |
| q | For piston cooling. |
Note| When renewing the oil spray jet, ensure correct allocation to piston → ETKA (electronic parts catalogue). |
| 10 - | 25 Nm |
| q | Insert without sealant. |
| 11 - | Conrod bolt, 30 Nm + turn (90°) |
| q | Renew. |
| q | Oil threads and contact surface. |
| q | Use old bolt for measuring radial clearance. |
