Volkswagen Golf / Golf Plus. Manual - part 300

 

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Volkswagen Golf / Golf Plus. Manual - part 300

 

 

– Carefully drive needle bearing in.
– Always measure the driving depth when driving in.
Renew bearing, if driving depth is too deep.

• Driving depth: Dimension -a- = 1.5 to 1.8 mm.

3.2

Crankshaft dimensions

(Dimensions in mm)

Honing dimen‐

sion

Crankshaft bearing

journal ∅

Conrod

journal ∅

Basic dimension 54.00 -0.022

-0.042

47.80 -0.022

-0.042

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

38

     Rep. Gr.13 - Crankshaft group

 

Assembly overview - pistons and conrods 

⇒ page 39

 .

Separating new conrod 

⇒ page 40

 .

Checking piston projection at TDC 

⇒ page 41

Piston and cylinder dimensions 

⇒ page 42

 .

Piston rings, cylinder bore and piston installation position

⇒ page 42

4.1

Assembly overview - pistons and conrods

1 - Piston rings

❑ Offset gaps by 120°.
❑ Use piston ring pliers to

remove and install.

❑ “TOP” faces towards

piston crown.

❑ Checking piston ring

gap 

⇒ page 42

 .

❑ Checking ring-to-groove

clearance 

⇒ page 42

 .

2 - Piston

❑ With combustion cham‐

ber.

❑ Mark installation posi‐

tion and cylinder num‐

ber.

❑ Installation position and

allocation of piston to

cylinder 

⇒ page 43

 .

❑ Arrow on piston crown

points to belt pulley end.

❑ Install using piston ring

clamp.

❑ Cracks on piston skirt,

renew piston.

❑ Checking piston projec‐

tion at TDC

⇒ page 41

3 - Piston pin

❑ If difficult to remove,

heat piston to 60 °C.

❑ Remove and install us‐

ing drift -VW 222- .

4 - Circlip
5 - Conrod

❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.

6 - Bearing shell

❑ Note installation position.
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐

cation: Black line on bearing surface in area of joint.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

4. Pistons and conrods    

39

 

7 - Cylinder block

❑ Checking cylinder bore 

⇒ page 43

 .

❑ Piston and cylinder dimensions 

⇒ page 42

 .

8 - Conrod bearing cap

❑ Note installation position.
❑ The cap only fits in one position and only on the appropriate conrod due to the breaking procedure

(cracking), separating the cap from conrod.

9 - Oil spray jet

❑ For piston cooling

Note

10 - 25 Nm

❑ Insert without sealant.

11 - Conrod bolt, 30 Nm + 

1

/4 turn (90°) further

❑ Renew
❑ Oil threads and contact surface.
❑ Use old bolt for measuring radial clearance.

4.2

Separating new conrod

– Mark cylinder allocation of conrod 

⇒ Item 5 (page 39)

– Lightly clamp the conrod in a vice using aluminium vice

clamps, as shown in the illustration.

Note

To prevent damage to the conrod, only clamp conrod in lightly.

Clamp conrod in below the marked line.

– Unscrew the two bolts -arrows- approx. 5 turns.

– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -arrow- until it is loose.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

40

     Rep. Gr.13 - Crankshaft group

 

Special tools and workshop equipment required
♦ Measuring bridge -VW 382/7-

♦ End dimension plate -VW 385/17-

♦ Dial gauge
Test procedure

Note

If different values are determined during the projection measure‐

ment, use the largest dimension for selecting the gasket.

Piston projection at TDC must be measured when installing new

pistons or a short engine. Install the appropriate cylinder head

gasket depending upon piston projection, according to following

table:

Note

Turn engine clockwise to measure piston projection at TDC.

Piston projection

Identification

Holes/notches

0.91 mm ... 1.00 mm

1

1.01 mm ... 1.10 mm

2

1.11 mm ... 1.20 mm

3

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

4. Pistons and conrods    

41

 

 

 

 

 

 

 

 

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