Volkswagen Golf / Golf Plus. Manual - part 301

 

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Volkswagen Golf / Golf Plus. Manual - part 301

 

 

Piston and cylinder dimensions

Honing dimension

Piston ∅

Cylinder bore ∅

Basic dimen‐

sion

mm

79.47

79.51

Stage I

mm

79.72

79.76

Stage II

mm

79.97

80.01

4.5

Piston rings, cylinder bore and piston in‐

stallation position

Checking piston ring gap

Special tools and workshop equipment required
♦ Feeler gauges
– Push piston ring squarely from above down to approx. 15 mm

from bottom end of cylinder.

Piston ring

dimensions in mm

New

Wear limit

1. compression ring

0.20...0.40

1.0

2. compression ring

0.20...0.40

1.0

Oil scraper ring

0.25...0.50

1.0

Checking ring-to-groove clearance

Special tools and workshop equipment required
♦ Feeler gauges

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

42

     Rep. Gr.13 - Crankshaft group

 

dimensions in mm

New

Wear limit

1. compression ring

0.06...0.09

0.25

2. compression ring

0.05...0.08

0.25

Oil scraper ring

0.03...0.06

0.15

Checking cylinder bores

Special tools and workshop equipment required
♦ Cylinder gauge 50...100 mm
– Take measurements at 3 positions in both transverse -A- and

longitudinal -B- directions, as illustrated. Difference between

actual and nominal diameter max. 0.10 mm.

Note

Cylinder bores must not be measured when cylinder block is

mounted on a repair stand with engine support bracket -VW 540- ,

as measurements may then be incorrect.

Piston installation position and allocation of piston to cylinder
Piston in cylinders 1 and 2:
Larger inlet valve chamber towards flywheel -arrows-.
Piston in cylinders 3 and 4:
Larger inlet valve chamber towards belt pulley side -arrows-.

Note

New piston allocation to cylinders is shown by a coloured

marking on piston crown.

Piston for cylinders 1 and 2: marked 1/2

Piston for cylinders 3 and 4: marked 3/4

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

4. Pistons and conrods    

43

 

Cylinder head

Note

When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and

the cam must be oiled before installing the cylinder head cov‐

er.

The plastic protectors fitted to protect the open valves must be

removed only immediately before the cylinder head is fitted.

If the cylinder head is replaced, all the coolant in the system

must also be renewed.

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

44

     Rep. Gr.15 - Cylinder head, valve gear

 

 .

Removing, installing and tensioning toothed belt 

⇒ page 50

Removing and installing cylinder head 

⇒ page 67

Checking compression 

⇒ page 71

 .

1.1

Assembly overview - cylinder head

1 - Toothed belt guard upper

part
2 - Toothed belt

❑ Mark direction of rota‐

tion before removing.

❑ Check for wear.
❑ Do not kink.
❑ Removing, installing

and tensioning

⇒ page 50

 .

3 - 10 Nm

❑ Renew

4 - 25 Nm
5 - 100 Nm
6 - Camshaft pulley
7 - Hub

❑ With sender wheel
❑ Use counterhold tool -

T10051- to loosen and

tighten.

❑ To remove, use puller -

T10052-

❑ Removing and installing

8 - Rear toothed belt guard
9 - Sealing grommet

❑ Renew if damaged.

10 - Hall sender -G40-

❑ For camshaft position
❑ To remove, unbutton

sealing grommet

⇒ Item 9 (page 45)

 from rear toothed belt guard.

11 - Stud

❑ 15 Nm

12 - Cylinder head bolt

❑ Observe sequence when loosening and tightening 

⇒ page 67

 .

❑ Before installing, place washers in cylinder head 

⇒ Item 4 (page 74)

 .

13 - Fuel return line
14 - Fuel supply line
15 - Coolant line
16 - Cylinder head cover

❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.

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

1. Cylinder head    

45

 

 

 

 

 

 

 

 

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