Volkswagen Golf Variant / Jetta. Manual - part 371

 

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Volkswagen Golf Variant / Jetta. Manual - part 371

 

 

Gr.  50 ; Noise Insulation .

– Clamp off the coolant hoses from the oil cooler using Hose

Clamps - Up To 25mm - 3094- .

– Loosen the spring clamps -arrows- using the Hose Clip Pliers

- VAS6362- .

Note

Catch leaking coolant with the Drip Tray - VAS6208- .

– Disconnect the coolant hoses from the oil cooler.
– Remove the oil filter bracket. Refer to

⇒ “4.1 Overview - Oil Filter Bracket and Oil Cooler”,

page 177

 .

– Remove the bolt -arrow- and the Engine Speed Sensor - G28- .
Installing:
Install in reverse order of removal. Note the following:
• Engine Speed Sensor - G28- tightening specification -item 9-

⇒ Item 9 (page 56)

 .

• Oil filter bracket tightening specifications. Refer to

⇒ “4.1 Overview - Oil Filter Bracket and Oil Cooler”,

page 177

 , Overview - Oil filter Bracket and Oil Cooler

– Check the coolant level and fill if necessary. Refer to

⇒ “1.9 Coolant, Draining and Filling”, page 209

 .

2. Sealing Flange and Flywheel    

67

Pistons and Connecting Rod

⇒ “3.1 Overview - Piston and Connecting Rod”, page 68
⇒ “3.2 New Connecting Rod, Separating”, page 71
⇒ “3.3 Bearing Shells - Installation Position”, page 72
⇒ “3.4 Piston and Cylinder Dimensions”, page 72
⇒ “3.5 Piston Projection in Top Dead Center (TDC), Checking”,

page 72

3.1

Overview - Piston and Connecting Rod

1 - Piston Rings

❑ Offset gaps by 120°
❑ Use piston ring pliers for

removing and installing

❑ “TOP” identification

faces toward piston

crown

❑ Checking the ring gap.

Refer to

⇒ Fig. ““Checking the

Piston Ring Gap”“ ,

page 69

 .

❑ Checking the groove

clearance. Refer to

⇒ Fig. ““Piston Ring

Groove Clearance,

Checking”“ , page 70

 .

2 - Piston

❑ With the internal com‐

bustion engine

❑ Mark the installed posi‐

tion and cylinder alloca‐

tion

❑ Installed position and al‐

location, piston/cylin‐

der. Refer to

⇒ Fig. ““Installed Posi‐

tion of Piston and Pis‐

ton/Cylinder Alloca‐

tion”“ , page 71

 .

❑ Arrow on piston crown

points toward belt pulley

side

❑ Install with piston ring

compressor

❑ Replace the piston if the

piston shaft is cracked

❑ Check the piston projection in TDC. Refer to

⇒ “3.5 Piston Projection in Top Dead Center (TDC), Checking”, page 72

 .

3 - Piston Pin

❑ If difficult to move, heat piston to 60 °C (140 °F)
❑ Remove and install using the Pilot Drift - VW222A-

4 - Circlip
5 - Connecting Rod

❑ Label the allocation to the cylinder using a color marker -A-

68

⇒ “3.2 New Connecting Rod, Separating”, page 71

 .

6 - Bearing Shell

❑ Note the installation position Refer to 

⇒ “3.3 Bearing Shells - Installation Position”, page 72

 .

❑ Pay attention to the version: upper bearing shell (facing the piston) is made from wear resistant material;

characteristic: a black line on the running surface near the separating point

❑ Do not interchange used bearing shells.
❑ Insert bearing shells in the center
❑ Check for secure fit
❑ Axial play wear limit: 0.37 mm
❑ Measure the radial play with Plastigage

®

: wear limit: 0.08 mm

❑ Do not turn the crankshaft when measuring radial clearance

7 - Cylinder Block

❑ Checking the cylinder bore. Refer to 

⇒ Fig. ““Cylinder Bore, Checking”“ , page 70

 .

❑ Pistons and cylinder dimensions. Refer to 

⇒ “3.4 Piston and Cylinder Dimensions”, page 72

 .

8 - Connecting Rod Bearing Cap

❑ Note the installation position
❑ Due to the separation procedure (cracking) of the connecting rod, the connecting rod bearing cap only

fits in one position and only to the corresponding connecting rod.

9 - Oil Spray Jet

❑ For piston cooling

10 - Bolt with Pressure Relief Valve

❑ 27 Nm
❑ Install without sealant

11 - Connecting Rod Bolt

❑ 30 Nm + 

1

/4 (90°) additional turn

❑ Replace
❑ Lubricate the threads and contact surface.
❑ Use the old bolt to measure the radial clearance

Checking the Piston Ring Gap

Special tools and workshop equipment required
♦ Feeler Gauge
Procedure
– Push the piston ring squarely from above down to approxi‐

mately 15 mm from edge of the cylinder.

3. Pistons and Connecting Rod    

69

Ring Gap

Dimensions in mm

New

Wear limit

1. Compression ring

0.20 to 0.40

1.0

2. Compression ring

0.20 to 0.40

1.0

Oil Scraping Ring

0.25 to 0.50

1.0

Piston Ring Groove Clearance, Checking

Special tools and workshop equipment required
♦ Feeler Gauge
Procedure
– Clean the ring groove before checking.

Piston Ring

Ring to Groove Clearance

Dimensions in mm

New

Wear limit

1. Compression ring

0.06 to 0.09

0.25

2. Compression ring

0.05 to 0.08

0.25

Oil Scraping Ring

0.03 to 0.06

0.15

Cylinder Bore, Checking

Special tools and workshop equipment required
♦ Inner measuring device 50 to 100 mm

70

 

 

 

 

 

 

 

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