Volkswagen Golf Variant / Jetta. Manual - part 372

 

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Volkswagen Golf Variant / Jetta. Manual - part 372

 

 

and lengthwise -B- in line with crankshaft.

• Deviations to the specified size: maximum 0.10 mm

Note

The cylinder bore must not be measured when the cylinder block

is mounted in the Engine and Gearbox Bracket - VAS6095A- be‐

cause the measurements may be incorrect.

Installed Position of Piston and Piston/Cylinder Allocation
The arrow on the piston crown -arrows- points toward the belt

pulley side.

3.2

New Connecting Rod, Separating

New connecting rods might not be completely separated at the

predetermined breaking point. If it is difficult to remove the con‐

necting rod bearing cap by hand, do the following:
– Mark which cylinder belongs to the connecting rod.
– To prevent damage, only clamp the connecting rod lightly in a

vise with protective covers over the jaws as shown.

Note

Clamp the connecting rod below the dotted line.

– Remove the bolts -arrows- approximately five turns.

– Carefully tap the connecting rod bearing cap with a plastic

hammer in direction of -arrow- until it comes loose.

3. Pistons and Connecting Rod    

71

Bearing Shells - Installation Position

Bearing shell -1- with connecting rod oil filler hole -arrow-.
Bearing shell -2- without oil filler hole for connecting rod cover.
– Place the bearing shells centrally into connecting rod and con‐

necting rod bearing cap.

The dimension -a- must be the same at left and right.

3.4

Piston and Cylinder Dimensions

Honing dimension

Piston and Cylinder Dimensions

Dimensions in mm

Piston diameter 

1)

Cylinder bore diameter

Standard dimension

80.960

81.010

1) Take measurement approximately 12 mm from the lower edge

of the piston and offset 90° to the piston pin axis.

3.5

Piston Projection in Top Dead Center

(TDC), Checking

⇒ “3.5.1 Cylinder Head Gasket Identification”, page 73

Special tools and workshop equipment required
♦ Measuring Bar - VW382/7-
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Dial Gauge - 0-10mm - VAS6079-
Test Sequence
When installing new pistons or working with a partial engine,

check the piston projection in TDC on all pistons. Depending on

the piston projection, install the corresponding cylinder head gas‐

ket according to the following table.

Note

To measure the piston position at TDC, turn the engine clock‐

wise.

If varying values occur when measuring the projection, use the

gasket for the largest value.

Piston Projection

Identification

Notches/Holes

Dimensions in mm

 

0.91 to 1.00

1

1.01 to 1.10

2

1.11 to 1.20

3

72

Cylinder Head Gasket Identification

♦ Part number = -arrow 1-
♦ Holes = -arrow 2-
♦ Control code = -arrow 3- (ignore this!)

Note

Depending on piston projection, varying cylinder head gasket

thicknesses can be installed. Be sure to use a gasket having

the identical identification when replacing.

Determine the piston position in TDC when installing new pis‐

tons or partial engines. Refer to

⇒ “3.5 Piston Projection in Top Dead Center (TDC), Check‐

ing”, page 72

 .

3. Pistons and Connecting Rod    

73

Crankshaft

⇒ “4.1 Overview - Crankshaft”, page 74
⇒ “4.2 Crankshaft Dimensions”, page 75
⇒ “4.3 Needle Bearings, Removing and Installing from Crank‐

shaft”, page 75

4.1

Overview - Crankshaft

Caution

♦ If the crankshaft is removed, a new intermediate sprocket

must

-item 14- 

⇒ Item 14 (page 154)

 be installed with coating

and the hub -item 11- 

⇒ Item 11 (page 154)

 including the

bolt -item 12- 

⇒ Item 12 (page 154)

 and axial bearing

discs -item 13- 

⇒ Item 13 (page 154)

 must be replaced,

or else the backlash will not be correct.

♦ Installation procedure. Refer to

⇒ “2.4.2 New Balance Shaft Assembly, Installing”,

page 161

 , New Balance Shaft Assembly, Installing

1 - Bearing Shells 1, 2, 4 and 5

❑ For bearing cap without

oil groove

❑ For cylinder block with

oil groove

❑ Do not interchange

used bearing shells

(mark them)

2 - Bolts

❑ 65 Nm + 

1

/4 (90 °) addi‐

tional turn

❑ Replace
❑ Tighten to 65 Nm to

measure radial clear‐

ance but do not tighten

further.

3 - Bearing Cap

❑ Bearing cap 1: belt pul‐

ley side

❑ Bearing cap 3 with

openings for thrust

washers

❑ Retaining tabs for cylin‐

der block/bearing cap

bearing shells must lie

above one another

4 - Bearing Shell 3

❑ For bearing cap without

oil groove

❑ For cylinder block with

oil groove

5 - Thrust Washer

❑ For the bearing cap 3

74

 

 

 

 

 

 

 

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