Piston and conrod - remove and install — VW

VW
Gol
1999
Engine
4-Cyl. injection engine (1.0 l, 2-valve, rocking rollers)
Edition
10.2003
Piston and conrod - remove and install
Note
Before performing assembly jobs it is necessary to lubricate support and sliding surfaces.
Piston
Check
Fig.
Mark assembly position and correspondence to respective cylinder
Piston head arrow must indicate pulley direction
Install with ring compressor
Piston pin
If applied for heavy duties, heat pistons to 60 °C
Remove and install with
10-206
Piston pin retaining ring
Conrod
Replace entire set only
Mark correspondence to cylinder
A
Installation position: Marks
B
must point toward flywheel
Axial gap piston / conrod 0,20 to 0,40 mm - Wear limit 0,50 mm
Bearing shell
Observe assembly position
Do not change used bearing shells
Center bearing shells
Measure radial gap with Plastigage: New: 0,010...0,057 mm Wear limit: 0,091 mm When measuring radial gap, do not turn crankshaft
Cylinder block
Check cylinder diameters
Fig.
Piston and cylinder specifications
Chapter
Conrod covers
Observe assembly position
Conrod covers may only be placed in one position and with corresponding conrod
Conrod bolt, 20 Nm + 90°
Renew
Lubricate thread and support surface
To measure radial gap, tighten with 20 Nm, without angle torque
Oil scraper ring
Remove and install carefully, manually, oil scraper rings formed by 3 parts
“TOP”
indication must point toward piston head
Check gap openings of rings
Fig.
Check ring gap on piston groove
Fig.
Compression rings
Openings moved in 120°
Remove and install compression rings using ring pliers
“TOP”
indication must point toward piston head
Check gap openings of rings
Fig.
Check ring gap on piston groove
Fig.
Gap openings of piston rings - check
Place ring from above, so that it is in right angle on cylinder bottom opening, at distance of approx. 15 mm of cylinder edge.
Piston ring
New part
Wear limit
1. Compression ring
0,15 to 0,30
1,0 mm
2. Compression ring
0,30 to 0,50
1,0 mm
Oil scraper ring
0,20 to 0,60
1,0 mm
Check ring gap on piston groove
Previously clean housing duct of rings.
ring
New part
Wear limit
1. Compression ring
0,040 to 0,075
0,150 mm
2. Compression ring
0,020 to 0,075
0,150 mm
Oil scraper ring
0,010 to 0,176
0,186 mm
Checking piston
Special tools and workshop equipment required
External micrometer 60...90 mm
Measure at approx. 10 mm from lower edge, perpendicularly to piston pin axle. Difference in relation to nominal specification max. 0,04 mm. Nominal specification
Chapter
.
Check cylinder diameter
Special tools and workshop equipment required
Gauge 50...100 mm
Measure on three points, in cross, in the transversal and
A
longitudinal -B-directions. Tolerances in relation to nominal measure max. 0,08 mm. Nominal specification
Chapter
.
Note
Cylinder internal diameter must not be measured when engine block is fixed to assembly anvil with engine support
VW 540
, as that may result in incorrect measurements.