CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Remove retaining ring from piston pin eye.
– Remove retaining ring -2- from piston pin eye.
– Drive out piston pin -3- using drift - VW 222A- .
Note
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
– Remove piston -1- from conrod -4-.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
•
Renew bolts that are tightened with turning further angle after
each removal.
•
Arrow on piston crown points to belt pulley end.
– Install oil scraper ring: procedure for 3-part oil scraper ring
⇒ page 82 .
– Install compression rings ⇒ page 82 .
– Oil contact surfaces of bearing shells and cylinder wall with
engine oil.
– Carefully push piston -1- into cylinder -arrow- by hand using
piston installation sleeve -T40347- .
– Install conrod bearing cap, noting installation position
⇒ Item 2 (page 80) .
– Install cylinder head ⇒ page 142 .
– Install upper part of sump ⇒ page 218 .
Specified torques
♦ ⇒ page 80
4.3
Checking pistons and cylinder bores
Checking piston
Special tools and workshop equipment required
♦ Micrometre 75 - 100 mm - VAS 6071-
– Using a micrometer, measure approx. 15 mm from the lower
edge, perpendicular to the piston pin axis.
♦ Difference between actual and nominal diameter max.
0.04 mm.
84
Rep. gr.13 - Crankshaft group
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Piston ∅
1)
Basic dimension
mm
82.42
1)
•
Dimensions without graphite coating (thickness 0.02
mm). The graphite coating will wear down.
Checking piston ring gap
– Push ring at right angles to cylinder wall from above down to
approx. 15 mm from bottom end of cylinder. Push in using a
piston without rings.
Piston ring gap in connection
with two-part oil scraper ring
New
Wear limit
compression ring
0.20 to
0.8 mm
0.40 mm
Oil scraper ring
0.25 to
0.8 mm
0.50 mm
Piston ring gap in connection
with three-part oil scraper ring
New
Wear limit
0.60 mm
0.70 mm
1st compression ring
2nd compression ring
Oil scraper ring
0.30 to
0.40 mm
0.40 to
0.50 mm
Cannot be
Cannot be
measured
measured
Checking ring-to-groove clearance
– Clean annular groove of piston before check.
Ring-to-groove clearance
in connection with two-
part oil scraper ring
New
Wear limit
1st compression ring
2nd compression ring
Oil scraper rings
0.06 to 0.09 mm
0.03 to 0.06 mm
0.20 mm
0.15 mm
Cannot be measured
Ring-to-groove clearance
in connection with three-
part oil scraper ring
New
Wear limit
1st compression ring
2nd compression ring
Oil scraper rings
Cannot be measured
Cannot be measured
Cannot be measured
Checking cylinder bores
Note
Do not measure cylinder bores when cylinder block is mounted
on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.
Special tools and workshop equipment required
♦ Cylinder gauge - VAS 6078-
4. Pistons and conrods
85
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Caution
The cylinder bore may not be worked on (reboring, honing,
grinding) may not be carried out using workshop tools! This will
damage the surface of the cylinder bore.
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
♦ Deviation from nominal dimension: max. 0.08 mm
Piston ∅
Cylinder bore ∅
82.51
1)
Basic dimension
mm
82.42
1)
•
Dimensions without graphite coating (thickness
0.02 mm). The graphite coating wears away.
4.4
Separating new conrod
On a new conrod, it is possible that the breaking point has not
fully separated. Proceed as follows if the conrod bearing cap can‐
not be removed by hand:
– Mark allocation of conrod to cylinder.
– Clamp conrod -1- in a vice below the dashed line using alu‐
minium vice clamps.
– Unscrew both bolts -2- about 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐
ing cap in -direction of arrow- until it is loose.
86
Rep. gr.13 - Crankshaft group
2024 VW Passat Owner's Manual
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