Volkswagen Golf / Golf GTI / Jetta. Manual — part 24

13-46

Special tools and equipment

Test sequence

Note:

The cylinder bores must not be
measured if the cylinder block is
mounted on a repair stand with
engine bracket 3269 or VW 540, as
incorrect measurements would then
result.

Fig. 4

Checking cylinder bores

Internal dial gauge 50...100 mm

- Measure bores at 3 locations in

both directions -A- across engine
and -B- in line with crankshaft.

Deviation from nominal

dimension: max. 0.08 mm

Piston and connecting rod, disassembling and assembling

13-47

Special tools and equipment

Note:

If a new installation tool (funnel) is
used to install the pistons, first pass
piston with oiled piston rings through
the funnel twice and remove the
resulting metal shavings if
necessary. Only then install piston
with piston rings.

Work sequence

Fig. 5

Installing pistons with
piston installation tool
(funnel) 3278

3278 Funnel

- Push piston by hand into oiled

installation tool (funnel). Flat side
of piston crown must face toward
tab on funnel (arrow).

- Hold installation tool (funnel) on

upper edge and press piston in
with both thumbs.

- Push piston in until it protrudes

approx. 15 mm from lower edge
of tool (funnel).

- Insert piston into appropriate

cylinder bore. Tab on tool (arrow)
must face center of cylinder block.

- Press installation tool (funnel)

tightly against cylinder block and
push piston in.

Piston and connecting rod, disassembling and assembling

13-48

Piston and cylinder dimensions

Honing
dimension

Piston

diameter

Cylinder

bore

diameter

Basic
dimension

mm

80.965

81.010

1st oversize

mm

81.465

81.510

2nd oversize mm

81.965

82.010

Piston and connecting rod, disassembling and assembling

15-1

Cylinder
head,
servicing

Note:

If an

exchange
cylinder
head is
installed, all
contact
surfaces
between
bearing
elements,
roller rocker
fingers and
cam
running
surfaces of
camshaft
must be
oiled before
installing
cylinder
head cover.

The plastic

protectors
installed to
protect the
open
valves must
only be
removed
immediately
before
installing
the cylinder
head.

When

replacing
the cylinder
head the
entire
coolant
quantity
must be
replaced.

Cylinder head, servicing