Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 662
– Using a Cylinder Dial Bore Gauge - VAS6078- measure in a
diagonal sequence at three positions transversely -A- and lon‐
gitudinally -B-.
♦ Deviation from specified size: maximum 0.08 mm
Basic Dimension
Cylinder Bore Diame‐
ter
in mm
82.51
5.4
New Connecting Rod, Separating
New connecting rods might not be separated at the location
where they should be. If the connecting rod bearing cap cannot
be removed by hand, proceed as follows:
– Label which cylinder goes with the connecting rod -item 11-
.
– Lightly clamp the connecting rod in a vise equipped with alu‐
minum protective pads.
Note
♦
Clamp the connecting rod lightly to prevent damaging it.
♦
Clamp the connecting rod below the dotted line.
– Loosen the bolts -arrows- approximately 5 turns.
– Carefully tap against the connecting rod bearing cap in direc‐
tion of -arrow- with a plastic hammer until the cap is loose.
5.5
Connecting Rods, Checking Radial
Clearance
Special tools and workshop equipment required
♦ Plastigage
®
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ Bolts - Connecting Rod
Procedure
– Remove the connecting rod bearing cap.
– Clean the bearing cap and journal.
– Place the Plastigage
®
over the entire width of the bearing
journal or into the bearing shells.
– Position the connecting rod bearing cap and tighten the old
bolts -item 1-
without turning the crankshaft.
– Install the connecting rod bearing cap.
– Compare width of Plastigage
®
with calibrated scale.
Radial clearance:
• New: 0.02 to 0.06 mm.
• Wear limit: 0.09 mm.
– Replace connecting rod bolts.
6
Special Tools
Special tools and workshop equipment required
♦ Locking Pin - T10060A-
♦ Seal Installer, Intermediate Shaft - T10356/1-
♦ Counterhold - Vibration Damper - T10355-
♦ Assembly Tool - T10531-
♦ Seal Installer - Sealing Flange Guide Sleeve - T20097-
♦ Dial Gauge - 0-10mm - VAS6079-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Bearing Installer - Bearing Press Piece - VW207C-
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