Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 660
– Pry out the seal in direction of -arrow A-.
– Clean the running and sealing surface.
– Coat the sealing surface of the balance shaft -2- with trans‐
mission oil.
– Push the seal -1- onto the balance shaft.
• “Luftseite” or (“Outside”) -arrow- must be readable from the
outside.
Note
The drive wheel bolt -2- has left-hand thread.
– Mount the Seal Installer, Intermediate Shaft - T10353/1- on the
shaft seal -1- and then tighten it all the way into the cylinder
block with the bolt -2-. Be careful not to tilt the shaft seal when
doing this.
– Install the toothed belt on the coolant pump. Refer to
5
Piston and Connecting Rod
⇒ “5.1 Overview - Piston and Connecting Rod”, page 77
.
⇒ “5.2 Pistons, Removing and Installing”, page 78
.
⇒ “5.3 Pistons and Cylinder Bore, Checking”, page 80
.
⇒ “5.4 New Connecting Rod, Separating”, page 84
.
⇒ “5.5 Connecting Rods, Checking Radial Clearance”,
5.1
Overview - Piston and Connecting Rod
1 - Connecting Rod Bolts
❑ 45 Nm + 90°
❑ Use old bolt to measure
radial play
❑ Lubricate the thread and
contact surface.
❑ Replace after removing
2 - Connecting Rod Bearing
Cap
❑ Pay attention to the in‐
stalled position.
❑ Due to the separation
procedure (cracking) of
the connecting rod, the
connecting rod bearing
cap only fits in one posi‐
tion and only to the cor‐
responding connecting
rod.
❑ Mark affiliation to cylin‐
der -A-
❑ Installed position: the
markings -B- face the
belt pulley side
❑ Disconnect the new
connecting rod. Refer to
.
3 - Bearing Shells
❑ Installed position. Refer
to
❑ Do not interchange used bearing shells (mark)
❑ Coat with oil before installing
❑ Axial play new: 0.10 to 0.35 mm, wear limit: 0.40 mm
❑ Check radial clearance with Plastigage
®
, new: 0.02 to 0.06 mm, wear limit: 0.09 mm. Do not turn crank‐
shaft when checking radial clearance
4 - Relief Valve
❑ 27 Nm
5 - Oil Spray Jet
❑ For piston cooling
6 - Locking Ring
❑ Replace after removing
7 - Piston Pin
❑ Coat with oil before installing
8 - Piston
❑ Removing and installing. Refer to
⇒ “5.2 Pistons, Removing and Installing”, page 78
.
❑ Mark installed position and cylinder allocation
❑ Arrow on piston face points toward belt pulley side
❑ Check piston and cylinder bore. Refer to
⇒ “5.3 Pistons and Cylinder Bore, Checking”, page 80
9 - Compression Rings
❑ Use piston ring pliers (commercially available) for removing and installing
❑ Offset gaps by 120°
❑ Installed Position: “TOP” “R” mark must face up toward piston crown
❑ Ring Gap/Groove Clearance, Checking. Refer to
⇒ “5.3 Pistons and Cylinder Bore, Checking”, page 80
.
10 - Oil Scraping Ring
❑ Two-part
❑ Install offset gaps by 120° to the neighboring compression ring
❑ The “TOP” or “R” marking must face toward the piston crown.
❑ Checking the ring gap. Refer to
⇒ “5.3 Pistons and Cylinder Bore, Checking”, page 80
❑ Side clearance cannot be measured.
11 - Connecting Rod
❑ Always replace as a set.
❑ Mark affiliation to cylinder -A-
❑ Installed position: the markings -B- face the belt pulley side
❑ Disconnect the new connecting rod. Refer to
⇒ “5.4 New Connecting Rod, Separating”, page 84
❑ Radial play, measuring. Refer to
⇒ “5.5 Connecting Rods, Checking Radial Clearance”, page 84
.
Installed Position of Bearing Shell
– Place bearing shells centrally into connecting rod and con‐
necting rod bearing cap.
Dimension -a- must be the same at left and right.
5.2
Pistons, Removing and Installing
Special tools and workshop equipment required
♦ Pilot Drift - VW222A-
♦ Piston ring compressor, commercially available
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ Bolts - Connecting Rod
♦ Ring - Locking
Removing
– Secure the engine to the Engine And Transmission Holder -
VAS6095- . Refer to
⇒ “1.3 Engine, Securing on Engine and Transmission Holder”,
– Remove the cylinder head. Refer to
⇒ “1.3 Cylinder Head, Removing and Installing”, page 94
.
– Remove the oil pan upper section. Refer to
⇒ “1.4 Oil Pan Upper Section, Removing and Installing”, page
– Mark the installed position and cylinder allocation.
– Mark installed position and connecting rod cylinder -item 11-
– Remove the connecting rod bearing cap and pull the piston
and connecting rod upward.
Note
Warm the piston to approximately 60 °C (140 °F) if it is difficult to
move the piston pin.
– Remove the locking ring from the eye of the piston bolt.
– Remove the piston pin using the Pilot Drift - VW222A- .
Installing
Install in reverse order of removal. Note the following:
Note
♦
Replace the bolts were tightened with an additional turn.
♦
Arrow on piston face points toward belt pulley side.
♦
Offset the piston ring gap by 120°.
– Coat the contact surfaces on the bearing shells with oil.
– Install the piston with a piston ring compressor. Pay attention
to the installed position -item 8-
.
– Install the connecting rod bearing cap. Pay attention to the in‐
stalled position -item 2-
– Install the cylinder head. Refer to
⇒ “1.3 Cylinder Head, Removing and Installing”, page 94
.
– Install the oil pan upper section. Refer to
⇒ “1.4 Oil Pan Upper Section, Removing and Installing”, page
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