Volkswagen Golf/Jetta 2 manual

Pistons and connecting rods - removal
Engine repair procedures - 1.05 and 1.3 litre pre August 1985 / Pistons and connecting rods - removal


1 Remove the cylinder head.

2 Remove the sump.

3 Unbolt and remove the pick-up tube and strainer from the oil pump and cylinder block.

Remove the flange gasket.

4 Using a feeler blade, check that the connecting rod big-end endfloat on each crankpin is within the specified limits (see illustration). If not, the components must be checked for wear and renewed as necessary.

17.4 Checking connecting rod endfloat
17.4 Checking connecting rod endfloat

5 Check the big-end caps and connecting rods for identification marks, if necessary use a centre punch to mark them for location and position. Note that the cut-outs in the connecting rods and caps face the timing belt end of the engine. The arrows on the piston crown also face the timing belt (see illustration).

17.5 Piston crown showing arrow which points to timing belt end of engine
17.5 Piston crown showing arrow which points to timing belt end of engine

6 Turn the crankshaft so that No 1 crankpin is at its lowest point.

7 Unscrew the big-end nuts and tap free the cap, together with its bearing shell (see illustration).

17.7 Withdrawing a big-end cap
17.7 Withdrawing a big-end cap

8 Using the handle of a hammer, tap the piston and connecting rod from the bore and withdraw it from the top of the cylinder block (see illustration).

17.8 Removing a piston
17.8 Removing a piston

9 Loosely refit the cap to the connecting rod.

10 Repeat the procedure given in paragraphs 7 to 9 on No 4 piston and connecting rod, then turn the crankshaft through half a turn and repeat the procedure on No 2 and 3 pistons.

11 Note that during reassembly, the connecting rod bolts must be renewed.


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