Removal pistons and connecting rods from the cylinder block (VW Golf 2)

The pistons and connecting rods are removed from the cylinder block upwards with the connecting rod bearing caps and liners previously removed. Before performing these operations, do the following:

Each connecting rod and piston group must be marked with the number of the cylinder from which it will be dismantled. This is best done with paint, applying the cylinder numbers to the piston bottom (figure 64). The numbers must be supplemented with arrows indicating the direction of piston installation towards the front of the engine.



When separating the piston with the connecting rod from the bearing cap, it is necessary to remember its position. Before removing the connecting rod bearing cap, it is recommended to simultaneously mark the cap and the lower head of the connecting rod, applying the cylinder number on one side (see figure 65). The cover and lower head of the connecting rod are provided with lugs during manufacturing (figure 66), which must be directed in the same direction during assembly (in the direction of the car).


You also need to mark the bearings of each connecting rod. To avoid confusing the upper and lower bearings, also mark them with paint.



Pistons differ in the depth of the recess in the bottom. If you want to replace the pistons, you need to measure the distance "b" (see figure 67). This is the so-called combustion chamber height for a given engine type. The pistons intended for replacement must have the same recess depth in the bottom. There are differences in several recess parameters that are not the same for all engine types. Figure 67 shows the dimensions of pistons intended for different engine types. It is recommended to remove the pistons as follows.



Remove the connecting rod bearing caps and liners, then push the pistons with connecting rods upward. Clean the pistons and cylinders from oil deposits.

After removing the retaining rings, knock out the piston pin. Using the recess next to the pin hole, pry up with an awl and remove the retaining rings (figure 68), The finger is knocked out using a rod of the same diameter as the finger.



Remove the piston rings one by one from the pistons using ring pliers (figure 69), If the ring can be reused, it must be marked. If you do not have piston ring pliers, you can use thin steel plates that are evenly placed under the rings around the circumference. One of the plates should be placed under the ring lock so as not to scratch the piston surface (see figure 203).




The parts of the connecting rod and piston group after disassembly are shown in Figure 70.

The original text can be found at: VWMANUAL.ru