Genuine Volkswagen Rabbit Piston

Volkswagen Rabbit Piston Parts and Q&A

• Piston
  07K-107-065-F
  Q: What steps should be followed before removing the piston and connecting rod assemblies on Volkswagen Rabbit?

  A:

  The oil pans and cylinder head should be removed before the removal of the piston and the connecting rod assemblies. First, examine whether there are any ridges at the upper limit of the range of travel of the rings in each cylinder, and remove them with a ridge reamer, to avoid the breaking of pistons. Once the ridges have been removed position the engine such that the Crankshaft is facing upward and remove the balance shaft assembly. Check the connecting rod endplay next, using feeler gauges, to make sure that it is within the given limits; otherwise, new connecting rods might be needed. Locate the connecting rods and caps, making sure that the marks face the end of the drivebelt on the engine and slowly loosen the connect rod cap bolts. Lift the first cap attaching the connecting rod and bearing insert without dropping the insert and then thrust the connecting rod/piston assembly out of the top of the engine making sure all the ridge material has been cleared. Proceed in the same manner with the other cylinders and install the connecting rod caps and bearing inserts in their respective rods leaving the old inserts until reassembly. The connecting rods and the pistons are now prepared by being inspected and overhauled. Check the ring end visitation and register the correctness of the piston ring side clearance before the installation of new piston rings. Prepare the assemblies of piston/connecting rods, and new sets of rings to match them during installation. Install the top ring into the first cylinder, align it with the walls of the cylinder and make measurements of the end gap using feeler gauges and adjusting when necessary. Ring: Installing of the oil control ring should be followed by the middle and top ring in proper orientation. Preparations Before fitting, the cylinder walls must be clean and the edges chamfered and the crankshaft fitted. Wipe the surfaces of the bearings and fit the new upper bearing insert, avoiding lubrication. Install the piston ring with the gaps at a 90-degree interval so that it can be lubricated and installed using a piston ring compressor. Put the piston/connecting rod assembly into the cylinder making sure that the connecting rod fits in the crankshaft journal. Check the connecting rod bearing oil clearance with Plastigage and in case the clearance is other than as required, check the bearing inserts and journal diameter. Clean and grease the bearing faces, replace the connecting rod and install the new rod cap bolts and tighten them to the required torque. Repeat with the rest of the assemblies cleaning and facing upward. Lastly, turn the crankshaft to ensure no binding and measure endplay of connecting rod and adjust where needed when new parts were fitted.