Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
5
Pistons and conrods
⇒ a5.2 nd installing pistons”, page 134
⇒ p5.3 istons and cylinder bores”, page 136
⇒ n5.4 ew conrod”, page 139
⇒ r5.5 adial clearance of conrods”, page 139
5.1
Assembly overview - pistons and conrods
130
Rep. gr.13 - Crankshaft group
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
1 - Bolts
❑ Renew after removal
❑ Apply engine oil to
thread and contact sur‐
face
❑ Use old bolts to meas‐
ure radial clearance.
❑ 45 Nm +90°
2 - Conrod bearing cap
❑ Observe installation po‐
sition
❑ Conrod bearing cap on‐
ly fits in one position
and only on the appro‐
priate conrod due to
the cracking procedure
separating the cap from
the conrod
❑ Mark allocation to cylin‐
der and conrod in col‐
our -A-
❑ Installation position:
Marking -B- faces to‐
wards pulley end.
❑ Separating new conrod
⇒ page 139 .
3 - Bearing bushes
❑ Fitting position ⇒ page
132
❑ Renew worn bearing
shells
❑ Apply engine oil before
installing
❑ Axial clearance
♦ New: 0.10 to 0.35 mm
♦ Wear limit: 0.40 mm
❑ Measuring radial clearance ⇒ page 139
4 - Connecting rod
❑ Renew as set only.
❑ Mark allocation to cylinder and to conrod bearing cap
❑ Installation position: Marking -B- faces towards pulley end.
❑ Separating new conrod ⇒ page 139 .
❑ Measuring radial clearance ⇒ page 139
5 - Pressure relief valve
❑ 27 Nm
6 - Oil spray jet
❑ For piston cooling
7 - Retaining ring
❑ Renew after removal
8 - Piston pin
❑ Apply engine oil before installing
9 - Piston
5. Pistons and conrods
131
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
❑ Installing with piston installation sleeve -T40347- ⇒ page 134
❑ Installation position: arrow on piston crown faces towards pulley end
❑ Mark allocation to cylinder
❑ Checking piston and cylinder bore ⇒ page 136
10 - Compression rings
❑ Offset gaps by 120°
❑ Installation position: “TOP” or “R” marking must face upwards towards piston crown.
❑ ⇒ Fig. ““Installing compression rings”“, page 133
❑ ⇒ Fig. ““Checking piston ring gap”“, page 136
❑ ⇒ Fig. ““Checking ring-to-groove clearance”“, page 137
11 - Oil scraper ring
❑ 2-part or 3-part, depending on version
❑ Install in such a way that upper gap of three-part oil scraper ring is offset by 120° relative to adjacent
compression ring
❑ ⇒ Fig. ““Checking piston ring gap”“, page 136
❑ ⇒ Fig. ““Checking ring-to-groove clearance”“, page 137
❑ ⇒ Fig. ““Installing oil scraper ring, 3-part”“, page 133
Bearing shells - installation position
– Position bearing shells in centre of conrod and conrod bear‐
ing cap when fitting.
Distance -a- must be identical on both sides.
Allocation of piston rings only in connection with 3-part oil scra‐
per ring
132
Rep. gr.13 - Crankshaft group
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
1 - Compression ring with chamfer -arrow A- on upper inner
side. »TOP« marking and lettering point inwards
2 - Compression ring shoulder -arrow B- on lower outer
side. »TOP« marking and lettering point inwards
3 - Oil scraper ring, three-piece design
Installing compression rings
•
•
»TOP« marking and lettering point upwards.
Compression ring -2- should not be opened using piston ring
pliers -VAS 211 003- any further than necessary to just push
it over piston -1-.
Installing oil scraper ring, 3-part
5. Pistons and conrods
133
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
– Note installation position of spring:
•
Butts of plates -2, 3- and spring -1- must have an offset of at
least 90° to each other.
– Install by hand.
Installation sequence:
1.
2.
3.
Insert spring -1- into groove.
Insert plate -3- in bottom of groove.
Insert plate -2- in top of groove.
5.2
Removing and installing pistons
Note
If pistons with 3-part oil scraper ring are installed without the
piston installation sleeve -T40347-, the oil scraper ring will be
damaged.
Special tools and workshop equipment required
♦ Pin -VW 222 A-
♦ Piston installation sleeve -T40347- (not shown)
Removing
– Remove engine, and secure it to engine and gearbox sup‐
port -VAS 6095-.
134
Rep. gr.13 - Crankshaft group
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
– Remove cylinder head ⇒ page 145 .
– Remove top section of sump ⇒ page 245 .
– Mark piston installation position and corresponding cylinder
number.
– Mark conrod installation position and corresponding cylinder
number ⇒ Item 4 (page 131) .
– Remove conrod bearing cap and withdraw piston and con‐
rod upwards.
– Remove retaining ring from piston pin eye.
– Remove retaining ring -2- from piston pin eye.
– Drive out piston pin -3- using drift -VW 222A-.
Note
If the piston pin is difficult to move, heat the piston to approx.
60°C.
– Remove piston -1- from conrod -4-.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
•
Renew bolts that are tightened with turning further angle
after each removal.
•
Arrow on piston crown points to belt pulley end.
– Install oil scraper ring: procedure for 3-part oil scraper ring ⇒
page 133 .
– Install compression rings ⇒ page 133 .
– Oil contact surfaces of bearing shells and cylinder wall with
engine oil.
5. Pistons and conrods
135
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
– Carefully push piston -1- into cylinder -arrow- by hand using
piston installation sleeve -T40347-.
– Install conrod bearing cap, noting installation position ⇒ Item
2 (page 131) .
– Install cylinder head ⇒ page 145 .
– Install upper part of sump ⇒ page 245 .
Specified torques
♦ ⇒ page 130
5.3
Checking pistons and cylinder bores
Checking piston
Special tools and workshop equipment required
♦ Micrometre 75 - 100 mm -VAS 6071-
– Using a micrometer, measure approx. 15 mm from the lower
edge, perpendicular to the piston pin axis.
♦ Difference between actual and nominal diameter max.
0.04 mm.
Piston diameter
1)
Basic dimension
mm
82.42
1)
•
Dimensions without graphite coating (thickness 0.02
mm). The graphite coating will wear down.
Checking piston ring gap
136
Rep. gr.13 - Crankshaft group
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
– Push in piston ring at right angles.
– Push piston ring from above to approx. 15 mm from bottom
end of cylinder.
– Push in using a piston without piston rings.
Piston ring gap in connection
with two-part oil scraper ring
New
Wear limit
1st compression ring
2nd compression ring
Oil scraper ring
0.30 to 0.40
0.40 to 0.50
0.20 to 0.40
0.80
0.80
0.80
Piston ring gap in connec‐
tion with three-part oil scra‐
per ring
New
Wear limit
1st compression ring
2nd compression ring
Oil scraper ring
0.30 to
0.60 mm
0.70 mm
0.40 mm
0.40 to
0.50 mm
Cannot be
Cannot be
measured
measured
Checking ring-to-groove clearance
– Clean annular groove of piston before check.
Ring-to-groove clearance
in connection with two-
part oil scraper ring
New
Wear limit
1st compression ring
2nd compression ring
Oil scraper rings
0.06 to 0.09 mm
0.03 to 0.06 mm
0.20 mm
0.15 mm
Cannot be measured
5. Pistons and conrods
137
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
Ring-to-groove clearance
in connection with three-
part oil scraper ring
New
Wear limit
1st compression ring
2nd compression ring
Oil scraper rings
Cannot be measured
Cannot be measured
Cannot be measured
Checking cylinder bores
Note
Do not measure cylinder bores when cylinder block is mounted
on engine and gearbox support -VAS 6095-, as measurements
may be incorrect.
Special tools and workshop equipment required
♦ Cylinder gauge -VAS 6078-
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Measure at 3 points -c-, in direction -a- and direction -b-,
using cylinder gauge -VAS 6078-.
♦ Deviation from nominal dimension: max. 0.08 mm
Piston diameter Cylinder bore
diameter
1)
Basic dimension
mm
82.51
82.42
1)
•
Dimensions without graphite coating (thickness
0.02 mm). The graphite coating wears away.
138
Rep. gr.13 - Crankshaft group
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
5.4
Separating new conrod
On a new conrod, it is possible that the breaking point has not
fully separated. Proceed as follows if the conrod bearing cap
cannot be removed by hand:
– Mark allocation of conrod to cylinder.
– Clamp conrod -1- in a vice below the dashed line using
aluminium vice clamps.
– Unscrew both bolts -2- about 5 turns.
– Using a plastic hammer, carefully knock against conrod
bearing cap in -direction of arrow- until it is loose.
5.5
Checking radial clearance of conrods
Special tools and workshop equipment required
♦ Plastigage
Sequence of operations
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten it using old bolts ⇒ Item
1 (page 131) . When tightening, make sure not to rotate
crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
•
•
New: 0.02 to 0.06 mm
Wear limit: 0.09 mm.
5. Pistons and conrods
139
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
– Renew conrod bolts.
5.6
Removing and installing oil spray jets
Special tools and workshop equipment required
♦ Multi-point bit -T10545-
Note
The crankshaft must be removed to allow for removing the oil
spray jet for cylinder 4.
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Remove top section of sump ⇒ page 245 .
– Turn crankshaft via vibration damper securing bolt in direc‐
tion of engine rotation until the respective bolt is accessible.
– Unscrew pressure relief valve -1- using TORX bit -T10545-.
– Remove oil spray jets -2-.
Installing
NOTICE
Risk of damage to oil spray jets caused by deformation.
– Do not bend oil spray jets.
1 - Pressure relief valve - specified torque ⇒ Item 5 (page
131)
140
Rep. gr.13 - Crankshaft group
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
02.2021
2 - Oil spray jet
•
Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
– Install upper part of sump ⇒ page 245 .
– Install noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview – noise
insulation.
5. Pistons and conrods
141
2024 VW Tiguan Owner's Manual
