Club 80-90 Forums

Piston removel?
Any ideas how to remove the 2 front gudgeon pins from a 1.9 Wasser?
Without using the VAG tool that is. Mr Haynes stout wire is a no hoper, a expanding rawl bolt will not hold either.

heat
hammer
drift....

Heat - Yes
Hammer and drift - No
No way to get drift in to the case for pistons 1 and 3.

treaded 8 OR 10 mm bar (about 8in long) , a washer that will fit through the pins hole , and a piece of plastic / copper tubeing ,big washer that fits over the plastic tube and a couple of nuts that fit the threaded bar

thread the bar through the plastic/copper tube and through the piston , fit the washer and the nut , fiddly but do-able , then tighten up the nuts and the pin should extract its self as you tighten up the nut

That sounds like a very good idea.

Thanks Mark

its sounds fiddly but once you get it set up they just wind out


oh and watch the heat, i bent a con rod on my 2.1

If the pistons are on the bench, get a bucket of HOT water and immerse the pistons for a few mins checking for movement all the while, when the alloy pistons are hot enough the gudgeon pin should slide out using thumb pressure only.

If the pistons are just sticking out of the casing, then try wrapping a towel round them, soak the towel in boiling water, carry out the procedure as above and the same result should occur.

Tex Ritter

I used an expanding steel anchor bolt, rawl-bolt, from a diy shop, [had to buy a bag of 4] it had an outside diameter of about 14mm as i remember, [fit nicely into piston pin] and an M8 thread, into which i screwed a 3ft length of M8 threaded bar. i slid a heavy bit of steel bar with a hole thru it onto the bar and put a washer and nut on the very end [basically a home made slide hammer with an expanding end!]
warm the piston up well with a hot air gun, shove the expanding bolt into the piston pin and tighten it, it'll need a nut on near the rawlbolt by the way, then firmly, but dont go mad, use the weight of the slide hammer to draw the pin out, sounds crude but it worked a treat! you will have to repeatedly warm the piston to get the pin out all the way, and probably retighten the exp. bolt a few times, none of the pistons were marked or damaged using this method,just take your time with it, i can garantee it worked for me, hope this helps!
Wasserleaker.

Yep! Anchor bolt worked for me You should not need to warm the piston, I did mine in early Feb last year so was freezing cold and they still slid out.

Sorted now thanks. may do a "How to make the tool" pictorial if any interest.
Pete how's it going? not spoken for a while, fancy a drive out on Sunday?
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