Piston

Piston

Special tools, testers and auxiliary items required

• Drift (VW 222 A)

• Piston ring compressor, commercially available

Removing

- Removing engine. Refer to => [ Engine, Removing ] Engine, Removing.

- Secure the engine to engine and transmission holder (VAS 6095). Refer to => [ Engine, Securing to Engine and Transmission Holder ] Procedures.

- Cylinder head, removing. Refer to => [ Cylinder Head ] Cylinder Head.

- Remove the balance shaft module with the oil pump. Refer to => [ Balance Shaft Module with Oil Pump ] Balance Shaft Module With Oil Pump.

- Mark installed position and cylinder allocation.

- Mark installed position and connecting rod cylinder => [ (Item 4) Connecting Rod ] Pistons and Connecting Rod Overview.

- Remove the connecting rod bearing cap and pull the piston and connecting rod upward.

• Warm the piston to approximately 60 °C (140 °F) if it is difficult to move the piston pin.

- Remove the locking ring from the eye of the piston bolt.

- Remove the piston pin using the (VW 222 A).

Installing

Installation is carried out in the reverse order while noting the following:

• Tightening specifications, refer to => [ Pistons and Connecting Rod Overview ] Pistons and Connecting Rod Overview.

• Replace bolts which have been tightened to an additional torque.

• Arrow on piston face points toward belt pulley side.

• Offset the piston ring gap by 120°.

- Coat the contact surfaces on the bearing shells with oil.

- Install the piston with a piston ring compressor. Pay attention to the installed position => [ (Item 7) Piston ] Pistons and Connecting Rod Overview.

- Install the connecting rod bearing cap. Pay attention to the installed position => [ (Item 2) Connecting Rod Bearing Cap ] Pistons and Connecting Rod Overview.

- Installing cylinder head. Refer to => [ Cylinder Head ] Cylinder Head.

- Install the balance shaft module with oil pump. Refer to => [ Balance Shaft Module with Oil Pump ] Balance Shaft Module With Oil Pump.