Piston and Connecting Rod, Assembly Overview

Piston and connecting rod, assembly overview





1 - Connecting rod bolt 30 Nm plus an additional 1/4 turn (90°)
^ Replace
^ Lubricate threads and contact surface
^ Tighten to 30 Nm to measure radial play, do not turn further

2 - Pressure relief valve, 27 Nm
^ Opening pressure 1.3 to 1.6 bar positive pressure

3 - Oil spray jet
^ For piston cooling

4 - Connecting rod bearing cap
^ Note installation position
^ Due to the way the separated connecting rod breaks (cracks), the cap fits only in one position and only on to respective connecting rod.
^ Affiliation to cylinder mark - B -
^ Installed location: Markings - A - point to belt pulley side

5 - Bearing shell
^ Note installation position
^ Do not interchange used bearing shells
^ Axial play new: 0.10 to 0.35 mm
- Wear limit: 0.4 mm
^ Measure radial clearance with Plastigage(R):
- New: 0.02 to 0.06 mm
- Wear limit: 0.09 mm
- Do not turn crankshaft when measuring radial play.

6 - Connecting rod
^ With cracked bearing cap
^ Only replace as set
^ Affiliation to cylinder mark - B -
^ Installed location: Markings - A - point to belt pulley side

7 - Circlip

8 - Piston pin
^ If difficult to move, heat piston to 60° C
^ Removing and installing using a Pilot Drift VW 222 A

9 - Piston
^ Mark installed position and cylinder allocation
^ Arrow on piston face points toward belt pulley side
^ Install with piston ring compressor

10 - Piston rings
^ Offset gaps by 120°
^ Use piston ring pliers for removal and installation
^ Markings face toward piston crown





Bearing shells - installed positions

Bearing shell - 1 - with oil bore - arrow - for connecting rod.

Bearing shell - 2 - without oil bore for connecting rod cover.
- Place bearing shells centrally into connecting rod and connecting rod cap.

Dimension - a - must be same at left and right.