Removal and Replacement

Pistons and Connecting Rod Overview

• The engine is to be secured to the engine lateral bracket (T03001) when performing assembly work.






1 Bolt

• 30 Nm + an additional 90° (1/4) turn.

• Always replace.

• Lubricate the threads and contact surface.

• Tighten to 30 Nm to measure radial play, do not tighten the additional 90° turn.

2 Pressure Relief Valve

• 27 Nm

• Opening pressure: 1.3 to 1.6 bar excess pressure.

3 Oil Spray Jet

• For piston cooling.

4 Connecting Rod Bearing Cap

• Pay attention to the installed position.

• Due to the separation procedure (cracking) for the connecting rod, the connecting rod bearing cap only fits in one position and only on the appropriate connecting rod.

• Mark which cylinder the cap belongs to.

• Installed position: the marks - A - point to the belt pulley side.

5 Bearing Shell

• Note the installed position, refer to => [ Bearing Shell Installed Position ].

• Do not interchange used bearing shells (mark them).

• Axial play:

New: 0.10 to 0.35 mm

Wear limit: 0.4 mm

• Measure radial clearance using Plastigage(R):

New: 0.02 to 0.06 mm

Wear limit: 0.09 mm

Do not rotate the crankshaft when measuring radial play.

6 Connecting Rod

• With a cracked bearing cap.

• Separating new connecting rods. Refer to => [ New Connecting Rod, Separating ] Procedures.

• Always replace as a set.

• Mark which cylinder the connecting rod belongs to.

• Installed position: The marks - A - point to the belt pulley side.

7 Circlip

8 Piston Pin

• If difficult to move, heat the piston to 60 °C (140 °F).

• Remove and install using a pilot drift (VW 222 A).

9 Piston

• Checking, refer to => [ Piston, Checking ] Testing and Inspection.

• Mark the installed position and cylinder allocation.

• The arrow on the piston face points toward the belt pulley side.

• Install using a piston ring compressor.

• Piston and cylinder bore, checking. Refer to => [ Pistons and Cylinder Bore, Checking ] Testing and Inspection.

10 Piston Rings

• Offset gaps by 120°.

• Use piston ring pliers for removal and installation.

• Marks face toward the piston crown.

• Checking the ring gap. Refer to => [ Piston Ring Gap, Checking ] Testing and Inspection.

• Checking the piston ring groove clearance. Refer to => [ Piston Ring Groove Clearance, Checking ] Testing and Inspection.

Bearing Shell Installed Position





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

Bearing shell - 2 - without a oil bore for the connecting rod cap.

- Place the bearing shells centrally into the connecting rod and connecting rod bearing cap.

Dimension - a - must be the same on the left and right.