Removal and Replacement

Piston and Connecting Rod Overview






1 Bolt

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

• Always replace.

• Use an old bolt to measure the radial play.

• Do not turn the additional 90° (1/4) turn when measuring the radial play.

• Lubricate the threads and contact surface.

2 Connecting Rod Bearing Cap

• Pay attention to the installed position.

• Mark the affiliation to the cylinder - A -.

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

• Due to the way the separated connecting rod breaks (cracks), the cap fits only in one position and only onto the respective connecting rod.

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

3 Bearing Shells

• Note the installed position, refer to => [ Bearing Shell, Installed Position ] 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: 0.020 to 0.060 mm

Wear limit: 0.090 mm

Do not rotate the crankshaft when measuring the radial play.

4 Pressure Relief Valve

27 Nm

• Opening pressure: 1.6 to 1.9 bar.

5 Oil Spray Jet

• For piston cooling.

• See the notes at the beginning of the => [ Oil Pan/Oil Pump Overview ] Oil Pan/Oil Pump Overview.

6 Circlip

7 Piston Pin

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

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

8 Piston

• 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.

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

• Checking the cylinder bore, refer to => [ Cylinder Bore, Checking ] Testing and Inspection.

• For the correct piston and cylinder dimensions, refer to => [ Piston and Cylinder Dimensions ] Piston and Cylinder Dimensions.

9 Compression Rings

• Offset gaps by 120°.

• Use piston ring pliers for removal and installation.

• The "TOP" mark must face up toward the piston crown.

• Checking ring gap, refer to => [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking.

• Checking the piston ring groove clearance, refer to => [ Piston Ring Groove Clearance, Checking ] Piston Ring Groove Clearance, Checking.

10 Oil Scraping Ring

• 2 piece.

• Install the upper steel ring so the gap is offset by 120° to the neighboring compression ring.

• Offset all oil scraping ring component gaps to each other.

• Checking the ring gap, refer to => [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking.

• Side clearance cannot be measured.

11 Connecting Rod

• Always replace as a set.

• Mark the affiliation to the cylinder - A -.

• Installed position: Marks - B - point to the belt pulley side.

• Separating a new connecting rod, refer to => [ New Connecting Rod, Separating ] Procedures.