Piston

Piston

Special tools, testers and auxiliary items required

• Pilot Drift (VW 222 A)

• Piston Installation Tool 82.5 mm Bore (SET 850)

Removing

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

- Separate the transmission from the engine. Refer to => [ Engine/Transmission, Separating and Assembling ] Engine/Transmission, Separating and Assembling.

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

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

- Remove the upper oil pan. Refer to => [ Upper Oil Pan ] Upper Oil Pan.

- Mark the installed position and cylinder allocation of the piston.

- Mark the installed position and cylinder affiliation, see - item 11 - in the => [ Piston and Connecting Rod Overview ] Piston and Connecting Rod Overview.

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

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

- Remove the lock ring from the eye of the piston pin.

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

Installing

Install in the reverse order of removal. Note the following:

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

• Replace any bolts that were tightened to an additional torque angle.

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

• Offset the piston ring gap by 120°.

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

- Oil the pistons and the piston rings.

- Install the piston using the piston installation tool 82.5 mm bore (SET 850). Pay attention to the installed position, see - item 8 - in the => [ Piston and Connecting Rod Overview ] Piston and Connecting Rod Overview.

- Install the connecting rod bearing cap. Pay attention to the installed position, see - item 2 - in the => [ Piston and Connecting Rod Overview ] Piston and Connecting Rod Overview.

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

- Install the upper oil pan. Refer to => [ Upper Oil Pan ] Upper Oil Pan.