Pistons

Pistons

Special tools, testers and auxiliary items required

• Pilot Drift (VW 222 A)

• Engine and Transmission Holder (VAS 6095)

• Piston ring compressor, commercially available

Removing

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

- Secure engine to the (VAS 6095). Refer to => [ Engine, Securing on Assembly Stand ] Engine, Securing to Assembly Stand.

- Remove the cylinder head.

• => [ Turbocharger ] Turbocharger

• => [ Cylinder Head ] Cylinder Head

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

- Mark installed position and cylinder allocation

- Mark installed position and connecting rod cylinder - item 11 - => [ (Item 11) 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 (VW 222 A).

Installing

Install in reverse order of removal. Note the following:

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

• Replace any bolts that were tightened with an additional turn.

• 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 8 - => [ (Item 8) Piston ] Pistons and Connecting Rod Overview.

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

- Install the cylinder head:

• => [ Turbocharger ] Turbocharger

• => [ Cylinder Head ] Cylinder Head

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