Replacement

LEGEND
1. Piston Rings
2. Piston
3. Connecting Rod
4. Connecting Rod Bearing Cap
5. Connecting Rod Bearing Cap Nut
6. Pressure Relief Valve
7. Oil Spray Nozzle
8. Bearing Shell
9. Cylinder Block
10. Connecting Rod Bolt
11. Circlip
12. Piston Pin

NOTE: During removal and installation procedures, refer to the component location illustration above and component notes below.

REMOVAL COMPONENT NOTES
Piston Rings (1)
- Remove using piston ring pliers.

Piston (2)
- Mark cylinder number on piston.

Connecting Rod (3)
- Only replace in full sets.

Bearing Shell (8)
- Note installation position.
- Do not interchange worn shells.

Connecting Rod Bolt (10)
- Always replace with nuts.

Piston Pin (12)
- If hard to move, heat piston to 60°C (140°F).

INSTALLATION COMPONENT NOTES
Piston Rings (1)
- Space ring end gaps 120° apart.
- Install using piston ring plier.
- Two part or three part oil scraper ring, mixed installation is permissible.

Piston (2)
- Note cylinder number mark on piston.
- Arrow on piston crown points toward front (pulley end).
- Install using piston ring compressor.

Connecting Rod (3)
- Only replace in full sets.
- Align markings -B-.
- Markings -A- point toward front (pulley end).
- With oil passage for piston pin lubrication.

Connecting Rod Bearing Cap (4)
- Note installation position.

Connecting Rod Bearing Cap Nut (5)
- Always replace together with connecting rod bolts.
- Tighten to: 30 Nm (22 ft. lbs.) plus an additional 1/4 turn (90°).
- Lubricate threads and contact surface.
- When measuring rod bearing radial clearance tighten only to 30 Nm (22 ft. lbs.), without extra 1/4-turn.

Pressure Relief Valve (6)
- Tighten to: 27 Nm (20 ft. lbs.).

Bearing Shell (8)
- Note installation position.
- Do not interchange worn shells.
- Make sure shell is properly seated in holding tabs.
- Axial clearance (end play):
New: 0.05-0.31 mm (0.0020-0.0122 inch).
Wear limit: 0.37 mm (0.0146 inch).
- Radial clearance (oil clearance).
- Do not turn crankshaft during measurement.
New: 0.01-0.06 mm (0.0004-0.0024 inch).
Wear limit: 0.12 mm (0.0047 inch).

Connecting Rod Bolt (10)
- Always replace with nuts.

Piston Pin (12)
- If hard to move, heat piston to 60°C (140°F).
- Remove and install using pilot drift tool No. VW 222a, or equivalent.
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