Service Specifications

Pistons and connecting rods





1. Connecting rod bolt, 30 Nm plus an additional 90° (1/4 turn)
^ Tighten 30 Nm when measuring radial clearance, but do not turn further

3. Connecting rod Bearing shell
^ Tighten bolts item -1- 30 Nm when measuring radial clearance, but do not turn further

6. Piston pins
^ In case of difficulty of movement, warm piston to approximately 60°C
^ When removing and installing, use VW222a Pilot drift

8. Piston rings
^ Offset gaps by 120°






Checking piston ring end gap
- Insert ring at right angle to cylinder wall from above to lower cylinder opening approximately 15 mm from cylinder edge. Use piston without rings to insert.









Checking piston ring side clearance
- Before measuring, clean piston ring groove








Checking pistons





Checking cylinder bore

Crankshaft

Main Bearing caps





-Replace bolts -A- and nuts -1- to -8-.
Tighten bearing cap nuts or bolts in following sequence:
1. - Screw in bolts -A- hand tight.
2. - Tighten nuts -1- to -8- 35 Nm
3. - Tighten nuts -1- to -8- 90° (1/4 turn) further using rigid wrench.
4. - tighten bolts -A- to 20 Nm
5. - Tighten bolts -A- 90° (1/4 turn) further using rigid wrench.






Number markings on crankshaft bearing cap
^ Bearing 1 is located on the belt pulley side





Application of crankshaft bearing shells for cylinder block
Bearing shells with the correct thickness are allocated to the cylinder block in the factory. Colored dots on the bearing shells serve for identifying bearing shell thickness.








Application of crankshaft bearing shells for bearing caps

Bearing shells with the correct thickness are allocated to the bearing caps in the factory. Colored dots on the bearing shells serve for identifying bearing shell thickness.