Removal and Replacement

Piston with Connecting Rod Component Overview

• Oil spray nozzle and pressure relief valve => [ Oil spray jet and pressure relief valve ]

• If large quantities of metal shavings or abraded material are found in the engine oil while servicing the engine, the oil passages must be carefully cleaned to prevent resulting damage and the oil cooler must be replaced.





1 Connecting rod bolt - 30 Nm plus an additional 90° ( 1/4 turn)

• Replace

• Lubricate threads and contact surface

• Use old bolt to measure radial play

• Tighten to 30 Nm to measure radial play, do not turn further

2 Connecting rod bearing cap

• Affiliation to the cylinder mark - B -

• Installation position: Markings - A - point to belt pulley side

3 Bearing shells

• Upper bearing shell with oil hole for piston pin lubrication

• Installed location => [ Installed position of bearing shell ]

• Do not interchange used bearing shells (mark)

• Axial play new: 0.10 to 0.35 mm, wear limit: 0.40 mm

• Measure the radial play using the Plastigage: new: 0.01 to 0.05 mm; wear limit: 0.12 mm; do not turn the crankshaft when measuring the radial play

4 Connecting rod

• Only replace as set

• Affiliation to the cylinder mark - B -

• Installation position: Markings - A - point to belt pulley side

• With oil hole for piston pin lubrication

5 Circlip

6 Piston pin

• If tight, heat piston to 60 °C

• Removing and installing using a Drift (VW 222 A )

7 Piston

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

• Mark installed position and cylinder allocation

• Arrow on piston face points toward belt pulley side

• Install with piston ring compressor

• Piston and cylinder dimensions, refer to => [ Piston and Cylinder Dimensions ] [1][2]Piston, Engine

• Cylinder bore, checking, refer to => [ Cylinder Bore, Checking ] Testing and Inspection

8 Piston rings

• Offset gaps by 120°

• Use piston ring pliers for removal and installation

• Mark "TOP" must face toward piston head

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

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

Installed position of bearing shell





- Insert the bearing shells centrally into the connecting rod and into the connecting rod cap.

• Dimension - a - = 3.0 mm

Oil spray jet and pressure relief valve





1. Oil spray jet for piston cooling

2. Bolt with pressure relief valve - 27 Nm

• Opening pressure 1.3 to 1.6 bar.