Piston and Connecting Rod

Piston and Connecting Rod





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

• 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 Pressure relief valve, 27 Nm

• Opening pressure 1.6 to 1.9 bar

3 Oil spray jet

• For piston cooling

4 Connecting rod bearing cap

• Note installation position

• Due to separation procedure (cracking) of connecting rod, cap only install in one position and only to corresponding connecting rod.

• Affiliation to cylinder mark - B -

• Installed location: Markings - A - point to belt pulley side

5 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 radial clearance with Plastigage: New: 0.02 to 0.06 mm. Wear limit: 0.09 mm. Do not turn crankshaft when checking radial clearance

6 Connecting rod

• Only replace as set

• Affiliation to cylinder mark - B -

• Installed location: Markings - A - point to belt pulley side

• With oil hole for piston pin lubrication

7 Circlip

8 Piston pin

• If difficult to move, heat piston to approx. 60°C

• Use pilot drift (VW 222 A) for removal and installation

9 Piston

• Checking => [ Piston, 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 => [ Cylinder Bores, Checking ] Testing and Inspection

10 Piston rings

• Offset gaps by 120°

• Use piston ring pliers for removal and installation

• "TOP" mark must face up toward piston crown

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

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

Installed position of bearing shell





Bearing shell - 1 - with connecting rod oil bore - arrow -.

Bearing shell - 2 - without connected rod cover oil bore.

- Place bearing shells centrally into connecting rod and connecting rod cover.

Dimension - a - must be the same at left and right.