Pistons and Connecting Rods Disassembling and Assembling

Disassembling and Assembling





1 - Piston rings
- Offset gaps by 120°
- Remove and install using piston ring pliers
- Install with word OBEN toward cylinder head
- Check ring gap, refer to "Piston Ring Gap, Checking". Testing and Inspection
- Ring land clearance, checking refer to "Piston Ring Groove Clearance, Checking". Testing and Inspection
2 - Piston
- Checking, refer to "Piston Diameter, Measuring". Testing and Inspection
- Identify position and
- Cylinder number
- Arrow on piston crown points toward pulley side
- Install using piston ring clamp
3 - Connecting rod
- Replace only as a complete set
- Mark cylinder number B
- Installation position: marking A faces toward pulley end
- With oil passage for piston pin lubrication
4 - Connecting rod; bearing cap
5 - 30 Nm (22 ft lb) + 1/4 additional turn
- Oil threads and contacting surfaces before assembling
- To measure radial clearance, tighten to 30 Nm (22 ft lb) but no more
6 - Pressure relief valve
- 27 Nm (20 ft lb)
- Opening pressure: 2.5 to 3.2 bar
7 - Oil jet spray
- For piston cooling
8 - Bearing shell
- Note installed position
- Do not interchange used bearing shells
- Check for secure fit in retaining tabs
- Axial play:
New: 0.05 to 0.31 mm
Wear limit: 0.37 mm
- Measure radial play with Plastigage:
New: 0.01 to 0.06
Wear limit: 0.12 mm
Do not turn crankshaft during radial play measurement
- With oil hole for piston lubrication
9 - Cylinder block
- Check cylinder bore, refer to "Cylinder Block, External Components/Bore, Measuring". Bore, Measuring
- Piston and cylinder dimensions, , refer to "Cylinder Block, External Components/Bore, Measuring". Bore, Measuring
10 - Connecting rod bolt
11 - Circlip
12 - Wrist pin
- If difficult to move: heat piston to: 140 °F
- Remove and install using VW 222A