Connecting Rod Bearing: Service and Repair

LEGEND
1 Piston Ring
2 Piston
3 Connecting Rod
4 Connecting Rod Bearing Cap
5 Connecting Rod Bolt
6 Connecting Rod Bearing Shell
7 Cylinder Block
8 Piston Pin
9 Piston Pin Circlip

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

COMPONENT NOTES
Piston Ring (1)
- Offset gaps by 120°.
- Remove and install with piston ring pliers.
- "TOP" faces towards piston crown.

Piston (2)
- Mark installation position for con rod and cylinder.
- High point of piston crown faces to center of engine block.





- Install with piston fitting tool No. 3278, or equivalent as follows:

NOTE: If a new tool is used to install the pistons, first pass piston with oiled piston rings twice through the tool and then if necessary remove the resulting metal shavings. Only then install piston with piston rings.

- Oil tool and push piston in. High point of the piston crown must face to the lug on the fitting tool -arrow-.
- Push piston in until it protrudes approx. 15 mm from the lower edge of the fitting tool.
- Place piston in appropriate cylinder bore. Lug on fitting tool -arrow- must face to center of cylinder block.
- Hold fitting tool tight against cylinder block and push piston in.

Connecting Rod (3)
- Only renew as a set.
- Mark cylinder number -B- in illustration.
- Note installation position.
- Marks -A- in illustration must be above one another.

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

Connecting Rod Bolt (5)
- Tighten to: 30 Nm (22 ft. lbs.) + 1/4 turn 90°.
- Always replace when removed.
- Oil threads and contact surface when installing.
- When measuring radial clearance only tighten to: 30 Nm (22 ft. lbs.).

Connecting Rod Bearing Shell (6)
- Note installation position.
- Do not interchange used bearing shells.
- The lugs on the bearing shells must fit tightly in the recesses.
- Axial clearance:

- New: 0.05-0.31 mm (0.0019-0.0122 inch).
- Wear limit: 0.40 mm (0.0157 inch).

- Check radial clearance with Plastigage(r):

- New: 0.01-0.06 mm (0.0004-0.0023 inch).
- Wear limit: 0.10 mm (0.0039 inch).

- Do not rotate crankshaft when checking radial clearance.

Piston Pin (8)
- If difficult to remove, heat piston to 60°C (140°F).
- Remove and install with pin tool No. VW 222A, or equivalent.