Connecting Rod, Engine

Pistons and connecting rods






1. Piston ring
- Offset gaps by 120°
- Remove and install using piston ring pliers
- "Top" faces piston crown
- Two part oil ring
2. Piston
- Mark installation position and cylinder number
- Arrow on piston crown points to pulley end
- Install using piston ring clamp
3. Connecting rod
- Only replace as set
- Mark cylinder number -B-
- Installation position:
- Marking -A- faces pulley end
4. Connecting rod bolt
- Engine code AEG
5. Connecting rod bearing cap
- Mark cylinder number -B-
- Installation position:
- Marking -A- faces pulley end
6. 30 Nm (22 ft. lbs.) + 1/4 turn (90°)
- Engine code AEG
- Oil threads and contact surfaces
- To measure radial clearance tighten to 30 Nm (22 ft. lb.) but no further
- 90° additional angle can be measured with torque angle meter i.e., Hazet 6690
7. 30 Nm (22 ft. lbs.) + 1/4 turn (90°)
- Engine codes AVH, AZG
- Always replace
- Oil threads and contact surfaces
- To measure radial clearance tighten to 30 Nm (22 ft. lb.) but no further
- 90° additional angle can be measured with torque angle meter i.e., Hazet 6690
8. Pressure relief valve
- 27 Nm (20 ft. lb.)
- Opening pressure: 2.5 to 3.2 bar (36 to 46 psi)
9. Oil spray jet
- For piston cooling
10. Bearing shell
- Note installation position
- Do not interchange used bearing shells
- Insure retaining lugs fit tightly in recess
- Axial Clearance:
- NEW 0.05 to 0.35 mm
- Wear Limit 0.37 mm
- Check radial clearance with plastigage:
- New 0.01 to 0.06 mm
- Wear Limit 0.12 mm
- Do not rotate crankshaft when checking radial clearance
11. Engine block
12. Circlip
13. Piston pin
- If difficult to remove heat piston to 60°C (140°F)
- Remove and install using VW 222a