Pistons and Connecting Rods, Assembly Overview

Pistons and Connecting Rods, Engine Codes AWW and AWP Assembly Overview






1 - Piston ring
Offset gaps by 120°
Remove and install with piston ring pliers
"TOP" faces towards piston crown
Checking ring gap refer Pistion Ring Gap, Checking Piston Ring Gap, Checking
Checking ring to groove clearance, refer to Checking Ring to Groove Clearance Checking Ring to Groove Clearance

2 - Piston
Checking, refer to Piston, Checking Piston, Checking
Mark installation position and cylinder number
Arrow on piston face points to belt pulley end
Install using piston ring clamp

3 - Piston pin
If difficult to remove, heat piston to 60°C / 140°F
Removing and installing using a Pilot-Drift -VW 222A-

4 - Circlip

5 - Connecting rod
Only replace as a set
Affliation to cylinder mark -B-
Installed location: Marking -A- points to belt pulley side

6 - Bearing shell
Note installation position refer to Bearing Shells, Installation Position Bearing Shells, Installation Position
Do not interchange used bearing shells
Axial play new: 0.05 to 0.31 mm , wear limit: 0.37 mm
Check radial clearance with Plastigage: New: 0.01 to 0.06 mm Wear limit: 0.09 mm
Do not rotate crankshaft when checking radial clearance

7 - Cylinder block
Checking cylinder bores refer to Cylinder Bores, Checking Testing and Inspection
Piston and cylinder dimensions

8 - Connecting rod bearing cap
Note installation position

9 - Oil spray jet
For piston cooling

10 - Pressure relief valve, 27 Nm
Opening pressure: 1.3 to 1.6 bar

11 - Connecting rod bolt, 30 Nm + 1/4 turn (90°) further
Replace
Lubricate threads and contact surfaces
To measure radial clearance use old bolts
To measure radial clearance tighten to 30 Nm but not further