Piston and Connecting Rod, Assembly Overview

Piston and connecting rod, assembly overview





1. Connecting rod bolt 30 Nm plus an additional 90° (1/4 turn)
^ Replace
^ Lubricate threads and contact surface
^ Tighten to 30 Nm to measure radial play, do not turn further
2. Bolt with pressure relief valve
^ 27 Nm
^ Opening pressure 1.3 to 1.6 bar pressure
3. Oil spray jet
^ For piston cooling
4. Connecting rod bearing cap
^ Note installation position
^ Due to the separation procedure (cracking) of connecting rod, cap only fits in one position and only to the corresponding connecting rod.
^ Affiliation to cylinder mark - B -
^ Installed location: Markings - A - point to belt pulley side
5. Bearing shell
^ Note installation position
^ Do not interchange used bearing shells
^ Axial play new: 0.10 to 0.35 mm Wear limit: 0.4 mm
^ Measure radial clearance with Plastigage(R): New: 0.02 to 0.06 mm Wear limit: 0.09 mm. Do not turn crankshaft when checking radial clearance
6. Connecting rod
^ With cracked bearing cap
^ Only replace as a set
^ Affiliation to cylinder mark - B -
^ Installed location: Markings - A - point to belt pulley side
7. Circlip
8. Piston pin
^ If difficult to move, heat piston to 60° C
^ Remove and install using a drift VW 222 A
9. Piston
^ Mark installed position and cylinder allocation
^ Arrow on piston face points toward belt pulley side
^ Install with piston ring compressor
10. Piston rings
^ Offset gaps by 120°
^ Use piston ring pliers for removal and installation
^ Markings face toward piston crown
^ Check piston ring groove clearance

Bearing shells, installed positions





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

Bearing shell - 2 - without oil bore for connecting rod cover.
- Place bearing shells centrally into connecting rod and connecting rod cap.

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