Piston and Connecting Rod Assembly Overview

Piston and Connecting Rod Assembly Overview





1. Connecting rod bolt 30 Nm + 90 degree (1/4 additional 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 the connecting rod, the cap only fits in one position and only to the corresponding connecting rod.
^ Affiliation to the cylinder mark - B -
^ Installation position: 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: 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 set
^ Affiliation to the cylinder mark - B -
^ Installation position: Markings - A - point to belt pulley side
7. Circlip
8. Piston pin
^ If difficult to move, heat piston to 60 degree C
^ Removing and installing 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 degrees
^ Use piston ring pliers for removal and installation
^ Markings face toward piston crown
^ Check piston ring groove clearance