Piston and Connecting Rod Assembly Overview

Piston and Connecting Rod Assembly Overview





1. Piston rings
^ Offset gaps by 120 degrees
^ Use piston ring pliers for removal and installation
^ "TOP" faces toward piston crown
^ Check piston ring groove clearance
2. Piston
^ Mark installed location to connecting rod and affiliation to cylinder
^ The two deep valve recesses in piston head point toward center of cylinder block.
3. Circlip
^ Ensure seated tightly
4. Connecting rod
^ Only replace as set
^ Affiliation to the cylinder mark - B
^ Installation position: Markings - A - must align
5. Bearing shell
^ Note installation position
^ Do not interchange used bearing shells
^ Bearing shell retaining tabs must be firmly seated in the notches
^ Axial play new: 0.05 to 0.31 mm Wear limit: 0.40 mm
^ Measure radial clearance with Plastigage: New: 0.02 to 0.07 mm Wear limit: 0.10 mm. Do not turn crankshaft when checking radial clearance
6. Connecting rod bearing cap
^ Affiliation to the cylinder mark - B -
^ Installation position: Markings - A - must align
7. 30 Nm + 1/4 turn (90 degree)
^ Replace
^ Lubricate threads and contact surface
^ Tighten to 30 Nm to measure radial play, do not turn further
8. Cylinder block
9. Piston pin
^ If difficult to move, heat piston to 60 degree C
^ Removing and installing using a drift VW 222 A