Cylinder Block Assembly: Locations

Piston and Connecting Rod Assembly Overview





1. Connecting Rod Bolt
^ M8: 30 Nm plus an additional 90 degree turn
^ M9: 45 Nm plus an additional 90 degree turn
^ Replace
^ Lubricate threads and contact surface
^ Use old bolt to measure radial play
^ Do not tighten 90 degree further when measuring radial play
2. 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.
^ Mark affiliation to cylinder - A -
^ Installation position: Markings - B - point to belt pulley side
3. Bearing Shells
^ Do not interchange used bearing shells (mark)
^ Axial play new: 0.10 to 0.35 mm. Wear limit: 0.40 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
4. Pressure Relief Valve
^ 27 Nm
^ Opening pressure 1.6 to 1.9 bar
5. Oil Spray Jet
^ For piston cooling
6. Circlip
7. Piston Pin
^ If difficult to move, heat piston to approximately 60 degree C
^ Removing and installing using a drift VW 222A
8. Piston
^ Mark installed position and cylinder allocation
^ Arrow on piston face points toward belt pulley side
^ Install with piston ring compressor
9. Compression Rings
^ Offset gaps by 120 degree
^ Use piston ring pliers for removal and installation
^ "TOP" mark must face up toward piston crown
10. Oil Scraping Ring
^ 2-part
^ Install upper steel ring so gap is offset by 120 degree to neighboring compression ring
^ Offset all oil scraping ring component gaps to each other.
^ Side clearance cannot be measured.
11. Connecting Rod
^ Only replace as set
^ Mark affiliation to cylinder - A -
^ Installation position: Markings - B - point to belt pulley side





Bearing Shell Installation Position
- Place bearing shells centrally into connecting rod and connecting rod cover.

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