Removal and Replacement

Piston and Connecting Rod Assembly Overview





1 Bolt, 30 Nm + 90° (1/4 additional turn)

• Always replace.

• Lubricate the threads and contact surface.

• Tighten to 30 Nm to measure radial play, do not rotate further.

2 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 way the separated connecting rod breaks (cracks), the cap fits only in one position and only on to the respective connecting rod.

• Affiliation to the cylinder mark - B -.

• Installation position: Markings - A - point to the belt pulley side.

5 Bearing shell

• Note installation position, refer to --> [ Bearing Shells, Installation Location ]

• 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 rotate the crankshaft when measuring radial play.

6 Connecting rod

• With cracked bearing cap.

• Separating the new connecting rod, refer to --> [ New Connecting Rod, Separating ] Procedures.

• Only replace as a set.

• Affiliation to the cylinder mark - B -.

• Installation position: Markings - A - point to the belt pulley side.

7 Circlip

8 Piston pin

• If difficult to remove, heat the piston to 60° C.

• Remove and install using a pilot drift (VW 222A).

9 Piston

• Checking, refer to --> [ Pistons, Checking ] Testing and Inspection

• Mark installed position and cylinder allocation.

• Arrow on piston face points toward the belt pulley side.

• Install with a piston ring compressor.

• Checking cylinder bore, refer to --> [ Cylinder Bore, Checking ] Testing and Inspection

• Piston and cylinder dimensions, refer to --> [ Piston and Cylinder Dimensions ] Piston and Cylinder Dimensions.

10 Piston rings

• Offset gaps by 120 degrees.

• Use piston ring pliers for removal and installation.

• Markings face toward the piston crown.

• Checking ring gap, refer to--> [ Piston Ring Gap, Checking ] Testing and Inspection

• Check piston ring groove clearance, refer to --> [ Piston Ring Groove Clearance, Checking ] Testing and Inspection

Bearing Shells, Installation Location





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

Bearing shell - 2 - without oil bore for the connecting rod cover.

- Place the bearing shells centrally into the connecting rod and connecting rod cap.

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