Removal and Replacement

Pistons and Connecting Rod Assembly Overview






1 Connecting rod bolt 30 Nm + 90° (1/4 additional turn)

• Replace

• Lubricate the threads and contact surface

• tighten to 30 Nm to measure radial play, do not turn further

2 Pressure relief valve, 27 Nm

• Opening pressure 1.3 to 1.6 bar excess pressure

3 Oil spray jet

• For piston cooling

4 Connecting rod bearing cap

• Pay attention to the installed 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 => [ Bearing Shells Installed position ]

• Do not interchange used bearing shells

• Axial clearance

New: 0.10 to 0.35 mm wear limit: 0.4 mm

• Measure radial clearance with Plastigage:

New: 0.01 to 0.06 mm wear limit: 0.09 mm Do not turn crankshaft when measuring radial play.

6 Connecting rod

• With cracked bearing cap

• Separate new connecting rod => [ Separating the new connecting rod ] Procedures

• 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° C

• removing and installing using a drift (VW 222 A)

9 Piston

• Checking, refer to => [ Pistons, Checking ]

• Mark installed position and cylinder allocation

• Arrow on piston face points toward belt pulley side

• Install with piston ring compressor

• Cylinder bore, checking => [ Cylinder Bore, Checking ]

• For the correct piston and cylinder dimensions, refer to => [ Piston and Cylinder Dimensions ] [1][2]Specifications

10 Piston rings

• Offset gaps by 120°

• Use piston ring pliers for removing and installing

• Markings face toward piston crown

• Checking ring gap => [ Piston Ring Gap, Checking ]

• Check piston ring groove clearance => [ Piston Ring Groove Clearance, Checking ]

Bearing Shells Installed position





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

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

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

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