Piston and connecting rod, assembly overview: Notes

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bolt

• Replace
• Lubricate threads and contact surface
• 60 Nm plus an additional 90° (¹ /₄ turn).
• Tighten to 60 Nm to measure radial play, do not turn further

2 - Connecting rod bearing cap

• Mark for re-installation
• Mark affiliation to cylinder with paint → Mark connecting rod 
• Installation position of connecting rod pairs → Connecting rod, installed location 

3 - Bearing shells

• Check that retaining tabs are secured
• Mark used bearing shells for reinstallation but not on running surface
• Radial clearance, measuring → Radial clearance of connecting rod, measuring 
• Over-sized bearings are available for reworked crankshaft connecting rod journals

4 - Connecting rod

• Only replace as set
• Mark affiliation to cylinder with paint → Mark connecting rod 
• Installation position of connecting rod pairs → Connecting rod, installed location 
• Axial play for each new connecting rod pair: 0.20 to 0.27 mm

• Axial play wear limit: 0.30 mm
• Radial clearance, measuring → Radial clearance of connecting rod, measuring 

5 - Piston pin

• If tight, heat piston to 60° C
• Removing and installing using a drift VW 222 A

6 - Circlip

7 - Piston

• Installation position of pistons → Piston installation position 
• Piston and cylinder dimensions → Piston and cylinder dimensions 
• Checking → Checking piston 
• Install with piston ring compressor

• Measuring cylinder bore → Measuring cylinder bore 

8 - Piston rings

• Offset gaps by 120°
• Use piston ring pliers for removal and installation
• "TOP" marking or inscribed side must point to piston head
• Gap, measuring → Piston ring end gap, measuring 

• Measuring side clearance → Measuring piston ring side clearance