Overview - Pistons And Connecting Rod
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- Bolts
- Replace after removing.
- Lubricate the threads and contact surface.
- Use the old bolts for radial clearance measurement
- Tightening Specifications:
- M8 Bolt: 30 Nm +90°
- M9 Bolt: 45 Nm +90°
- Connecting Rod Bearing Cap
- Note the installation position
- Due to the separation procedure (cracking) of the connecting rod, the connecting rod bearing cap only fits in one position and only to the corresponding connecting rod.
- Use a color to mark the cylinder and connecting rod to which it belongs -A-
- Installation position: the marks -B- face the belt pulley side
- Separating the new connecting rod. Refer to NEW CONNECTING ROD, SEPARATING .
- Bearing shells
- Installation position. Refer to Fig 5 .
- Replace any worn bearing shells
- Coat with engine oil before installing
- Axial clearance
- New: 0.10 to 0.35 mm
- Wear limit: 0.40 mm.
- Radial play, measuring. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE .
- Connecting Rod
- Always replace as a set
- Identify the cylinder and connecting rod bearing cap to which it belongs
- Installation position: the marks -B- face the belt pulley side
- Separating the new connecting rod. Refer to NEW CONNECTING ROD, SEPARATING .
- Radial play, measuring. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE .
- Relief Valve
- 27 Nm
- Oil Spray Jet
- For piston cooling
- Removing and Installing. Refer to OIL SPRAY JETS, REMOVING AND INSTALLING .
- Circlip
- Replace after removing.
- Piston Pin
- Coat with engine oil before installing
- Piston
- Removing and Installing. Refer to PISTONS, REMOVING AND INSTALLING .
- Mark the installation position and cylinder allocation
- Arrow on piston crown points toward belt pulley side
- Check piston and cylinder bore. Refer to PISTON AND CYLINDER BORE, CHECKING .
- Compression rings
- Install with Piston Ring Pliers :VAS211 003 . Refer to Fig 3 .
- Offset gaps by 120°
- Installation position in connection with two-piece oil scraping ring: installation position "TOP" "R" must point to the piston crown
- Allocation and installation position in connection with three part oil scraping ring. Refer to Fig 2 .
- Checking the piston ring gap. Refer to Figure .
- Checking the groove clearance. Refer to Figure .
- Oil Scraping Ring
- Depending on the version two or three part. Refer to the Parts information for the allocation.
- Two-Piece Oil Scraping Ring:
- Install offset gaps by 120° to the neighboring compression ring
- The "TOP" or "R" marking must face toward the piston crown.
- Checking the piston ring gap. Refer to Figure .
- Height clearance cannot be measured
- Three Part Oil Scraping Ring:
- Compression ring with bevel -arrow A- on the upper side inside. >>TOP<< marking or lettering points upward
- Compression ring offset -arrow B- on the bottom outside. >>TOP<< marking or lettering points upward
- Three Part Oil Scraping Ring
- >>TOP<< marking or lettering points upward.
- Only open the compression ring -2- using the Piston Ring Pliers :VAS211 003 only until it can be pushed over the pistons -1-.
-- Pay attention to the spring installation position:
- The plunger of the plates -2 and 3- and the spring -1- must be offset 90° to each other.
-- Install by hand.
Installation sequence:
-- Insert the spring -1- in the groove.
-- Insert the lower plate -3- in the groove.
-- Insert the upper plate -2- in the groove.
- Install the upper joint of the 3-part oil scraping ring 120° offset to the neighboring compression ring
-- Place the bearing shells centrally into connecting rod and connecting rod bearing cap.
- Dimension -a- = dimension -a-.