Piston and connecting rod, component overview: Notes

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NOTE:

Oil injector jet for piston cooling Oil spray jet for piston cooling

Fig 1: Piston And Connecting Rod, Component Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Connecting rod bolt - 30 Nm plus an additional ¹ /₄ turn (90 °)

Replace
Lubricate threads and contact surface
Tighten to 30 Nm to measure radial play, do not turn further

2 - Connecting rod bearing cap

Do not interchange
Mark allocation to cylinder using a color marker - B - Mark connecting rod
When installing bearing cap, observe: The wide thrust flange - A - must point to same side on connecting rod and connecting rod bearing cap
Installation position of connecting rod pairs Connecting rod, installed location

3 - Bearing shells

Check that retaining tabs are secured
Do not interchange used bearing shells (mark, but not on running surface)
Radial clearance, measuring → Connecting rod radial clearance, measuring
Over-sized bearings are available for reworked crankshaft connecting rod journals

4 - Connecting rod

Only replace as set
Mark allocation to cylinder with paint - B - Mark connecting rod
When installing bearing cap, observe: The wide thrust flange - A - must point to the same side on connecting rod and connecting rod bearing cap
Installation position of connecting rod pairs Connecting rod, installed location

Axial play for each new connecting rod pair: 0.20 to 0.38 mm
Axial play wear limit: 0.60 mm
Radial clearance, measuring → Connecting rod radial clearance, 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
Measuring end cap Measuring piston ring gap

Measuring side clearance Measuring piston ring side clearance