Pistons And Connecting Rod Overview

Fig 1: Identifying Pistons And Connecting Rod Overview

Courtesy of AUDI OF AMERICA, LLC

1. Bolts
   • Replace
   • 45 Nm plus an additional 90° turn
   • Lubricate threads and contact surface
   • Use old bolts for radial play measurement, tighten to 45 Nm but do not tighten further
2. Connecting Rod Bearing Cap
   • Mark allocation to cylinder with paint -B-
   • Installed position: Markings -A- face the pulley side
3. Bearing Shells
   • Upper bearing shell with oil bore for piston pin lubrication
   • Installed position, refer to Fig 2
   • Mark used bearing shells for reinstallation but not on the running surface
   • Replace bearing shells that have worn down to the nickel layer
4. Connecting Rod
   • With oil bore for piston pin lubrication
   • Only replace as set
   • Mark allocation to cylinder with paint -B-
   • Installed position: Markings -A- face the pulley side
   • Measuring axial play, refer to CONNECTING ROD, MEASURING AXIAL CLEARANCE 
   • Radial clearance, measuring, refer to CONNECTING ROD, MEASURING RADIAL CLEARANCE 
5. Locking Ring
   • Replace
6. Piston Pin
   • Heat piston to 60 °C (140 °F) if it is difficult to move.
   • Removing and installing using a pilot drift VW 222 A
7. Piston
   • Checking, refer to Figure
   • Mark installed location to connecting rod and affiliation to cylinder
   • Installed position: Arrow on the piston face points toward the belt pulley side
   • Install with piston ring compressor
   • Cylinder bore, checking, refer to Figure
8. Piston Rings
   • Offset gaps by 120°
   • Use piston ring pliers for removing and installing
   • "TOP" faces toward piston crown
   • Checking ring gap, refer to Figure
   • Check piston ring groove clearance, refer to Figure

Fig 2: Installation Position Of Bearing Shells

Courtesy of AUDI OF AMERICA, LLC

-- Install the bearing shell in the center of the connecting rod or in the connecting rod cover.

• Dimension -a- = approximately 1.5 mm.

Fig 3: Identifying Oil Spray Jet And Pressure Relief Valve

Courtesy of AUDI OF AMERICA, LLC

1. Bolt with pressure relief valve - 27 Nm
2. Oil spray jet (for piston cooling)

• Installed position: Align the guiding edge of the oil spray jet to the machined surface of the cylinder block.