Piston and connecting rod, component overview: Notes

Fig 1: Piston And Connecting Rod, Component Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

• 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 the same side on connecting rod and connecting rod bearing cap
• Installation position of connecting rod pairs Connecting rod, installed location 

3 - Bearing shell

• Upper bearing shell (for connecting rod) made of wear-resistant material; identification: Bright color of bearing
• Lower bearing shell (for bearing cap) identification: Dark color of bearing
• Check that retaining tabs are secured
• Do not interchange used bearing shells (mark)

• Radial clearance, measuring → Radial clearance of connecting rod, checking 

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 

5 - Piston pin

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

6 - Circlip

7 - Piston

• Installed position and allocation, piston/cylinder Installed position of piston and piston/cylinder allocation 
• Arrow on piston face points toward belt pulley side
• Checking Checking piston 
• Install with piston ring compressor

• Piston and cylinder dimensions → Piston and cylinder dimensions 
• Cylinder bore, checking Checking cylinder bores 

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
• Checking ring gap Checking piston ring gap 

• Check piston ring groove clearance Checking ring to groove clearance