Piston and connecting rod, assembly overview: Notes

Fig 1: Piston And Connecting Rod, Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Connecting rod bolt, 40 Nm plus an additional 90 ° ( ¹ /₄ turn)

• Replace
• Lubricate threads and contact surface
• Tighten to 40 Nm to measure radial play, do not turn further

2 - Connecting rod bearing cap

• Do not interchange
• 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
• Do not interchange used bearing shells (mark, but not on running surface)
• Radial clearance, measuring → Radial clearance of connecting rod, measuring 
• To measure radial play, tighten bolt - 1  - to 40 Nm but no further

• Over-sized bearings are available for reworked crankshaft connecting rod journals
• Insert bearing shells with correct color marking → Connecting rod, allocating with connecting rod bearing shells to crankshaft 

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 
• Insert connecting rod with correct identification letter → Connecting rod, allocating with connecting rod bearing shells to crankshaft 

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 dimension, piston allocation to cylinder bore → 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