Overview - Pistons And Connecting Rod

• Lubricate all bearing and contact surfaces when assembling.

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1. Bolts
   • 45 Nm + 90°
   • Replace after removing.
   • Use the old bolts for radial clearance measurement
   • Lubricate the threads and contact surface.
2. Connecting Rod Bearing Cap
   • Note the installation position
   • Due to the separation procedure (cracking) of the connecting rod, the cap only fits in one position and only to the corresponding connecting rod.
   • Mark allocation to the cylinder with paint -B-.
   • Installation position: marks -A- face the belt pulley side.
3. Bearing Shells
   • Replace any worn bearing shells
   • Without oil filler hole
   • Installation position. Refer to Fig 5.
4. Connecting Rod
   • Always replace as a set
   • Mark allocation to the cylinder with paint -B-.
   • Installation position: marks -A- face the belt pulley side.
   • Radial Play, Checking. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE 
5. Circlip
   • Replace after removing.
6. Piston Pin
   • Removing and installing. Refer to PISTONS, REMOVING AND INSTALLING .
7. Piston
   • Mark the installed location to connecting rod and the cylinder to which it belongs
   • Installation position: the arrow on the piston crown points toward the belt pulley side. Refer to Fig 4.
   • Removing and installing. Refer to PISTONS, REMOVING AND INSTALLING .
   • Check piston and cylinder bore. Refer to PISTON AND CYLINDER BORE, CHECKING .
8. Circlip
   • Replace after removing.
9. Compression Rings
   • Install with Piston Ring Pliers:VAS211003  . Refer to Fig 2.
   • Allocation and installation position. Refer to Fig 1.
   • Checking the piston ring gap. Refer to Figure.
   • Offset gaps by 120°
   • Height clearance cannot be measured
10. Oil Scraping Ring
    • Three part, depending on the version
    • Remove and install carefully by hand
    • Piston ring gap is not measurable
    • Height clearance cannot be measured
    • Installation position. Refer to Fig 3.
    • Allocation. Refer to Fig 1.
11. Oil Spray Jet
    • For piston cooling
    • With alignment pin
    • Removing and installing. Refer to OIL SPRAY JETS, REMOVING AND INSTALLING .
12. Relief Valve
    • 27 Nm

Allocation and Piston Ring

Fig 1: Allocation Of The Piston Ring On Connection With The Three Part Oil Scraping Ring.

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1. Compression ring with bevel -arrow A- on the inside upper side
2. Compression ring with offset -arrow B- on the bottom outside
3. Three part oil scraping ring, version depends on the version

Installing the Compression Ring 

Fig 2: Installing Compression Ring

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• Installation position: "TOP" lettering or side with lettering faces the piston crown.
• Only open the compression ring -2- using the Piston Ring Pliers:VAS211003  only until it can be pushed over the pistons -1-.

Installing the Oil Scraping Ring 

Fig 3: Install The Three Part Oil Scraping Ring

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-- 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.

Piston Installed Position

Fig 4: Piston Installed Position

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• Installation position: arrow to belt pulley side

Bearing Shell Installation Position in the Connecting Rods

Fig 5: Bearing Shell Installed Position

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-- Install the bearing shells in the center of the connecting rod or into the connecting rod bearing cap.

• Dimension -a- = dimension -a-.