Overview - Pistons And Connecting Rod

Fig 1: Exploded View Of Pistons And Connecting Rod

Courtesy of AUDI OF AMERICA, LLC

1. Bolts
   • Replace after removing
   • Use the old bolts for radial clearance measurement
   • Oil the threads and contact surface
   • Tightening Specifications and Sequence. Refer to Fig 2.
2. Connecting Rod Bearing Cap
   • There are different versions. Refer to the Parts Information for the allocation.
   • Use color to identify the cylinder and connecting rod to which it belongs. Refer to Fig 7.
   • Installation position of the connecting rod pairs. Refer to Fig 8.
3. Bearing Shells
   • There are different versions. Refer to the Parts Information for the allocation.
   • Make sure the retaining tabs are secure.
   • Replace any worn bearing shells
4. Connecting Rod
   • There are different versions. Refer to the Parts Information for the allocation.
   • Always replace as a set
   • Use color to identify the cylinder and the connecting rod bearing cap to which it belongs. Refer to Fig 7.
   • Installation position of the connecting rod pairs. Refer to Fig 8.
   • Axial play for each connecting rod pair: 0.30 to 0.54 mm
   • Radial play, measuring. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE .
5. Circlip
   • There are different versions. Refer to the Parts Information for the allocation.
   • Replace after removing
6. Piston Pin
   • There are different versions. Refer to the Parts Information for the allocation.
   • Removing and Installing. Refer to PISTONS, REMOVING AND INSTALLING .
7. Piston
   • There are different versions. Refer to the Parts Information for the allocation.
   • Label the installation position and cylinder allocation. Refer to Fig 6.
   • Replace the piston if there are cracks on the piston crown or piston shaft
   • Removing and Installing. Refer to PISTONS, REMOVING AND INSTALLING .
   • Check piston and cylinder bore. Refer to PISTON AND CYLINDER BORE, CHECKING .
8. Circlip
   • There are different versions. Refer to the Parts Information for the allocation.
   • Replace after removing
9. Compression ring
   • There are different versions. Refer to the Parts Information for the allocation.
   • Install using the Piston Ring Pliers :VAS 211 003  . Refer to Fig 4.
   • Measuring the gap. Refer to Figure.
   • Measuring side clearance. Refer to Figure.
   • Allocation and installation position. Refer to Fig 3.
   • Offset gaps by 120° to -Item  10-
10. Compression ring
    • There are different versions. Refer to the Parts Information for the allocation.
    • Install using the Piston Ring Pliers :VAS 211 003  . Refer to Fig 4.
    • Measuring the gap. Refer to Figure.
    • Measuring side clearance. Refer to Figure.
    • Allocation and installation position. Refer to Fig 3.
    • Offset gaps by 120°
11. Oil Scraping Ring
    • There are different versions. Refer to the Parts Information for the allocation.
    • Carefully remove and install the three-part oil scraping ring by hand
    • Installation position. Refer to Fig 5.
    • Piston ring gap is not measurable
    • Height clearance cannot be measured
    • Allocation. Refer to Fig 3.
12. Oil Spray Jet
    • with spray nozzle valve
    • do not bend
    • Removing and Installing. Refer to OIL SPRAY JETS, REMOVING AND INSTALLING .
13. Banjo Bolt
    • Replace after removing
    • 10 Nm +45°

Connecting rod bearing cap - tightening specification and sequence

Fig 2: Connecting Rod Bearing Cap

Courtesy of AUDI OF AMERICA, LLC

• Replace bolts that were tightened with an additional turn after removing them.

-- Tighten the bolts -arrows- in steps:

Allocation and piston ring

Fig 3: Allocation and Piston Ring

Courtesy of AUDI OF AMERICA, LLC

1. Compression Ring with Labeling "1R" on the Top
2. Compression Ring with Labeling "2R" on the Top and the Sleeve -arrow- on the Outside Bottom
3. Three Part Oil Scraping Ring

Installing the compression ring

Fig 4: Compression Ring Installation

Courtesy of AUDI OF AMERICA, LLC

• Only open the compression ring -2- using the Piston Ring Pliers :VAS 211 003  until it can be pushed evenly over the piston -1-.

Installing the oil scraping ring

Fig 5: Install The Three Part Oil Scraping Ring

Courtesy of AUDI OF AMERICA, LLC

-- 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.

• Install the upper joint of the 3-part oil scraping ring 120° offset to the neighboring compression ring

Piston installed position

Fig 6: Piston Installed Position

Courtesy of AUDI OF AMERICA, LLC

Installation position:

Pfeil -  To the belt pulley side

x -  Cylinder bank identification: L = left, R = right

Connecting Rod, Marking

Fig 7: Identifying Mark Connecting Rod

Courtesy of AUDI OF AMERICA, LLC

-- Mark the connecting rod and connector rod bearing cap to each other and to the cylinder -arrow- with paint for reinstallation.

Connecting rod installation position

Fig 8: Connecting Rod, Installed Location

Courtesy of AUDI OF AMERICA, LLC

• The molded tabs at the beveled surfaces -arrows- of the connecting rod pairs must point toward each other.