Overview - Pistons And Connecting Rod

Fig 1: Exploded View Of Pistons And Connecting Rod

Courtesy of AUDI OF AMERICA, LLC

1. Bolts
   • Tightening Specifications and Sequence. Refer to Fig 2.
   • Replace after removing.
   • Use the old bolts for radial clearance measurement
   • Oil the threads and contact surface
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
   • Replace any worn bearing shells
   • There are different versions. Refer to the Parts Information for the allocation.
   • Make sure the retaining tabs are secure.
4. Connecting Rod
   • Always replace as a set
   • There are different versions. Refer to the Parts Information for the allocation.
   • 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
   • Replace after removing.
   • There are different versions. Refer to the Parts Information for the allocation.
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
   • Install using the Funnel:T40369 
   • 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.
   • There are different versions. Refer to the Parts Information for the allocation.
9. Compression Ring
   • There are different versions. Refer to the Parts Information for the allocation.
   • Install with 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 with Piston Ring Pliers:VAS211003  . 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
    • 10 Nm +45°
    • Replace after removing.

Connecting Rod Bearing Cap - Tightening Specification and Sequence

Fig 2: Connecting Rod Bearing Cap

Courtesy of AUDI OF AMERICA, LLC

• Replace the 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

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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: Installing Compression Ring

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• Only open the compression ring -2- using the Piston Ring Pliers:VAS211003  until it can be pushed evenly over the piston -1-.

Installing the Oil Scraping Ring

Fig 5: 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.

• 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

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Installation position:

Arrow - To the belt pulley side

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

Connecting Rod, Marking

Fig 7: Identifying Mark Connecting Rod

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-- 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

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