Assembling Pistons

Information 

• If re-using a piston, do not remove combustion residues on the piston crown mechanically. 

1. Clean the piston.
2. Fit oil scraper ring.
   1. 2.1 Insert spring -1-  into the groove on the piston so that the gaps are touching.

      The gaps must not overlap.

   2. 2.2 Carefully spread the upper and lower lamella -2 and 3-  and push onto the piston.

      Fit the upper gap in the oil scraper ring offset by 120° with respect to the adjacent compression ring.

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      Fitting oil scraper ring

3. Allocate compression rings.

   Compression ring -1-  with chamfer -arrow A-  at the inner top side.

   Compression ring -2-  with shoulder -arrow B-  at the outer bottom side.

   Oil scraper ring -3-  (three parts).

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   Allocation of piston rings

   CAUTION: Risk of engine damage if piston rings are overstretched! 
   → Do not overstretch piston rings with the piston ring pliers. Only open up the piston rings until they just fit over the piston.
4. Fit compression rings -3-  .
   1. 4.1 Grip lower compression ring at the gap using > Nr.58 - piston ring pliers, size 1  .
   2. 4.2 Spread the piston ring just enough for it to fit over the piston -1-  .
   3. 4.3 Insert compression ring -3-  into the relevant groove -2-  on the piston -1-  .
   4. 4.4 Repeat the procedure for the upper compression ring.

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   Compression rings

5. Check that the piston rings are correctly seated and positioned.
6. Fit piston-pin circlip -1-  on one side.
   1. 6.1 Insert new piston-pin circlip -1-  into the ring groove of the piston so that the ring gap -3-  is offset with respect to the piston crown (6 or 11 o'clock position).

      Press one end -3-  into the ring groove with your thumb.

   2. 6.2 Carefully lever the circlip -1-  into the ring groove using a small screwdriver while continuing to press it down.
   3. 6.3 If the piston-pin circlip -1-  cannot be levered correctly into the ring groove, lever the other end -3-  into the ring groove first.
   4. 6.4 Check that the piston-pin circlip is seated correctly -1-  .

      The piston-pin circlip must be inserted fully in the ring groove of the piston.

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      Piston-pin circlip

7. Fit connecting rod -2-  .
   1. 7.1 Insert connecting rod -2-  into the piston -1-  and check that it is positioned correctly.
   2. 7.2 Coat piston pin -arrow-  with engine oil.
   3. 7.3 Fit piston pin -arrow -  and drive it in carefully using > VW222A - Mandrel  .

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      Piston pin

8. Fit second piston-pin circlip -1-  .
   1. 8.1 Insert new piston-pin circlip -1-  into the ring groove of the piston so that the ring gap -3-  is offset with respect to the piston crown (6 or 11 o'clock position).

      Press one end -3-  into the ring groove with your thumb.

   2. 8.2 Carefully lever the circlip -1-  into the ring groove using a small screwdriver while continuing to press it down.
   3. 8.3 If the piston-pin circlip cannot be levered correctly into the ring groove, lever the other end -3-  into the ring groove first.
   4. 8.4 Check that the piston-pin circlip is seated correctly -1-  .

      The piston-pin circlip must be inserted fully in the ring groove of the piston.

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Piston-pin circlip

9. Check piston and connecting rod for smooth operation.