Disassembling Pistons

NOTIFICATION 

Incorrect handling of piston rings 

• Risk of strain and damage to piston rings 

  → Only open up the piston ring using the piston ring pliers sufficiently to allow you to remove or fit it.

  → Do not use force to install pistons.

Information 

Pistons must not be marked using mechanical tools.

1. Mark allocation of piston, connecting rod and cylinder for re-installation using a coloured marker.
2. Remove piston-pin circlip -1-  .

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   Piston-pin circlip

   1. 2.1  Insert a small screwdriver into the cut-out -2-  on the circlip -1-  .
   2. 2.2  Carefully lever out piston-pin circlip -1-  .
3. Remove connecting rod.

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   Piston pin

   1. 3.1  Carefully drive out piston pin -Arrow-  using > VW222A - drift  .
   2. 3.2  If the piston pin -Arrow-  is stiff, heat the piston -1-  to approx. 60°C and drive out the piston pin -Arrow -  .
   3. 3.3  Remove connecting rod -2-  from the piston -1-  .
   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.

   Information 

   • Compression rings and oil scraper rings are installed and removed differently. 
4. Remove compression rings.

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   Compression rings

   1. 4.1  Place the piston -1-  on a clean surface and look for the gaps in the compression rings -3-  .
   2. 4.2  Remove the compression rings -3-  , starting at the piston crown. To do this, move the middle point of > Nr.58 - piston ring pliers, size 1  into the gap in the relevant compression ring -3-  . The holding arms of the piston ring pliers should clasp the compression ring -3-  from above. Only open the compression rings -3-  as far as required so that they can be removed from the groove -2-  .
   3. 4.3  Loosen the piston ring pliers and remove the compression ring -3-  from the pliers.
5. Remove oil scraper ring.

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   Oil scraper ring

   1. 5.1  Look for gaps -1-  in the oil scraper ring.
   2. 5.2  Carefully spread the upper and lower lamella and remove from the piston.
   3. 5.3  Disconnect and remove spring -2-  .