Disassembling Pistons

Information 

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

Information 

• When disassembling the piston/connecting rod unit, note or mark the position, relationship to cylinder and installation position using a waterproof felt tip pen. 

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

   Do not mark pistons using a mechanical tool!

2. Remove piston-pin circlip -1-  .
   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-  .

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   Piston-pin circlip

3. Remove connecting rod.
   1. 3.1 Carefully drive out piston pin -arrow-  using > VW222A - Mandrel  .
   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-  .

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   Piston pin

   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. Remove compression rings.
   1. 4.1 Place the piston -1-  on a clean surface and look for the gaps in the piston rings -3-  .
   2. 4.2 Remove the piston 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 piston ring -3-  . The holding arms of the piston ring pliers should clasp the piston ring -3-  from above. Only open the piston ring -3-  as far as required so that the piston ring -3-  can be removed from the groove -2-  . Do not overstretch it!
   3. 4.3 Relieve the piston ring pliers and remove the piston ring -3-  from the pliers.

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   Compression rings

5. Remove 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-  .

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   Oil scraper ring