Pistons and connecting rods, disassembling and assembling: Notes
WARNING: This page is about a different car, the 1999 Volkswagen Jetta, 1998 Volkswagen Jetta, 1997 Volkswagen Jetta, 1996 Volkswagen Passat, and 1996 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
The following list pertains to Fig 1.
- Piston ring
- Offset ring gaps by 120°
- Remove and install using piston ring pliers
- "OBEN" points toward piston crown
- Checking ring gap, see Checking Piston Ring Gap
- Checking ring to groove clearance, see Checking Ring To Groove Clearance
- Piston
- Engine codes 1Z, AHU: with combustion chamber
- Mark installed position and cylinder number; engine codes 1Z, AHU, see Piston Installation And Cylinder Orientation
- Arrow on piston crown points toward pulley end
- Install using piston ring clamp
- If there are cracks on piston skirt, replace piston
- Piston position at TDC, checking, see Piston position at TDC, checking
- Piston Pin
- If difficult to remove, heat piston to 60° C (140° F)
- Remove and install using VW222a pilot drift
- Circlip
- Connecting Rod
- Only replace as a set
- Mark cylinder number (arrows -A-)
- Installation position: marking (arrow -B-) faces pulley end
- Bearing Shell
- Note installed position
- Do not interchange used bearing shells
- Make sure that retaining lugs fit tightly in recesses
- Axial clearance, wear limit: 0.37 mm (0.0146 in.)
- Check radial clearance using Plastigage®, wear limit: 0.08 mm (0.0031 in.)
- Do not rotate crankshaft when checking radial clearance
- Cylinder Block
- Checking cylinder bore diameter, see Checking Cylinder Bore Diameter
- Piston and cylinder dimensions, see Piston and cylinder dimensions
- Connecting Rod Bearing Cap
- Note installation position.
- Locating Pin
- The fitted pin must seat securely in connecting rod, not in bearing cap
- Oil Spray Jet
- For piston cooling
- 10 Nm (7 ft lb)
- Install using AMV 188 100 02
- Connecting Rod Bolt
- Always replace
- 30 Nm (22 ft lb) + 1/4-turn (90°)
- Oil threads and contact surfaces
- Use old bolts to measure radial clearance