Pistons and connecting rods (engine code AWD), assembly overview: Notes

Fig 1: Pistons And Connecting Rods (Engine Code AWD), Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Piston rings

• Offset gaps by 120 °
• Use piston ring pliers for removal and installation
• "TOP" faces toward piston crown
• Checking ring gap Checking piston ring gap  under Checking piston ring gap 

• Check piston ring groove clearance Checking ring to groove clearance  under Pistons and connecting rods (engine code AWD), assembly overview 
• Oil scraping ring, 2-part or 3-part, mixed installation is permitted

2 - Piston

• Checking Checking piston  under Pistons and connecting rods (engine code AWD), assembly overview 
• Mark installed position and cylinder allocation
• Arrow on piston face points toward belt pulley side
• Install with piston ring compressor

3 - Connecting rod

• Only replace as set
• Affiliation to cylinder mark - B  -
• Installed location: Markings - A  - point to belt pulley side

4 - Connecting rod bearing cap

• Installed location: Markings - A  - point to belt pulley side
• Affiliation to cylinder mark - B  -

5 - 30 Nm plus an additional ¹ / ₄ turn (90 ° )

• Replace
• Lubricate threads and contact surface
• Tighten to 30 Nm to measure radial play, do not turn further

6 - Pressure relief valve, 27 Nm

• Opening pressure 1.3 to 1.6 bar positive pressure

7 - Oil spray jet

For piston cooling

8 - Bearing shell

• Note installation position
• Do not interchange used bearing shells
• Check for secure fit in retaining tabs
• Axial play new: 0.10 to 0.31 mm, wear limit: 0.40 mm
• Measure radial clearance with Plastigage: New: 0.01 to 0.05 mm, wear limit: 0.09 mm
• Do not turn crankshaft when checking radial clearance

9 - Cylinder block

• Cylinder bore, checking Checking cylinder bores  under Pistons and connecting rods (engine code AWD), assembly overview 
• Piston and cylinder dimensions, refer to Piston and cylinder dimensions, engine code AWD 

10 - Connecting rod bolt

• Replace

11 - Circlip

12 - Piston pin

• If difficult to move, heat piston to 60 ° C
• Removing and installing using a Pilot Drift VW 222 A