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

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

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 - Piston pin

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

4 - Circlip

5 - Connecting rod

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

6 - Bearing shell

Note installation position Bearing shells - installed positions under Pistons and connecting rods (engine code AWD, AWW), assembly overview
Do not interchange used bearing shells
Axial play new: 0.05 to 0.31 mm, wear limit: 0.37 mm
Measure radial clearance with Plastigage: New: 0.01 to 0.06 mm, wear limit: 0.09 mm

Do not turn crankshaft when checking radial clearance

7 - Cylinder block

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

8 - Connecting rod bearing cap

Note installation position

9 - Oil spray jet

For piston cooling

10 - Pressure relief valve, 27 Nm

Opening pressure 1.3 to 1.6 bar positive pressure

11 - Connecting rod bolt, 30 Nm plus an additional ¹ / ₄ turn (90 ° )

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