Piston and connecting rod, disassembling and assembling: Notes

Fig 1: Piston And Connecting Rod Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Piston rings

• Offset gaps by 120 °
• Use piston ring pliers to remove and install
• "TOP" faces towards piston crown
• Checking ring gap Checking piston ring gap 

• Checking ring to groove clearance Checking ring to groove clearance  under Piston and connecting rod, disassembling and assembling 

2 - Piston

• Checking Checking piston  under Piston and connecting rod, disassembling and assembling 
• Mark installation position to connecting rod and cylinder
• Flatter side of piston crown faces toward center of cylinder block
• Install with piston installation tool Funnel 3278 Installing pistons with piston installation tool  under Piston and connecting rod, disassembling and assembling 

3 - Snap ring

4 - Conrod

• Only replace as a set
• Mark position to cylinder - B  -
• Installation position: Marks - A  - must be aligned above one another

5 - Bearing shell

• Observe installation position
• Do not interchange used bearing shells
• Lugs on bearing shells must fit tightly in recesses
• Axial clearance, New: 0.05...0.35 mm, Wear limit: 0.40 mm

• Check radial clearance with Plastigage: New: 0.02...0.07 mm, Wear limit: 0.10 mm. Do not turn crankshaft when checking radial clearance

6 - Conrod bearing cap

• Mark position to cylinder - B  -
• Installation position: Marks - A  - must be aligned above one another

7 - 30 Nm plus additional ¹ / ₄ turn (90 ° ) further

• Replace
• Oil thread and contact surface
• To measure radial clearance tighten to 30 Nm, but do not turn further

8 - Cylinder block

• Checking cylinder bore Checking cylinder bores  under Piston and connecting rod, disassembling and assembling 
• Removing and installing crankshaft → Crankshaft, removing and installing 
• Piston and cylinder dimensions → Piston and cylinder dimensions 

9 - Piston pin

• If difficult to remove, heat piston to 60 ° C
• Remove and install with drift VW 222a