Piston and connecting rod, disassembling and assembling

The following list pertains to Fig 1.

1. Piston rings 
   • Offset gaps by 1207°
   • Remove and install with piston ring pliers
   • "TOP" marking faces toward piston crown
   • Checking ring gap, see Checking piston ring gap 
   • Checking side clearance, see Checking piston ring side clearance 
2. Piston 
   • Checking, see Checking Piston 
   • Mark installation position and relationship to cylinder
   • Arrow on base of piston points toward pulley end
   • Install with piston ring compressor
   • Dimensions, see Piston Dimensions 
3. Connecting rod 
   • Replace only as set
   • Mark matching cylinder number -B-
   • Installation position: marking -A- points toward pulley end
   • With oil hole for piston pin lubrication
4. Bearing cap 
   • Note installation position
5. 30 Nm (22 ft lb) plus 1/4-turn (90°) 
   • Oil threads and contact surface
   • Measuring radial clearance: tighten to 30 Nm (22 ft lb), but NOT additional 1/4-turn (90°)
   CAUTION: DO NOT turn crankshaft while measuring radial clearance.
6. Pressure relief valve 
   • Tightening torque: 27 Nm (20 ft lb)
   • Opening pressure: 2.5 -3.2 bar (36 -46 psi)
   • Not applicable 08.95 and up
7. Oil spray nozzle 
   • For piston cooling
   • Not applicable 08.95 -->
   NOTE: The oil spray nozzles and pressure relief valves have been discontinued with production from August 1995.
8. Bearing shell 
   • Note installation position
   • Do not interchange worn bearing shells
   • Ensure correct seat in holding tabs

     Axial clearance:

   • New: 0.05 -0.31 mm (0.0020 -0.0122 in.)
   • Wear limit: 0.37 mm (0.0146 in.)

     Measure radial clearance with Plastigage:

   • New: 0.01 -0.06 mm (0.0004 -0.0024)
   • Wear limit: 0.12 mm (0.0047 in.)
   • With oil hole toward piston pin
   CAUTION: DO NOT turn crankshaft while measuring radial clearance.
9. Cylinder block 
   • Checking cylinder bore, see Checking Cylinder Bore 
   • Piston and cylinder dimensions, see
10. Connecting rod bolt 
11. Circlip 
12. Piston pin 
    • If difficult to move, warm piston to 60 °C (140 °F)
    • Remove and install with VW222a
Fig 1: Exploded View Of Piston & Connecting Rod
Courtesy of VOLKSWAGEN OF AMERICA, INC.