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

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