Pistons and connecting rods, disassembling and assembling

Fig 1: Exploded View - Piston And Connecting Rod

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Piston rings

• Offset gaps by 120 °
• Remove and install using piston ring pliers
• "TOP" faces piston crown
• Checking ring gap

• Checking ring-to-groove clearance

2 - Piston

• With combustion chamber
• Mark with installed position and cylinder number
• Installed position and allocation of piston/cylinder
• Arrow on piston crown points to belt pulley end

• Install using piston ring clamp
• If cracks are observed on piston skirt, replace piston
• Checking piston projection at TDC. Refer to Piston projection at TDC, checking 

3 - Piston pin

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

4 - Circlip

5 - Connecting rod

• Mark cylinder allocation - A  - with colored felt tip pen
• Installed position: Marking - B  - faces belt pulley end
• With industrially cracked bearing caps

6 - Bearing shell

• Note installed position
• Note version: Upper bearing shell (toward piston) made of a more wear resistant material; Identification: Black line on bearing surface in area of joint
• Do not interchange used bearing shells
• Insert bearing shells centrally
• Check for secure seating
• Axial clearance, wear limit: 0.37 mm
• Check radial clearance with Plastigage: Wear limit: 0.08 mm. Do not rotate crankshaft when checking radial clearance.

7 - Cylinder block

• Checking cylinder bores.
• Piston and cylinder dimensions. Refer to Piston and cylinder dimensions  .

8 - Connecting rod bearing cap

• Note installed position
• Caps only fit in one position and only on appropriate connecting rod due to breaking procedure (cracking) separating cap from connecting rod

9 - Oil spray jet

• For piston cooling

10 - 25 Nm

• Insert without sealant

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

• Replace
• Oil threads and contact surface
• Use old bolts to measure radial clearance