Assembly overview: 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 for removal and installation
• Identification "TOP" faces towards piston crown
• Checking ring gap Checking piston ring gap  , under Assembly overview 
• Check piston ring groove clearance Checking ring to groove clearance  , under Assembly overview 

2 - Piston

• Checking Checking piston  under Assembly overview 
• Mark installed location to connecting rod and affiliation to cylinder
• Flatter side of piston crown faces toward center of cylinder block
• Installing piston Installing piston  , under Assembly overview 

3 - Circlip

4 - Connecting rod

• Only replace as set
• Affiliation to the cylinder mark - B  -
• Installed location: Markings - A  - must lie above one another

5 - Bearing shell

• Note installation position
• Do not interchange used bearing shells
• Bearing shell retaining tabs must be firmly seated in the notches
• Axial clearance:
• New: 0.05 to 0.31 mm
• Wear limit: 0.40 mm
• Measure radial clearance with Plastigage:
• New: 0.02 to 0.07 mm
• Wear limit: 0.10 mm
• Do not turn crankshaft when checking radial clearance

6 - Connecting rod bearing cap

• Affiliation to the cylinder mark - B  -
• Installed location: Markings - A  - must lie above one another

7 - 30 Nm + ¹ / ₄ turn (90 ° )

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

8 - Cylinder block

• Cylinder bore, checking Checking cylinder bores  under Assembly overview 
• Removing and installing crankshaft, refer to Crankshaft, removing and installing 
• Piston and cylinder dimensions, refer to Piston and cylinder dimensions 

9 - Piston pin

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