Industrially cracked connecting rod

Fig 1: Exploded View Of Industrially Cracked Connecting Rod

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Piston rings 

• Offset gaps by 120 °
• Use piston ring pliers to remove and install
• Manufacturer's mark faces piston crown
• Checking ring gap. See Checking piston ring gap  .

• Checking ring to groove clearance. See Checking ring to groove clearance  .

2 - Piston 

• Checking. See Checking piston  .
• Mark installation position and cylinder number
• Arrow on piston crown points to belt pulley end
• Install using piston ring clamp

3 - Piston pin 

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

4 - Circlip 

5 - Connecting rod 

• With split bearing cap
• Only replace as a set
• Mark relation to cylinder -B-
• Installation position: Marking -A- faces belt pulley end

6 - Bearing shell 

• Observe installation position. See Checking piston  .
• Insert bearing shells centrally
• Do not interchange used bearing shells
• Check seated securely

• Axial clearance, New: 0.10... 0.35 mm; Wear limit: 0.4 mm
• Check radial clearance with Plastigage: New: 0.01... 0.05 mm; Wear limit: 0.09 mm (Do not rotate crankshaft when checking radial clearance)

7 - Cylinder block 

• Checking cylinder bores. Refer to Piston and cylinder dimensions  , Fig. 5
• Piston and cylinder dimensions. Refer to Piston and cylinder dimensions 

8 - Connecting rod bearing cap 

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

9 - 30 Nm plus 1/4 turn (90 ° ) 

• Torx E10
• Replace
• Oil thread and contact surface
• To measure radial clearance tighten to 30 Nm, but do not turn further