Pistons And Connecting Rod Assembly Overview

Fig 1: Identifying Exploded View - Piston And Connecting Rod

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Piston rings
- Offset gaps by 120 degrees
- Use piston ring pliers for removal and installation
- "TOP" faces toward piston crown
- Checking ring gap PISTON RING GAP, CHECKING .
- Check piston ring groove clearance PISTON RING GROOVE CLEARANCE, CHECKING .
Piston
- With combustion chamber
- Mark installed position and cylinder allocation
- Installed position and allocation, piston/cylinder INSTALLED POSITION OF PISTON AND PISTON/CYLINDER ALLOCATION .
- Arrow on piston face points toward belt pulley side
- Install with piston ring compressor
- Replace if piston skirt is cracked
- Checking piston position at TDC PISTON POSITION AT TDC, CHECKING .
Piston pin
- If difficult to move, heat piston to 60° C
- Removing and installing using a drift VW 222 A
Circlip
Connecting rod
- Mark matching cylinder with colored marker -arrows A-
- Installation position: Markings -arrows B- point to belt pulley side
- With cracked bearing cap
- Separate new connecting rod NEW CONNECTING ROD, SEPARATING .
Bearing shell
- Note installation position
- Note version: Upper bearing shell (to piston) made of wear-resistant material. Identification: Black line on contact surface in area of separating point
- Do not interchange used bearing shells
- Insert bearing shells in center
- Ensure seated tightly
- Axial play wear limit: 0.37 mm
- Measure radial clearance with Plastigage
  Wear limit: 0.08 mm Do not turn crankshaft when checking radial clearance
Cylinder block
- Cylinder bore, checking CYLINDER BORE, CHECKING .
- Piston and cylinder dimensions PISTON AND CYLINDER DIMENSIONS .
Connecting rod bearing cap
- Note installation position
- Due to the separation procedure (cracking) of the connecting rod, the cap only fits in one position and only to the corresponding connecting rod.
Oil spray jet
- For piston cooling
  NOTE:
  When replacing the oil injector jet, pay attention to the correct allocation for the pistons.
25 Nm
- Install without sealant
Connecting rod bolt 30 Nm + 90° ( ¹ / ₄ additional turn)
- Replace
- Lubricate threads and contact surface
- Use old bolt to measure radial play