Piston And Connecting Rod Assembly Overview

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Piston And Connecting Rod Assembly Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Piston Rings
- Offset the gaps by 120 degrees.
- Use piston ring pliers for removal and installation.
- Identification "TOP" faces towards the piston crown.
- Checking ring gap, refer to Figure.
- Checking piston ring groove clearance, refer to Figure.
Piston
- Checking, refer to Figure.
- Mark the installed location to the connecting rod and the affiliation to the cylinder.
- Flatter side of piston crown faces toward the center of the cylinder block.
- Installing piston, refer to PISTON, INSTALLING .
Circlip
Connecting Rod
- Only replace as a set.
- Affiliation to the cylinder mark -B-.
- Installation position: Markings -A- must align.
Bearing Shell
- Note the installation position.
- Do not interchange the 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 the crankshaft when measuring radial play.
Connecting Rod Bearing Cap
- Affiliation to the cylinder mark -B-.
- Installation position: Markings -A- must align.
Bolt, 30 Nm + 90° (1/4) additional turn
- Always replace.
- Lubricate the threads and contact surface.
- Tighten to 30 Nm to measure the radial play, but do not turn further.
Cylinder Block
- Checking cylinder bore, refer to Figure.
- Crankshaft assembly overview, refer to CRANKSHAFT ASSEMBLY OVERVIEW .
- Piston and cylinder dimensions, refer to PISTON AND CYLINDER DIMENSIONS .
Piston Pin
- If difficult to move, heat the piston to 60 °C (140 °F).
- Remove and install using a pilot drift VW 222A.