LEMON Manuals: Even more car manuals for everyone
Home >> Volkswagen >> 2006 >> GTI 1.8 E, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 11 (2.0L - Crankshaft, Cylinder Block - Engine Code(S): BPY) >> 13 Crankshaft, Cylinder Block >> Description And Operation >> Pistons And Connecting Rod Overview

Pistons And Connecting Rod Overview

WARNING: This page is about a different variant/trim than selected.
Fig 1: Piston And Connecting Rod, Assembly Overview
GWWN13-10138Courtesy of VOLKSWAGEN UNITED STATES, INC.
  1. 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, do not tighten the additional torque.
  2. Bolt with Pressure Relief Valve
    • 27 Nm
    • Opening pressure 1.3 to 1.6 bar pressure.
  3. Oil Spray Jet
    • For the piston cooling.
  4. Connecting Rod Bearing Cap
    • Pay attention to the installed 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.
    • -B- is the affiliation to the cylinder mark.
    • Installed position: Marks -A- point to the belt pulley side.
  5. Bearing Shell
    • Note the installed position, refer to BEARING SHELL, INSTALLED POSITION .
    • Do not interchange used bearing shells.
    • Axial play new: 0.10 to 0.35 mm wear limit: 0.4 mm.
    • Measure radial clearance using Plastigage: New: 0.02 to 0.06 mm wear limit: 0.09 mm. Do not rotate the crankshaft when checking the radial clearance.
  6. Connecting Rod
    • With a cracked bearing cap.
    • Only replace as a set.
    • -B- is the affiliation to the cylinder mark.
    • Installed position: Marks -A- point to the belt pulley side.
  7. Circlip
  8. Piston Pin
    • If difficult to move, heat the piston to 60°C (140°F).
    • Remove and install using a pilot drift VW 222 A.
  9. Piston
    • Checking, refer to Figure.
    • Mark the installed position and cylinder allocation.
    • Arrow on the piston face points toward the belt pulley side.
    • Install with piston ring compressor.
    • Cylinder bore, checking. Refer to Figure.
    • For the correct piston and cylinder dimensions, refer to PISTON AND CYLINDER DIMENSIONS .
  10. Piston Rings
    • Offset gaps by 120°.
    • Use piston ring pliers for removing and installing.
    • Marks face toward the piston crown.
    • Checking ring gap, refer to Figure.
    • Checking piston ring groove clearance, refer to Figure.
scientia non olet · About LEMON Manuals