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Home >> Volkswagen >> 2009 >> Golf Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 187 (2.0L - Crankshaft, Cylinder Block - Engine Code(S): AXX, BPY & BWA (A5 Platform)) >> 13 Crankshaft, Cylinder Block >> Description And Operation >> Piston And Connecting Rod Assembly Overview

Piston And Connecting Rod Assembly Overview

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Piston And Connecting Rod, Assembly Overview
GWWM13-0235Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Bolt, 30 Nm + 90° (1/4) additional turn 
    • Always replace
    • Lubricate the threads and contact surface.
    • Tighten to 30 Nm to measure radial play, do not turn further.
  2. Bolt with Pressure Relief Valve, 27 Nm 
    • Opening pressure: 1.3 to 1.6 bar.
  3. Oil Spray Jet 
    • For piston cooling.
  4. Connecting Rod Bearing Cap 
    • Note the installed position.
    • Due to the way the separated connecting rod breaks (cracks), the cap fits only in one position and only onto the respective connecting rod.
    • Affiliation to the cylinder mark -B-.
    • Installation position: Marking -A- point to the belt pulley side.
  5. Bearing Shell 
    • Note the installed position, refer to BEARING SHELL INSTALLATION LOCATION .
    • Do not interchange used bearing shells.
    • Axial play: new 0.10 to 0.35 mm.
    • Wear limit: 0.4 mm.
    • Measure radial clearance with Plastigage.
    • Radial clearance: new 0.02 to 0.06 mm.
    • Wear limit: 0.09 mm.
    • Do not turn the crankshaft when checking the radial clearance.
  6. Connecting Rod 
    • With cracked bearing cap.
    • Only replace as set.
    • Separate the new connecting rod. Refer to SEPARATING NEW CONNECTING RODS .
    • Affiliation to the cylinder mark -B-.
    • Installed position: Marking -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 the pilot drift VW 222A.
  9. Piston 
    • Checking, refer to Figure.
    • Mark installed position and cylinder allocation.
    • Arrow on the piston face points toward the belt pulley side.
    • Install with a piston ring compressor.
    • Checking cylinder bore, refer to Figure.
    • Piston and cylinder dimensions. Refer to PISTON AND CYLINDER DIMENSIONS .
  10. Piston Rings 
    • Use piston ring pliers for removal and installation.
    • TOP marking faces the piston crown.
    • Offset gaps by 120 degrees.
    • 2 part oil scraping ring.
    • Checking ring gap, refer to Figure.
    • Checking piston ring groove clearance, refer to Figure.
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