Pistons And Connecting Rods Overview

Fig 1: Identifying Piston And Connecting Rod Assembly Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Connecting Rod Bolt
   • 30 Nm + 90° turn
   • Lubricate threads and contact surface
   • Tighten to 30 Nm to measure radial play, do not turn further.
   • Replace after removing
2. Relief Valve
   • 27 Nm
   • Opening pressure: 1.3 to 1.6 bar (18.8 to 23.2 psi) pressure
3. Oil Spray Jet
   • For piston cooling
4. Connecting Rod Cover
   • 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.
   • Mark which cylinder to which it belongs -B-.
   • Installed position: markings -A- face the pulley side
5. Bearing Shell
   • Pay attention to the 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 with Plastigage®:

     New: 0.02 to 0.06 mm

     Wear limit: 0.09 mm

     Do not turn crankshaft when measuring radial play.

6. Connecting Rod
   • With cracked bearing cap
   • New connecting rod, separating NEW CONNECTING ROD, SEPARATING .
   • Always replace as a set.
   • Mark which cylinder to which it belongs -B-.
   • Installed position: markings -A- face the pulley side
7. Locking Ring
8. Piston Pin
   • If difficult to move, heat piston to 60° C (140° F)
   • Remove and install with the Pilot Drift VW 222 A
9. Piston
   • Checking, refer to Figure
   • Mark installed position and cylinder allocation
   • Arrow on piston face points toward belt pulley side
   • Install with piston ring compressor
   • Checking the cylinder bore, refer to Figure.
10. Piston Rings
    • Offset gaps by 120°
    • Use piston ring pliers for removing and installing
    • Markings face toward piston crown
    • Checking the ring gap, refer to Figure.
    • Checking the piston ring groove clearance, refer to Figure.

Fig 2: Bearing Shells - Installed Positions

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bearing shell -1- with connecting rod oil bore -arrow-.

Bearing shell -2- without connected rod cover oil bore.

-- Place bearing shells centrally into connecting rod and connecting rod cover.

Dimension -a- must be the same at left and right.