Overview - Pistons And Connecting Rod

1. Connecting Rod Bolts
   • 45 Nm +90°
   • Replace after removing.
   • Tighten to 45 Nm to measure radial play. Do not tighten further.
   • Lubricate the threads and contact surface.
   • Use the old bolt for the radial clearance measurement
2. Connecting Rod Bearing Cap
   • Note the installation position
   • Due to the separation procedure (cracking) of the connecting rod, the connecting rod bearing cap only fits in one position and only to the corresponding connecting rod.
   • Mark the cylinder to which it belongs -A-
   • Installation position: the marks -B- face the belt pulley side
   • Disconnect the new connecting rod. Refer to NEW CONNECTING ROD, SEPARATING .
3. Bearing Shells
   • Installation position. Refer to Fig 2.
   • Do not interchange used bearing shells (mark them)
   • Lubricate before installing
   • New axial play: 0.10 to 0.35 mm, wear limit: 0.40 mm
   • Radial play, measuring. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE .
4. Connecting Rod
   • Always replace as a set
   • Mark the cylinder to which it belongs -A-
   • Installation position: the marks -B- face the belt pulley side
   • Disconnect the new connecting rod. Refer to NEW CONNECTING ROD, SEPARATING .
   • Radial play, measuring. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE .
5. Relief Valve
   • 27 Nm
6. Oil Spray Jet
   • For piston cooling
   • Removing and Installing. Refer to OIL SPRAY JETS, REMOVING AND INSTALLING .
7. Circlip
   • Replace after removing.
8. Piston Pin
   • Coat with engine oil before installing
9. Piston
   • Install with the Funnel: T40347  . Refer to PISTONS, REMOVING AND INSTALLING .
   • Mark the installation position and cylinder allocation
   • Arrow on piston crown points toward belt pulley side
   • Check piston and cylinder bore. Refer to PISTON AND CYLINDER BORE, CHECKING .
10. Compression Rings
    • Install with Piston Ring Pliers: VAS211003  . Refer to Fig 4.
    • Offset gaps by 120°
    • Installed Position: "TOP" "R" mark must face upward toward piston crown
    • Checking the piston ring gap. Refer to Figure.
    • Side clearance cannot be measured.
11. Oil Scraping Ring
    • 3-part
    • Removing and installing by hand. Refer to Fig 5.
    • Install the upper joint of the 3-part oil scraping ring 120° offset to the neighboring compression ring
    • Piston ring gap is not measurable.
    • Side clearance cannot be measured.
    • Allocation. Refer to Fig 3.

Bearing Shell Installation Position 

-- Place the bearing shells centrally into connecting rod and connecting rod bearing cap.

The dimension -a- must be the same at left and right.

Allocation of the Piston Ring in Connection with the Three-Part Oil Scraping Ring 

1. Compression ring with bevel -arrow A- on the upper side inside. >>TOP<< marking or lettering points upward
2. Compression ring offset -arrow B- on the bottom outside. >>TOP<< marking or lettering points upward
3. Three Part Oil Scraping Ring

Installing the Compression Ring 

• >>TOP<< marking or lettering points upward.
• Only open the compression ring -2- using the : VAS211003  only until it can be pushed over the pistons -1-.

Install the Three-Part Oil Scraping Ring 

-- Pay attention to the spring installation position:

• The plunger of the plates -2 and 3- and the spring -1- must be 90° to each other.

-- Install by hand.

Installation sequence: 

1. Insert the spring -1- in the groove.

2. Insert the lower plate -3- in the groove.

3. Insert the upper plate -2- in the groove.