Overview - Pistons And Connecting Rod

Fig 1: Exploded View Of Pistons And Connecting Rod

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Bolts
   • 30 Nm + 90°
   • Always replace after removing.
   • Use old bolts for the radial clearance measurement and do not tighten with an additional turn
   • Lubricate the threads and contact surface.
2. Connecting Rod Bearing Cap
   • 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 allocation to the cylinder and connecting rod with paint -B-.
   • Installed position: the tab -A- on the connecting rod bearing cap faces the belt pulley side.
3. Bearing Shells
   • Installation position. Refer to Fig 3.
   • Replace the used bearing shells after removal.
   • Check for secure fit
4. Connecting Rod
   • With a cracked connecting rod bearing cap
   • Always replace as a set
   • Mark allocation to the cylinder and connecting rod bearing cap with paint -B-
   • Installed position: the tab -A- on the connecting rod bearing cap faces the belt pulley side.
   • Radial play, measuring. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE .
   • New connecting rod, separating. Refer to NEW CONNECTING ROD, SEPARATING .
5. Circlip
   • Always replace after removing.
   • Quantity: 2
6. Piston Pin
   • Removing and installing. Refer to PISTONS, REMOVING AND INSTALLING .
7. Piston
   • Label the installation position and cylinder allocation. Refer to Fig 2.
   • Check piston and cylinder bore. Refer to PISTON AND CYLINDER BORE, CHECKING .
   • Removing and installing. Refer to PISTONS, REMOVING AND INSTALLING .
8. Piston Rings
   • Compression rings
   • Measuring the gap. Refer to Figure.
   • Measuring side clearance. Refer to Figure.
   • Use piston ring pliers (commercially available) for removing and installing
   • Installation position: "TOP" lettering or side with lettering faces the piston crown.
   • Offset gaps by 120°
9. Piston Ring
   • Oil Scraping Ring
   • Measuring the gap. Refer to Figure.
   • Measuring side clearance. Refer to Figure.
   • Use piston ring pliers for removing and installing
   • Installation position: "TOP" lettering or side with lettering faces the piston crown.
   • Offset gaps by 120° on the lower compression ring

Piston Installation Location and Allocation, Piston to Cylinder 

Fig 2: Identifying Piston Installed Location And Allocation, Piston To Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Arrow on the piston crown facing the belt pulley side -arrow-.

Bearing Shell Installation Position 

Fig 3: Bearing Shell Installed Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the bearing shells in the center of the connecting rod and into the connecting rod bearing cap.

• Dimension -a- must = dimension -a-.

Oil Spray Jet and Pressure Relief Valve 

Fig 4: Exploded View Of Oil Spray Jet And Pressure Relief Valve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Bolt with Pressure Relief Valve
2. Piston Cooling Oil Spray Jet

Removing and Installing. Refer to NEW CONNECTING ROD, SEPARATING .