Overview - Pistons And Connecting Rod

Fig 1: Exploded View Of Pistons And Connecting Rod

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Bolts
   • Replace after removing
   • Coat the threads and contact surfaces with engine oil
   • Use old bolts for the radial clearance measurement
   • 45 Nm + 90°
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.
   • Use a color to mark the cylinder and connecting rod to which it belongs -A-
   • Installation position: the marks -B- face the belt pulley side
   • Separating the new connecting rod. Refer to NEW CONNECTING ROD, SEPARATING .
3. Bearing Shells
   • Installation position. Refer to Fig 2.
   • Replace any worn bearing shells
   • Coat with engine oil before installing
   • Axial clearance
     • New: 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
   • Identify the cylinder and connecting rod bearing cap to which it belongs
   • Installation position: the marks -B- face the belt pulley side
   • Separating 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
7. Circlip
   • Replace after removing
8. Piston Pin
   • Coat with engine oil before installing
9. Piston
   • Install with the Piston Ring Pliers Piston Installation Tool:T40347  . Refer to PISTONS, REMOVING AND INSTALLING .
   • Installation position: the arrow on piston face points toward belt pulley side.
   • Mark which cylinder belongs to which
   • Check piston and cylinder bore. Refer to PISTON AND CYLINDER BORE, CHECKING .
10. Compression Rings
    • Offset gaps by 120°
    • Installed Position: "TOP" "R" mark must face up toward piston crown
    • Refer to Fig 4
    • Refer to Figure
    • Refer to Figure
    • Refer to Fig 3
11. Oil Scraping Ring
    • Install the upper joint of the 3-part oil scraping ring 120° offset to the neighboring compression ring
    • Refer to Figure
    • Refer to Figure
    • Refer to Fig 5
    • Refer to Fig 3

Bearing shell installation position

Fig 2: Bearing Shell - Installation Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 and piston ring

Fig 3: Allocation Of The Piston Ring On Connection With The Three Part Oil Scraping Ring.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Compression Ring Installation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• >>TOP<< marking or lettering points upward.
• Only open the compression ring -2- using the Piston Ring Pliers:VAS 211 003  only until it can be pushed over the pistons -1-.

Three-Piece Oil Scraping Ring, Installing

Fig 5: Install The Three Part Oil Scraping Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pay attention to the spring installation position:

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

-- Install by hand.

Installation sequence:

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

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

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