Pistons, Removing And Installing: Removing

-- Remove the cylinder head. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .

-- Remove the oil pan. Refer to TRANSMISSION FLUID PAN, REMOVING AND INSTALLING .

-- Label the installation position and allocation of the piston to the cylinder  OVERVIEW - PISTONS AND CONNECTING ROD.

-- Mark installation position and allocation of the connecting rod cylinder  OVERVIEW - PISTONS AND CONNECTING ROD.

-- Remove the connecting rod bearing cap and remove the piston and connecting rod upward.

-- Remove the circlip from the piston pin eye.

-- Remove the piston pin using the Pilot Drift:VW 222 A  .

NOTE:

The Piston Installation Funnel:T10333  with pistons inserted for assembly is placed on the cylinder block so that the straight side of the high installation plate -arrow- faces toward the center of the cylinder block.

Fig 1: Identifying Piston Installation Funnel

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Procedure

-- Before installing pistons, remove the fitting sleeve -arrow- from its hole.

Fig 2: Identifying Alignment Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pistons for cylinders 1, 3 and 5 must be installed so that the deep valve recesses -1- point toward center of cylinder block and arrows -3- point toward vibration damper.

Fig 3: Identifying Piston And Cylinder Positions

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pistons for cylinders 2, 4 and 6 must be installed so that the deep valve recesses -2- point toward center of cylinder block and arrows -3- point toward vibration damper.

Fig 4: Identifying Piston And Cylinder Positions

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slide the piston for each cylinder into the Piston Installation Funnel:T10333  from the top. The short side of the piston -arrow- must extend approximately 15 mm past the lower edge of the funnel.

Fig 5: Identifying Piston Position In Piston Installation Funnel

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Now place the pistons with the funnel in the appropriate cylinder bore. The high side of the funnel -arrow- must face toward center of cylinder block.

-- Place the funnel securely on cylinder block and slide piston completely into cylinder bore.

Fig 6: Placing Funnel Securely On Cylinder Block And Slide Piston Completely Into Cylinder Bore

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the alignment sleeve into the hole -arrow- after installing the piston.

Fig 7: Identifying Alignment Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.