Removal and Replacement

Pistons and Connecting Rod Overview






1 Piston Ring

• Offset gaps by 120°.

• Use piston ring pliers for removal and installation.

• "TOP" faces toward the piston crown.

• Checking the ring gap. Refer to => [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking.

• Checking the piston ring groove clearance. Refer to => [ Piston Ring Groove Clearance, Checking ] Piston Ring Groove Clearance, Checking.

2 Piston

• Checking, refer to => [ Piston, Checking ] Testing and Inspection.

• Mark the installed location to the connecting rod and to which cylinder it belongs.

• The 2 deep valve recesses in the piston head point toward the center of the cylinder block.

• Removing and installing, refer to => [ Piston ] Piston.

3 Lock Ring

• Make sure it is secure.

4 Connecting Rod

• Always replace as a set.

• Mark which cylinder to which it belongs - B -.

• Installed position: The marks - A - must align.

5 Bearing Shell

• Pay attention to the installed position.

• Do not interchange used bearing shells (mark them).

• Bearing shell retaining tabs must be firmly seated in the notches.

• Axial clearance:

New: 0.05 to 0.31 mm

Wear limit: 0.40 mm

• Measure the radial clearance using Plastigage(R):

New: 0.02 to 0.07 mm

Wear limit: 0.10 mm

• Do not rotate the crankshaft when measuring the radial play.

6 Connecting Rod Bearing Cap

• Mark which cylinder to which it belongs - B -.

• Installed position: The marks - A - must align.

7 Bolt

• 40 Nm + an additional 90° (1/4) turn.

• Always replace.

• Lubricate the threads and contact surface.

• Tighten to 40 Nm to measure radial play, do not tighten the additional torque angle.

8 Piston Pin

• If difficult to move, heat the piston to 60° C (140 °F).

• Remove and install using the pilot drift (VW 222 A).