Removal and Replacement

Piston and Connecting Rod Component Overview

• Oil injector jet for piston cooling => [ Oil spray jet for piston cooling ]





1 Connecting rod bolt - 30 Nm plus an additional 90° ( 1/4 turn)

• Replace

• Lubricate threads and contact surface

• Tighten to 30 Nm to measure radial play, do not turn further

2 Connecting rod bearing cap

• Do not interchange

• Mark allocation to cylinder using a color marker - B - => [ Mark connecting rod ]

• When installing bearing cap, observe: The wide thrust flange - A - must point to the same side on connecting rod and connecting rod bearing cap

• Installation position of connecting rod pairs => [ Connecting rod, installed location ]

3 Bearing shell

The version depends on construction:

• Lower bearing shell (for bearing cap), identified by a dark-colored bearing. Upper bearing shell (for connecting rod) made of wear-resistant material, identified by a light-colored bearing

or

• The same bearing, no allocation

• Check that retaining tabs are secured

• Do not interchange used bearing shells (mark)

• Radial clearance, measuring, refer to => [ Connecting Rod, Checking Radial Clearance ] Testing and Inspection

• When measuring radial clearance, tighten bolts => [ (Item 1) Connecting rod bolt - 30 Nm plus an additional 90° (/ turn) ] to 30 Nm but do not turn further

4 Connecting rod

• Only replace as set

• Mark allocation to cylinder with paint - B - => [ Mark connecting rod ]

• When installing bearing cap, observe: The wide thrust flange - A - must point to the same side on connecting rod and connecting rod bearing cap

• Installation position of connecting rod pairs => [ Connecting rod, installed location ]

5 Piston pin

• If tight, heat piston to 60 °C

• Removing and installing using a drift (VW 222 A )

6 Circlip

• Replace

7 Piston

• Installed position and allocation, piston/cylinder => [ Installed position of piston and piston/cylinder
allocation ]

• Arrow on piston face points toward belt pulley side

• Checking => [ Pistons, Checking ] Testing and Inspection

• Install with piston ring compressor

• Piston and cylinder dimensions, refer to => [ Piston and Cylinder Dimensions ] [1][2]Piston, Engine

• Cylinder bore, checking => [ Cylinder Bore, Checking ] Testing and Inspection

8 Piston rings

• Offset gaps by 120°

• Use piston ring pliers for removal and installation

• "TOP" marking or inscribed side must point to piston head

• Checking ring gap => [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking

• Check piston ring groove clearance => [ Ring to Groove Clearance, Checking ] Ring to Groove Clearance, Checking

Installed position of piston and piston/cylinder allocation





- Mark installed position and allocation to cylinder on piston head using chalk or waterproof felt pen.

• Do not use a center punch or scribe, since the piston head coating will be damaged.

• Installation position: Arrow on piston face points toward belt pulley side.

Mark connecting rod





• Only replace connecting rod as a set.

• Do not interchange connecting rod bearings.

- Before removing, mark allocation of connecting rod and connecting rod bearing caps to each other and to cylinder with paint - arrow -.

Connecting rod, installed location





• The molded tabs - arrows - at the beveled surfaces of the connecting rod pairs 1 and 2, 3 and 4, and 5 and 6 must point toward each other.

Oil spray jet for piston cooling





1. Install bolt - 9 Nm - using a locking compound.

2. Oil spray jet with spray nozzle valve