Connecting Rod: Service and Repair

Piston and Connecting Rod, Assembly Overview





1 Piston rings

• Offset gaps by 120 degrees

• Use piston ring pliers for removal and installation

• "TOP" faces toward piston crown

• Checking ring gap --> [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking.

• Check piston ring groove clearance --> [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking.

2 Piston

• Checking --> [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking.

• Mark installed location to connecting rod and affiliation to cylinder

• Flatter side of piston crown faces toward center of cylinder block

• Install using funnel (T10147)

3 Circlip

4 Connecting rod

• Only replace as set

• Affiliation to the cylinder mark - B -

• Installation position: Markings - A - must align

5 Bearing shell

• Note installation position

• Do not interchange used bearing shells

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

• Axial play new: 0.05 to 00.31 mm, Wear limit: 0.40 mm

• Measure radial clearance with Plastigage: New: 0.02 to 00.07 mm, Wear limit: 0.10 mm. Do not turn crankshaft when checking radial clearance

6 Connecting rod bearing cap

• Affiliation to the cylinder mark - B -

• Installation position: Markings - A - must align

7 30 Nm + 1/4 turn (90°)

• Replace

• Lubricate threads and contact surface

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

8 Cylinder block

• Cylinder bore, checking --> [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking.

• Removing and installing crankshaft --> [ Crankshaft, Assembly Overview ] Crankshaft, Assembly Overview.

• Piston and cylinder dimensions --> [ Piston Ring Gap, Checking ] Piston Ring Gap, Checking.

9 Piston pin

• If difficult to move, heat piston to 60° C

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