Table of contents: Mounting position of the piston ↓ Installation position: arrows on the… ↓ Mark the connecting rods ↓ Mounting position of the connecting… ↓ Removal the piston ↓ Installation ↓
Pistons and connecting rods 1. Bolts. Replace. Lubricate the threads and mating surface with oil. 30 Nm + 90° turn; 2. Connecting rod cap. Mark for reassembly. Mark cylinder alignment with coloured pencil "B". When installing the bearing cap, note the following: the wide adjusting flange "A" must face the same direction on both the connecting rod and the connecting rod cap; 3. Bearing shell. Ensure that the locking tabs are firmly seated. Mark previously used shells, but not on the working surface. Replace bearing shells that are worn down to the original material; 4. Connecting rod. Replace only the entire set. Mark the cylinder with a colored pencil "B". When installing the bearing cap, note the following: the wide adjusting flange "A" must be directed in the same direction, both on the connecting rod and on the connecting rod cap; 5. Piston pin. If the pin is difficult to install, then preheat the plunger to 60°C. Remove and install using the "VW 222 A" mandrel; 6. Retaining ring. Replace; 7. Piston. Mark the installation position and the cylinder. The arrow on the piston bottom points towards the belt pulley. Check. Install with a piston ring clamp. Measure the inner diameter of the cylinder; 8. Piston rings. Position the locks with a 120° offset. Remove and install with piston ring pliers. Mounting position: "TOP" mark or written side facing the piston bottom
Mounting position of the piston
Caution! Risk of damage to the piston bottom coating. To ensure correct subsequent installation of used pistons, mark the piston to cylinder with paint. Do not make notches on the piston bottom with a center punch or similar tools.
Installation position: arrows on the piston bottoms point towards the belt pulleys.
Mark the connecting rods
The connecting rod must be replaced as an assembly only. Mark the connecting rods and the lower connecting rod head caps with paint for reassembly to indicate their correspondence to each other and to the cylinder "arrow".
Mounting position of the connecting rod
The toes of the "arrows" on the ground surfaces of the pairs of connecting rods "1 and 2", "3 and 4", and also "5 and 6" must be facing each other-
Piston cooling oil nozzle 1. Insert the bolt with threaded varnish and tighten to 9 Nm; 2. Oil injection nozzle with valve (opening at excess pressure of 2...2.4 bar)
Note: Do not bend the oil spray nozzles. Bent oil spray nozzles must be replaced.
Removal the piston
Remove the engine. Secure the engine to the assembly stand. Remove the cylinder heads. Remove the upper section of the oil pan. Due to the connecting rods being broken (cracking), the connecting rod cap can only be installed in one position and only on the corresponding connecting rod. Mark the installation position and correspondence to the cylinder. Risk of damaging the piston crown coating. To ensure correct subsequent installation of used pistons, mark the correspondence of the piston to the cylinder with paint. Do not make notches on the piston crown with a center punch or similar tools. Mark the installation position and correspondence of the piston to the cylinder. To ensure correct subsequent installation of used pistons, mark the correspondence of the piston to the cylinder with paint. Do not make notches on the piston crown with a center punch or similar tools. Mark the connecting rods and the connecting rod lower head caps with paint for reassembly to indicate their correspondence to each other and to the cylinder "arrow".
Remove the connecting rod cap and pull out the piston with the connecting rod upwards. If the piston bolt is difficult to move, heat the piston to approximately 60°C. Remove the retaining ring from the piston pin seat and remove the piston pin using the punch "VW 222 A".
Installation
Installation is in the reverse order, taking into account the tightening torque. The arrow on the piston bottom points towards the belt pulley. Move the piston ring lock by 120°. Lubricate the working surface of the liners with oil. Install the pistons using a standard piston ring tension band, taking into account the installation position. The toes of the "arrow" on the ground surfaces of connecting rod pairs "1 and 2", "3 and 4", and "5 and 6" must face each other.
Install the connecting rod head cover, taking into account the installation position. Install the cylinder heads. Install the upper part of the oil pan. Install the engine.
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