Pistons and connecting rods 1. Bolts: replace; lubricate the threads and the contact surface with oil; 35 Nm + 90°; 2. Connecting rod head cover: mark for reassembly; mark the correspondence to the cylinder with a colored pencil -B-; Installation position: Observe molded marks -A-; 3. Bearing shells: install in proper position; mark previously used inserts, but not on the working surface; replace bearing shells worn down to the original material; 4. Connecting rod: replace only the entire set; mark the correspondence to the cylinder with a colored pencil -B-; Installation position: Observe molded marks -A-; axial clearance for each new connecting rod pair: 0.20...0.44 mm; 5. Retaining ring: replace; 6. Piston pin: if the pin is difficult to install, then heat the piston to 60°C; remove and install using a mandrel -VW 222 A-; 7. Piston: mark the mounting position and cylinder affiliation; if a scratch forms on the piston bottom or on the piston skirt, replace the piston; check; install using a piston ring clamp; measure the internal diameter of the cylinder; check the protrusion of the pistons in "TDC"; 8. Piston rings: place locks offset by 120°; remove and install using piston ring pliers; mark "TOP" facing the piston bottom; measure thermal gap
Piston cooling oil nozzle
- 1. Bolt, 9 Nm
- 2. Oil injector for cooling the piston with injector valve
Note: Do not bend the oil nozzles to spray oil. Curved oil spray nozzles must be replaced.
Piston mounting position
Carefully! Risk of destruction of the piston crown coating. To ensure correct subsequent installation of used pistons, mark the piston to cylinder with paint. Do not score the piston crown with a center punch or similar tools.
Installation position: arrow -pos. 1-on the piston bottom points towards the belt pulleys.
Mark connecting rods
Mark connecting rods and connecting rod lower end caps with reassembly paint to indicate their alignment with each other and with the cylinder -arrow-. Replace the connecting rod only as an assembly. Do not mix up the connecting rod bearings.
Mounting position of connecting rods
Installation position: The larger shoulder of the connecting rods -arrows- faces the adjacent main bearing. The picture shows the front connecting rod pair.
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