❑ Do not interchange used bearing shells (mark)
❑ Coat with oil before installing
❑ Axial play new: 0.10 to 0.35 mm, wear limit: 0.40 mm
❑ Check radial clearance with Plastigage

, new: 0.02 to 0.06 mm, wear limit: 0.09 mm. Do not turn crank‐

shaft when checking radial clearance

4 - Relief Valve

❑ 27 Nm

5 - Oil Spray Jet

❑ For piston cooling

6 - Locking Ring

❑ Replace after removing

7 - Piston Pin

❑ Coat with oil before installing

8 - Piston

❑ Removing and installing. Refer to

⇒ “5.2 Pistons, Removing and Installing”, page 78

❑ Mark installed position and cylinder allocation
❑ Arrow on piston face points toward belt pulley side
❑ Check piston and cylinder bore. Refer to

⇒ “5.3 Pistons and Cylinder Bore, Checking”, page 80

9 - Compression Rings

❑ Use piston ring pliers (commercially available) for removing and installing
❑ Offset gaps by 120°
❑ Installed Position: “TOP” “R” mark must face up toward piston crown
❑ Ring Gap/Groove Clearance, Checking. Refer to

⇒ “5.3 Pistons and Cylinder Bore, Checking”, page 80

10 - Oil Scraping Ring

❑ Two-part
❑ Install offset gaps by 120° to the neighboring compression ring
❑ The “TOP” or “R” marking must face toward the piston crown.
❑ Checking the ring gap. Refer to

⇒ “5.3 Pistons and Cylinder Bore, Checking”, page 80

❑ Side clearance cannot be measured.

11 - Connecting Rod

❑ Always replace as a set.
❑ Mark affiliation to cylinder -A-
❑ Installed position: the markings -B- face the belt pulley side
❑ Disconnect the new connecting rod. Refer to

⇒ “5.4 New Connecting Rod, Separating”, page 84

❑ Radial play, measuring. Refer to

⇒ “5.5 Connecting Rods, Checking Radial Clearance”, page 84

Installed Position of Bearing Shell
– Place bearing shells centrally into connecting rod and con‐

necting rod bearing cap.

Dimension -a- must be the same at left and right.

5.2

Pistons, Removing and Installing

Special tools and workshop equipment required
♦ Pilot Drift - VW222A-
♦ Piston ring compressor, commercially available

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Bolts - Connecting Rod
♦ Ring - Locking
Removing
– Secure the engine to the Engine And Transmission Holder -

VAS6095- . Refer to

⇒ “1.3 Engine, Securing on Engine and Transmission Holder”,

page 23

– Remove the cylinder head. Refer to

⇒ “1.3 Cylinder Head, Removing and Installing”, page 94

– Remove the oil pan upper section. Refer to

⇒ “1.4 Oil Pan Upper Section, Removing and Installing”, page

185

– Mark the installed position and cylinder allocation.
– Mark installed position and connecting rod cylinder -item 11-

⇒ Item 11 (page 78)

– Remove the connecting rod bearing cap and pull the piston

and connecting rod upward.

Note

Warm the piston to approximately 60 °C (140 °F) if it is difficult to

move the piston pin.

– Remove the locking ring from the eye of the piston bolt.
– Remove the piston pin using the Pilot Drift - VW222A- .
Installing
Install in reverse order of removal. Note the following:

Note

♦

Replace the bolts were tightened with an additional turn.

♦

Arrow on piston face points toward belt pulley side.

♦

Offset the piston ring gap by 120°.

– Coat the contact surfaces on the bearing shells with oil.
– Install the piston with a piston ring compressor. Pay attention

to the installed position -item 8-

⇒ Item 8 (page 78)

– Install the connecting rod bearing cap. Pay attention to the in‐

stalled position -item 2-

⇒ Item 2 (page 77)

– Install the cylinder head. Refer to

⇒ “1.3 Cylinder Head, Removing and Installing”, page 94

– Install the oil pan upper section. Refer to

⇒ “1.4 Oil Pan Upper Section, Removing and Installing”, page

185

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