New Beetle L4-1.9L DSL Turbo (BEW) (2006)
‹› Replace if piston skirt is cracked
‹› Checking piston position at TDC => [ Piston Position, Checking at TDC ] See: Testing and Inspection/Piston Position, Checking at TDC.
3
Piston pin
‹› If difficult to move, heat piston to 60° C
‹› Removing and installing using a drift (VW 222 A )
4
Circlip
5
Connecting rod
‹› Mark the allocation to the cylinder using a color marker - A -
‹› Installation position: Markings - B - point to belt pulley side
‹› With cracked bearing cap
6
Bearing shell
‹› Note installation position => [ Bearing Shells, Installation Location ] See: Service and Repair/Bearing Shells, Installation Location
‹› Note version:
Upper bearing shell (to piston) made of wear-resistant material, identification: Black line on contact surface in area of separating point
‹› Do not interchange used bearing shells
‹› Insert bearing shells in center => [ Bearing Shells, Installation Location ] See: Service and Repair/Bearing Shells, Installation Location
‹› Ensure seated tightly
‹› Axial Clearance, Measuring
Wear limit: 0.37 mm
‹› Measure radial clearance with Plastigage(R):
Wear limit: 0.08 mm (do not turn the crankshaft when checking radial clearance)
7
Cylinder block
‹› Cylinder bore, checking => [ Cylinder Bore, Checking ] See: Testing and Inspection/Piston and Cylinder Bore, Checking
‹› Piston and cylinder dimensions => [ Piston and Cylinder Dimensions ] See: Specifications/Piston and Cylinder Dimensions.
8
Connecting rod bearing cap
‹› Note installation position
‹› Due to the way the separated connecting rod breaks (cracks), the cap fits only in one position and only on to the respective connecting rod.
9
Oil spray jet
‹› For piston cooling
10
25 Nm
‹› Install without sealant
11
Connecting rod bolt 30 Nm + 90° (1/4 additional turn)
‹› Replace