New Beetle L4-2.0L (AVH) (2005)
1 - Piston rings
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Gaps offset by 120°
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Remove and install using piston ring pliers
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"TOP" faces piston crown
2 - Piston
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Mark with installation position and cylinder number
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Arrow on piston crown points to belt pulley end
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Install using piston ring clamp
3 - Piston pin
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If difficult to remove, heat piston to 60°C
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Remove and install with VW 222 A.
4 - Circlip
5 - Connecting rod
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With industrially cracked bearing caps
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Replace as set only
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Mark with cylinder number - B -
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Installation position: Marking - A - faces belt pulley end
6 - Bearing shell
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Note installed position.
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Insert bearing shells centrally
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Do not interchange used bearing shells
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Check for secure seating
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Axial clearance
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New: 0.10 to 0.35 mm
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Wear limit: 0.4 mm
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Check radial clearance with Plastigage:
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New: 0.01 to 0.05 mm
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Wear limit: 0.09 mm