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Pistons and conrods - exploded view
   
Pistons and conrods - exploded view
  Note
Oil spray jet and pressure relief valve → Fig.
1 - Piston rings
q   Offset gaps by 120°
q   Use piston ring pliers to remove and install
q   “TOP” must face towards piston crown
q   Checking ring gap → Fig.
q   Checking ring-to-groove clearance → Fig.
2 - Piston
q   Checking → Fig.
q   Mark installation position and cylinder number
q   Arrow on piston crown points to pulley end
q   Install using piston ring clamp
q   Piston and cylinder dimensions → Chapter
3 - Conrod
q   Only renew as a complete set
q   Mark cylinder number -B-
q   Installation position: Markings -A- face towards pulley end
q   With oil drilling for piston pin lubrication
4 - Conrod bearing cap
q   Mark cylinder number -B-
q   Installation position: Markings -A- face towards pulley end
5 - 30 Nm + 90° (1/4 turn) further
q   Renew conrod bolt → Item
q   Lubricate threads and contact surface
q   To measure radial clearance, tighten to 30 Nm but do not turn further
6 - Bearing shell
q   Upper bearing shell with oil hole for piston pin lubrication
q   Note installation position
q   Do not interchange used bearing shells (mark positions)
q   Ensure tight fit in retaining lugs
q   Axial clearance (new): 0.10 ... 0.35 mm
q   Axial clearance: wear limit: 0.40 mm
q   Measuring radial clearance → Chapter
7 - Cylinder block
q   Checking cylinder bore → Fig.
q   Piston and cylinder dimensions → Chapter
8 - Conrod bolt
q   Renew
9 - Circlip
10 - Piston pin
q   If difficult to move, heat piston to approx. 60 °C
q   Remove and install using drift -VW 222 A-

   
Checking piston ring gap
–  Insert ring at right angle to cylinder wall from above and push down into lower cylinder opening approx. 15 mm from bottom of cylinder. Use a piston without rings to push ring into bore.
  V13-0016
Piston ring
Dimensions in mm
NewWear limit
1st compression ring0.20 … 0.400.80
2nd compression ring0.20 … 0.400.80
Oil scraper ring0.25 … 0.500.80

   
Checking ring-to-groove clearance
–  Clean groove in piston before checking clearance.
  V13-0687
Piston ring
Dimensions in mm
NewWear limit
1st compression ring0.06 … 0.090.20
2nd compression ring0.05 … 0.080.20
Oil scraper ring0.03 … 0.060.15

   
Checking piston
–  Measure approx. 10 mm from the bottom edge, perpendicular to the piston pin axis.
l  Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension → Chapter „Piston and cylinder dimensions“.
  V13-0010
Checking cylinder bore
–  Use 50 ... 100 mm internal dial gauge to take measurements at 3 points in transverse direction -A- and longitudinal direction -B-.
l  Maximum deviation from nominal dimension: 0.08 mm.
Nominal dimension → Chapter „Piston and cylinder dimensions“.
  V13-0280
Oil spray jet and pressure relief valve
1 - Oil spray jet (for cooling of pistons)
2 - Bolt with pressure relief valve, 27 Nm
l  Opening pressure: 2.5 ... 3.2 bar.
  A17-0217

Power unit > 4-cylinder 1.8 ltr. 5-valve turbocharged engine (154-165 kW), mechanics > Enginecrankshaft group, pistons > Dismantling and assembling pistons and conrods > Pistons and conrods - exploded view

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