Audi Workshop Service and Repair Manuals

Note:

Oil spray jet and pressure relief valve

=> Fig.13-88

• Piston rings
• ◆ Offset gaps by 120°
• ◆ Remove and install with piston ring pliers.
• ◆ "TOP" faces towards piston crown
• ◆ Checking ring gap
  => Fig.13-86
• ◆ Checking ring to groove play
  => Fig.13-86
• Piston
• ◆ Checking => Fig.13-87
• ◆ Mark installation position and cylinder number.
• ◆ Arrow on piston crown points to pulley end.
• ◆ Install using piston ring clamp.
• ◆ Piston and cylinder dimensions
  =>Page 13-89.

• Conrod
• ◆ Only replace as a set
• ◆ Mark cylinder number B
• ◆ Installation position:
  Markings A face towards pulley side
• ◆ With oil bore for piston pin lubrication
• Conrod bearing cap
• ◆ Mark cylinder number B
• ◆ Installation position:
  Markings A face towards pulley side
• 30 Nm + 90° (1/4 turn) further
• ◆ Replace conrod bolt -Item 8-
• ◆ Oil threads and contact surface
• ◆ To measure radial play tighten to 30 Nm but no further

• Bearing shell
• ◆ Upper bearing shell with oil bore for piston bolt lubrication
• ◆ Note installation position
• ◆ Do not interchange used bearing shells (mark).
• ◆ Ensure retaining lugs fit tightly in recesses.
• ◆ Axial play
  New: 0.05...0.31 mm
  Wear limit: 0.37 mm
• ◆ Check radial play with Plastigage:
  New: 0.01...0.06 mm
  Wear limit: 0.12 mm.
  Do not rotate crankshaft when checking radial play

• Cylinder block
• ◆ Checking cylinder bore
  => Fig.13-87
• ◆ Piston and cylinder dimensions
  =>Page 13-89.
• Conrod bolt
• ◆ Replace
• Circlip
• Piston pin
• ◆ If difficult to remove, heat piston to approx. 60 °C.
• ◆ Remove and install with VW 222a