Overview - Pistons And Connecting Rod

1. Bolts
   • 45 Nm + 90°
   • Replace after removing
   • Coat the threads and contact surfaces with engine oil
   • Use old bolts for the radial clearance measurement
2. Connecting Rod Bearing Cap
   • Note the installation position
   • Due to the separation procedure (cracking) of the connecting rod, the connecting rod bearing cap only fits in one position and only to the corresponding connecting rod.
   • Use a color to mark the cylinder and connecting rod to which it belongs -A-
   • Installation position: the locating tabs -B- face the belt pulley side
   • Separating the new connecting rod. Refer to NEW CONNECTING ROD, SEPARATING .
3. Bearing Shells
   • Installation position. Refer to Fig 3.
   • Allocation. Refer to Fig 2.
   • Coat with engine oil before installing
   • Radial play, measuring. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE .
4. Connecting Rod
   • Always replace as a set
   • Label the allocation of the cylinder to the connecting rod bearing cap -A-.
   • Installation position: the locating tabs -B- face the belt pulley side
   • Separating the new connecting rod. Refer to NEW CONNECTING ROD, SEPARATING .
   • Radial play, measuring. Refer to CONNECTING RODS, CHECKING RADIAL CLEARANCE .
5. Relief Valve
   • 27 Nm
6. Oil Spray Jet
   • For piston cooling
   • Installation position. Refer to Fig 7.
   • Removing and Installing. Refer to OIL SPRAY JETS, REMOVING AND INSTALLING .
7. Circlip
   • Replace after removing
8. Piston Pin
   • Coat with engine oil before installing
9. Piston
   • Removing and Installing. Refer to PISTONS, REMOVING AND INSTALLING .
   • Installation position: the arrow on piston face points toward belt pulley side.
   • Mark which cylinder belongs to which
   • Check piston and cylinder bore. Refer to PISTON AND CYLINDER BORE, CHECKING .
10. Compression Rings
    • Install using the Piston Ring Pliers: VAS211003  . Refer to Fig 5.
    • Allocation and installation position. Refer to Fig 4.
    • Checking the piston ring gap. Refer to Figure.
    • Height clearance cannot be measured
    • Offset gaps by 120°
11. Oil Scraping Ring
    • Carefully remove and install the three-part oil scraping ring by hand
    • Install the upper joint of the 3-part oil scraping ring 120° offset to the neighboring compression ring
    • Piston ring gap is not measurable
    • Height clearance cannot be measured
    • Installation position. Refer to Fig 6.
    • Allocation. Refer to Fig 4.

Bearing Shell - Allocation

1. Connecting Rod Bearing Cap Bearing Shell: Two White Stripes
2. Connecting Rod Bearing Shell: One White Stripe

Bearing Shell - Installation Position

-- Place the bearing shells centrally into connecting rod and connecting rod bearing cap.

• Dimension -a- = dimension -a-.

Allocation and Piston Ring

1. Compression ring with bevel -A- on the inside top in the upper groove. >>TOP<< marking or lettering points upward.
2. Compression ring with offset -B- on the outside bottom in the center groove. >>TOP<< marking or lettering points upward.
3. Oil Scraping Ring

Installing the Compression Ring

• >>TOP<< marking or lettering points upward.
• Only open the compression ring -2- using the Piston Ring Pliers: VAS211003  until it can be pushed evenly over the piston -1-.

Installing the Oil Scraping Ring

-- Pay attention to the spring installation position:

• The plunger of the plates -2 and 3- and the spring -1- must be offset 90° to each other.
• Install by hand.

Installation sequence:

-- 1. Insert the spring -1- in the groove.

-- 2. Insert the lower plate -3- in the groove.

-- 3. Insert the upper plate -2- in the groove.

Oil Spray Jets - Installation Position

• The side surface of the oil spray jet -1- must be parallel to the neighboring crankshaft bearing -2-.
• Dimension -a- = dimension -a-.