Connecting Rod: Service and Repair

Pistons and connecting rods, disassembling and assembling






1. Piston rings
- Shift by 120 °
- Use piston ring pliers to remove and install
- Marking "TOP" faces piston head
2. Pistons
- Mark installation position to connecting rod and matching
- flat side of the piston head points toward center of cylinder block
- install using 3278 piston installation tool
3. Snap ring
4. Connecting rod
- Replace only as a set
- Mark to indicate which cylinder corresponds to each cover -B-
- Installation position: Markings -A- must align
5. Bearing shell
- Note installed position
- Do not interchange used bearing shells
- Retaining tabs of bearing shells must be seated securely in openings
- Axial clearance
New: 0.05 to 0.31 mm
Wear limit: 0.40 mm
- Measure radial play with Plastigage:
New: 0.02 to 0.07 mm.
Wear limit: 0.10 mm.
Do not turn crankshaft when measuring radial play.
6. Connecting rod cover
- Mark to indicate which cylinder corresponds to each cover -B
- Installation position: Markings -A- must align
7. Bolt: Tighten to 30 Nm + 1/4 turn (90 °)
- Always replace Connecting rod bolts
- Grease thread and contact surface
- When measuring radial clearance, tighten to 30 Nm (15 ft. lbs.) but do not turn further
8. Cylinder block
- Piston and cylinder measurements, refer to specifications table below.
9. Piston pins
- In case of difficulty of movement, warm piston to 60 °C.
- remove and install using VW222a pilot drift