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Table of Contents > Crankshaft group > Pistons and conrods > Assembly overview - pistons and conrods

VW Passat B6 Service Manual ➜ Assembly overview - pistons and conrods

CC 2010 ➀ , Eos 2006 ➀ , Golf 2004 ➀ , Golf 2009 ➀ , Passat 2006 ➀ , ...  
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018  
4
Pistons and conrods  
β‡’ β€œ4.1 Assembly overview - pistons and conrods”, page 80  
β‡’ β€œ4.2 Removing and installing pistons”, page 83  
β‡’ β€œ4.3 Checking pistons and cylinder bores”, page 84  
β‡’ β€œ4.4 Separating new conrod”, page 86  
β‡’ β€œ4.5 Checking radial clearance of conrods”, page 87  
4.1  
Assembly overview - pistons and conrods  
1 - Bolts  
❑ Renew after removal  
❑ Apply engine oil to  
thread and contact sur‐  
face  
❑ Use old bolts to meas‐  
ure radial clearance.  
❑ 45 Nm +90Β°  
2 - Conrod bearing cap  
❑ Observe installation po‐  
sition  
❑ Conrod bearing cap on‐  
ly fits in one position and  
only on the appropriate  
conrod due to the break‐  
ing procedure (crack‐  
ing) separating the cap  
from the conrod  
❑ Mark allocation to cylin‐  
der and conrod in colour  
-A-  
❑ Installation position:  
Marking -B- faces to‐  
wards pulley end.  
❑ Separating new conrod  
β‡’ page 86 .  
3 - Bearing bushes  
❑ Fitting position  
β‡’ page 81  
❑ Renew worn bearing  
shells  
❑ Apply engine oil before  
installing  
❑ Axial clearance  
♦ New: 0.10 … 0.35 mm  
♦ Wear limit: 0.40 mm  
❑ Measuring radial clearance β‡’ page 87  
4 - Connecting rod  
❑ Renew as set only.  
❑ Mark allocation to cylinder and to conrod bearing cap  
❑ Installation position: Marking -B- faces towards pulley end.  
❑ Separating new conrod β‡’ page 86 .  
❑ Measuring radial clearance β‡’ page 87  
80  
Rep. gr.13 - Crankshaft group  
 
CC 2010 ➀ , Eos 2006 ➀ , Golf 2004 ➀ , Golf 2009 ➀ , Passat 2006 ➀ , ...  
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018  
5 - Pressure relief valve  
❑ 27 Nm  
6 - Oil spray jet  
❑ For piston cooling  
7 - Retaining ring  
❑ Renew after removal  
8 - Piston pin  
❑ Apply engine oil before installing  
9 - Piston  
❑ Installing with piston installation sleeve -T40347- β‡’ page 83  
❑ Installation position: arrow on piston crown faces towards pulley end  
❑ Mark allocation to cylinder  
❑ Checking piston and cylinder bore β‡’ page 84  
10 - Compression rings  
❑ Offset gaps by 120Β°  
❑ Installation position: β€œTOP” or β€œR” marking must face upwards towards piston crown.  
❑ β‡’ Fig. β€œβ€œInstalling compression ringsβ€β€œ , page 82  
❑ β‡’ Fig. β€œβ€œChecking piston ring gapβ€β€œ , page 85  
❑ β‡’ Fig. β€œβ€œChecking ring-to-groove clearanceβ€β€œ , page 85  
❑ β‡’ Fig. β€œβ€œAllocation of piston rings only in connection with 3-part oil scraper ringβ€β€œ , page 82  
11 - Oil scraper ring  
❑ 2-part or 3-part, depending on version  
❑ Install in such a way that upper gap of three-part oil scraper ring is offset by 120Β° relative to adjacent  
compression ring  
❑ β‡’ Fig. β€œβ€œChecking piston ring gapβ€β€œ , page 85  
❑ β‡’ Fig. β€œβ€œChecking ring-to-groove clearanceβ€β€œ , page 85  
❑ β‡’ Fig. β€œβ€œInstalling oil scraper ring, 3-partβ€β€œ , page 82  
❑ β‡’ Fig. β€œβ€œAllocation of piston rings only in connection with 3-part oil scraper ringβ€β€œ , page 82  
Bearing shells - installation position  
– Position bearing shells in centre of conrod and conrod bearing  
cap when fitting.  
Distance -a- must be identical on both sides.  
4. Pistons and conrods  
81