- generously lubricate the inner surfaces of the cylinders with engine oil;
Pic. 63. Details of the piston group: 1 - compression piston rings; 2 - oil scraper ring; 3 - piston; 4 - connecting rod cover; 5 - connecting rod mounting bolt; 6 - connecting rod inserts; 7 - connecting rod; 8 - cylinder block; 9 - retaining ring; 10 - piston pin; arrow A points towards the front of the engine
- Arrange all connecting rods according to cylinder numbers. The cast lugs on the connecting rod and connecting rod cap must point towards the crankshaft pulley (pic. 63). After installing the connecting rods, the cast lugs must be located on the other side of the arrow;
- the arrows on the bottom of the pistons must point towards the front of the engine;
- orient the piston ring locks relative to each other at an angle of 120°along the surface of the cylinder;
Pic. 66. Piston installation with special tool VW3278
- slide the 3278 band clamp onto the piston rings on the piston (pic. 66) and press the piston rings into the piston grooves;
Pic. 67. Alternative band clamp for piston installation
- for this purpose, you can also use the company's «Volkswagen» assembly tool - band clamp (pic. 67);
- check that the piston rings are fully engaged in their grooves;
- rotate the crankshaft so that the two connecting rod journals of the crankshaft are at bottom dead center (NMT);
- install the connecting rod bearing shell into the connecting rod;
- insert the connecting rod from above into the bore of the cylinder. To do this, lay the engine on its side so that the connecting rod can be directed towards the main journal. Make sure that the cylinder bore and connecting rod neck are not scratched;
- insert the pistons in such a way that the piston rings in turn enter the holes of the cylinders and the heel of the connecting rod sits on the connecting rod journal of the crankshaft;
- insert the second liner into the bearing cap so that the bent tab of the liner sits in the groove of the bearing cap. Lubricate the bearing surfaces with engine oil;
- press the connecting rod cap against the connecting rod and lightly tap it. Lubricate the connecting rod bolts with engine oil and screw them in;
Pic. 56. Assembling the connecting rod and connecting rod bearing cap. The arrows show the protrusions
- be sure to double check that both molded lugs are positioned as shown in fig. 56. Both cast lugs on the connecting rod and connecting rod cap should be opposite and pointing in the direction of the pulley;
- alternately tighten the connecting rod bearing bolts to 30 Nm, then turn them from this end position by 90° (a quarter turn);
- after installing the connecting rod, rotate the crankshaft several times to make sure that it rotates easily, without jamming;
- check the markings of all connecting rods again to make sure that the piston arrows point in the right direction;
Pic. 68. Measurement of the axial clearance between the side plane of the connecting rod bearing and the side surface of the crankshaft
- using a feeler gauge, measure the axial clearance between the side plane of the connecting rod bearings and the side surface of the crankshaft (pic. 68), which should not exceed 0.31 mm;
- install oil pan (see subsection 4.1);
- all further assembly work is carried out in the reverse order of disassembly.
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