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5
Pistons and connecting rods - dis‐
mantle and assemble
Note
All bearing and running surfaces must be lubricated before as‐
sembly.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
1 - Piston ring
❑ Displace the apertures
in 120°.
❑ Remove and install us‐
ing the piston ring pliers.
❑ The mark “TOP” should
face the piston head.
❑ Check ring gap
❑ Check ring to groove
clearance
2 - Piston
❑ With combustion cham‐
ber.
❑ Mark installation posi‐
tion and correspond‐
ence with respective
cylinder
⇒ page 34
❑ The arrow on the piston
head should be pointed
in the direction of the
pulley.
❑ Install by using a piston
ring compressing tool.
❑ Replace piston in case
of cracks on its skirt.
❑ Check the piston projec‐
tion at TDC
⇒ page 34
3 - Piston pin
❑ In case of difficulties in
the removal, heat the
piston to 60 °C.
❑ Remove and install with
Puller and fitter -VW 222
A- .
4 - Piston pin retaining ring
5 - Connection rod
❑ Only replace as a set.
❑ Mark correspondence with cylinder -A-.
❑ Mounting position: Marks -B- shall point towards the pulley.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
32
Rep. Gr.13 - Crankshaft, pistons
