Pro
te
c
t
ed
b
y
co
p
y
rig
h
t.
C
o
p
y
in
g
fo
r
pr
iv
a
t
e
o
r
c
o
m
m
e
r
c
ia
l
p
u
rp
o
s
e
s
,
i
n
p
a
rt
o
r i
n
w
h
o
le
,
is
n
o
t
p
e
r
m
it
t
e
d
u
n
l
e
s
s
a
ut
ho
r
i
s
ed
b
y
V
olk
sw
a
ge
n AG
.
V
olk
s
w
a
g
en
AG do
es
n
ot g
uar
ante
e
or a
c
c
ep
t
a
ny
li
a
b
i
li
t
y
w
ith
r
e
s
p
e
c
t
t
o
th
e
c
o
rr
e
c
t
n
e
s
s
o
f
in
fo
r
m
a
tio
n
in
th
is
d
o
c
um
en
t.
C
o
py
rig
ht b
y
V
olk
sw
a
ge
n
A
G.
3.2
Separating new conrod
On a new conrod, it is possible that the breaking point has not
fully separated. Procedure if conrod bearing cap cannot be re‐
moved manually:
– Mark allocation of conrod to cylinder.
– Lightly clamp conrod in a vice using aluminium vice jaws, as
shown in illustration.
Note
♦
Only clamp the conrod lightly in order to avoid damaging it.
♦
Conrod is clamped below dashed line.
– Unscrew both bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐
ing cap in -direction of arrow- until it is loose.
3.3
Piston and cylinder dimensions
Caution
The cylinder bore may not be worked on (reboring, honing,
grinding) may not be carried out using workshop tools! This will
damage the surface of the cylinder bore.
Piston ∅
Cylinder bore ∅
Basic dimension
mm
82.465
1)
82.51
•
1)
Dimensions without graphite coating (thickness 0.02
mm). The graphite coating will wear down.
Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
3. Pistons and conrods
39
