1.2 TDI CR engine (EA189) · Crankshaft group · Pistons and conrods

Pistons and conrods – assembly overview and fastening

  • 1 Retaining ring
    • Renew
  • 2 Piston ring
    • compression ring
    • Offset gaps by 120°
    • Use piston ring pliers to remove and install.
    • Installation position marking: “TOP” or side with lettering towards piston crown.
    • Installation position: marking “dots or line” -arrows- towards piston crown.
    • Measuring ring gap ⇒ 4.3 Measuring piston projection at “TDC”
    • Measuring ring-togroove clearance ⇒ 4.4.1 Checking piston
  • 3 Piston ring
    • compression ring
    • Offset gaps by 120°
    • Use piston ring pliers to remove and install.
    • Installation position marking: “TOP” or side with lettering towards piston crown.
    • Installation position: marking “dots or line” -arrows- towards piston crown.
    • Measuring ring gap ⇒ 4.3 Measuring piston projection at “TDC”
    • Measuring ring-to-groove clearance ⇒ 4.4.1 Checking piston
  • 4 Piston ring
    • Oil scraper ring
    • Offset gap 120° relative to lower compression ring
    • Use piston ring pliers to remove and install.
    • Installation position marking: “TOP” or side with lettering towards piston crown.
    • Installation position: marking “dots or line” -arrows- towards piston crown.
    • Measuring ring gap ⇒ 4.3 Measuring piston projection at “TDC”
    • Measuring ring-to-groove clearance ⇒ 4.4.1 Checking piston
  • 5 Bolt
    • Renew
    • Oil threads and contact surface
    • 30 Nm +90°
  • 6 Conrod bearing cap
    • The conrod bearing cap only fits in one position and only on the appropriate conrod due to the breaking procedure (cracking) separating the cap from the conrod.
    • Mark cylinder allocation in colour -B-.
    • Installation position: markings -A- face towards belt pulley end.
  • 7 Bearing bushes
    • Fitting position ⇒ 4.4.1 Checking piston
    • Mark used bearing shells for re-installation but not on bearing surface.
    • Renew bearing shells worn down to base layer.
    • Note version: upper bearing shell (towards piston) made of a more wear-resistant material. Identification on new bearing shells: black line on bearing surface in area of joint
    • Ensure firm seating
  • 8 27 Nm
    • Bolt with pressure relief valve
  • 9 Oil spray jet (for cooling of pistons)
  • 10 Connecting rod
    • Renew as set only.
    • With industrially cracked conrod bearing cap
    • Separate new conrod ⇒ 4.4.2 Cylinder bore
    • Mark cylinder allocation in colour -B-.
    • Installation position: markings -A- towards belt pulley end
    • Axial clearance, wear limit: 0.37 mm
    • Measuring radial clearance ⇒ 4.4.2 Cylinder bore
  • 11 Retaining ring
    • Renew
  • 12 Piston pin
    • If difficult to move, heat piston to approx. 60 °C.
    • Remove and install using drift - VW 222 A-.
  • 13 Piston