Removal pistons and connecting rods (VW Sharan 1)

The pistons and connecting rods are knocked out of the cylinder block in an upward direction using a hammer handle, after removing the caps and connecting rod bearing liners. Before carrying out these operations, the following recommendations should be observed:

• apply (preferably in color) marking on each piston (Fig. 54) and the connecting rod associated with it. It is necessary to indicate the cylinder number from which the piston and connecting rod were removed;
• draw an arrow (Fig. 54) on the bottom of the piston pointing to the front of the engine;

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• immediately after removing the piston with the connecting rod, mark the connecting rod and the connecting rod bearing cap on the side (Fig. 55), indicating the cylinder number. The connecting rod and the connecting rod bearing cap must be assembled in such a way that both cast projections are located opposite each other (Fig. 56);
• mark the bearing shells according to the connecting rod and connecting rod cap;

Caution! Both cast projections after connecting rod installation must always be located on the crankshaft pulley side.

• color code the upper and lower bearing shells on their back side.

Remove the pistons as follows:

• remove the connecting rod caps and liners and knock out the parts. If necessary, scrape off any oil deposits on the top of the cylinder with a scraper. To do this, turn the crankshaft slightly to lower the piston deeper into the cylinder bore. Be careful not to scratch the cylinder with the scraper;

• using a sharp object or a small punch (Fig. 57), remove the snap rings located on each side of the piston pin. The notch in the piston pin bore makes it easier to use the punch;
• use a drift to knock out the piston pin. When striking, make sure that the drift does not jump out and hit the piston;

• mark the piston rings and remove them using a puller (Fig. 58);

• if you don't have a piston ring puller, you can insert metal strips opposite each other under the piston rings (Fig. 59). Place one of the metal strips under the end of the piston ring to avoid scratches on the piston surface;
• remove the piston rings and attach tags with the cylinder number to them. When inspecting the piston rings, make sure that there is an "Oben" or "Top" mark on one side. When installing the piston rings, this inscription should be visible from the piston bottom side.