SEAT Workshop Service and Repair Manuals

• Piston ring
• ◆ Offset gaps by 120 °
• ◆ Remove and install with piston ring pliers
• ◆ "TOP" faces towards piston crown
• ◆ Checking ring gap=> Fig. 1
• ◆ Checking ring to groove clearance
  => Fig. 2
• ◆ 2-part oil scraper ring
• Piston
• ◆ Checking => Fig. 3
• ◆ Mark installation position and cylinder number
• ◆ Arrow on piston crown points to pulley end
• ◆ Install using piston ring clamp
• Piston pin
• ◆ If difficult to remove, heat piston to 60 °C
• ◆ Remove and install with VW 222a

• Circlip
• Conrod
• ◆ Only renew as a set
• ◆ Mark cylinder number -B-
• ◆ Installation position:
  Marking -A- faces towards pulley end
• Bearing shell
• ◆ Note installation position
• ◆ Do not interchange used bearing shells
• ◆ Insert bearing shells centrally
• ◆ Check securely seated
• ◆ Axial clearance
  New: 0.10...0.35 mm
  Wear limit: 0.4 mm
• ◆ Check radial clearance with Plastigage:
  New: 0.01...0.05 mm
  Wear limit: 0.12 mm
  Do not rotate crankshaft when checking radial clearance

• Cylinder block
• ◆ Checking cylinder bores
  =>Fig. 4
• ◆ Piston and cylinder dimensions
  =>Page 13-39
• Conrod bearing cap
• ◆ Note installation position
• ◆ The caps only fit in one position and only on the appropriate con-rod, this is due to the breaking procedure (cracking) separating the cap from the con-rod
• Conrod bolt, 30 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Oil threads and contact surface
• ◆ To measure radial clearance tighten to 30 Nm but not further

→ Fig. 1    Checking piston ring gap

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Feeler gauges

• ‒ Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.

→ Fig. 2    Checking ring to groove clearance

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Feeler gauges

Clean groove before check.

→ Fig. 3    Checking piston

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Micrometer 75...100 mm

Measure pistons approx. 10 mm from the lower edge of skirt, at 90 ° to the piston pin axis.

Deviation from nominal dimension
    max. 0.04 mm

→ Fig. 4    Checking cylinder bores

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Internal dial gauge 50...100 mm
• ◆ Measure bores at 3 locations in both directions -A- across the engine and -B- in line with crankshaft.
• ◆ Deviation from nominal dimension
      max. 0.08 mm

Note:

Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with adapter bracket VW 540, as incorrect measurements would then be possible.