SEAT Workshop Service and Repair Manuals

Assembly overview

1 -

Circlip

2 -	Piston pin

q	If difficult to move, heat piston to 60 °C

q	Remove and install with the awl -10 - 14-, see equivalent → Anchor

3 -

Piston

q	Checking → Fig.

q	Mark installation position and cylinder number.

q	Arrow on piston crown points to pulley end

q	Install using piston ring clamp

4 -	Compression rings

q	Offset gaps by 120°

q	Remove and fit compression rings using pliers adapted for piston rings

q	The mark „TOP“ must face towards piston crown

q	Checking ring gap → Fig.

q	Checking ring-to-groove clearance → Fig.

5 -	Oil scraper rings

q	Carefully remove and install 3-part oil scraper rings by hand.

q	Checking ring gap → Fig.

q	Ring-to-groove clearance not measurable.

6 -

Conrod

q	Renew as set only.

q	Mark cylinder allocation -A-

q	Fitting position: The marks -B- should point in the direction of the pulley

q	Guided axially by piston.

7 -	Conrod bearing cap

q	Rods divided by fracturing (cracking) can only be fitted in one position and only with the corresponding conrod

8 -	Conrod bolt

q	20 Nm + further 1/4 (90 °)

q

Replace

q	Oil threads and contact surface.

q	To measure radial play, tighten to 20 Nm, without retightening

9 -	cylinder block

q	Checking cylinder bore → Fig.

q	Piston and cylinder dimensions → Chapter

10 -	Bearing cap

q	Do not interchange used bearing shells.

q	Insert bearing shells centrally.

Check radial clearance with Plastigage

Do not rotate crankshaft when checking radial clearance.

q	new: 0.020..0.061 mm

q	Wear limit: 0.091 mm

Checking piston ring gap Special tools and workshop equipment required t  Feeler gauge –  Insert ring at right angles from above into lower cylinder opening approx. 15 mm from edge of cylinder.

Piston ring Dimensions in mm	When new	Wear limit
1. compression ring	0,20...0,50	1,0
2nd compression ring	0,40...0,70	1,0
Oil scraping ring	0,25...0,50	--- → Remark

1)  It is not possible to give an indication of the wear limit

Checking ring-to-groove clearance Special tools and workshop equipment required t  Feeler gauge –  Clean ring groove before checking.

Piston ring Dimensions in mm	When new	Wear limit
1. compression ring	0,04...0,08	0,15
2nd compression ring	0,02...0,06	0,15
Oil scraping ring	Not measurable

Checking pistons Special tools and workshop equipment required t  Outer micrometer 75...100 mm –  Measure pistons approx. 10 mm from the lower edge of skirt, at 90 ° to the piston pin axis. Difference in relation to max. specified measurement 0.04 mm. Nominal dimension → Chapter

Check bore Special tools and workshop equipment required t  Internal dial gauge 50...100 mm –  Take measurements at 3 positions in both lateral direction -A- and longitudinal direction -B-. Deviation to the nominal value: max. 0.08 mm. Nominal dimension → Chapter   Note Measuring the cylinder bores must not be done when the cylinder block is mounted to the engine and gearbox stand -VAS 6095-, as incorrect measurements may result.