Leon Mk2
Dismantling and assembling pistons and conrods |
Note!
When working on engine, secure to repair stand using engine and gearbox support -VW 540- and engine and gearbox support supplement set -VW 540/1 B-. |
1 - | Piston rings |
q | Offset gaps by 120 °. |
q | Remove and install using piston ring pliers. |
q | “TOP” faces towards piston crown. |
q | Checking ring gap → Fig. |
q | Checking ring-to-groove clearance → Fig. |
q | 2 or 3 part oil scraper ring, mixed installation permitted. |
2 - | 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. |
3 - | Conrod |
q | Renew as set only. |
q | Installation position: markings -A- face towards pulley end. |
q | Mark cylinder number -B-. |
4 - | Conrod bearing cap |
q | Installation position: markings -A- face towards pulley end. |
q | Mark cylinder number -B-. |
5 - | 30 Nm + 1/4 turn (90 °) further |
q | Renew. |
q | Oil threads and contact surface. |
q | To measure radial clearance, tighten to 30 Nm but not turn further. |
6 - | Pressure relief valve, 27 Nm |
q | Opening pressure: 1.3...1.6 bar. |
7 - | Oil spray jet |
q | For piston cooling. |
8 - | Bearing shell |
q | Note installation position. |
q | Do not interchange used bearing shells. |
q | Ensure retaining lug fits tightly in recess |
q | Axial clearance new: 0.10...0.31 mm, wear limit 0.40 mm. |
q | Check radial clearance with Plastigage: new: 0.01...00.05 mm, wear limit: 0.12 mm. Do not rotate crankshaft when checking radial clearance. |
9 - | Cylinder block |
q | Checking cylinder bores → Fig.. |
q | Piston and cylinder dimensions → Chapter. |
10 - | Conrod bolt |
q | Renew. |
11 - | Circlip |
12 - | Piston pin |
q | If difficult to remove, heat piston to 60 °C. |
q | Remove and install with drift -VW 222 A- |