Leon Mk1
Assembly overview - pistons and conrods |
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. |
2 - | Piston |
q | Mark installation position and cylinder number. |
q | Installation position and allocation of piston to cylinder → Fig.. |
q | Arrow on piston crown points to pulley end. |
q | Install using piston ring clamp. |
q | If piston skirt is cracked, renew piston. |
q | Checking piston projection at TDC → Chapter. |
3 - | Piston pin |
q | If difficult to remove, heat piston to 60 °C. |
q | Remove and install with drift -VW 222A-. |
4 - | Circlip |
5 - | Conrod |
q | Renew as set only. |
q | Mark cylinder allocation -A- with coloured pen. |
q | Installation position: Marking -B- faces towards pulley end. |
6 - | Bearing shell |
q | Note installation position. |
q | Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identification: Black line on bearing surface in area of joint. |
q | Do not interchange used bearing shells. |
q | Insert bearing shells centrally. |
q | Check for secure seating. |
q | Axial clearance: wear limit: 0.37 mm |
q | Check radial clearance with Plastigage; wear limit: 0.08 mm. |
q | Do not rotate crankshaft when checking radial clearance |
7 - | Cylinder block |
q | Checking cylinder bores → Fig.. |
q | Piston and cylinder dimensions → Chapter. |
8 - | Bearing cap |
q | Note installation position. |
9 - | Oil spray jet |
q | For piston cooling. |
10 - | 25 Nm |
q | Insert without sealant. |
11 - | Conrod bolt, 30 Nm + 1/4 turn (90°) further |
q | Renew |
q | Oil threads and contact surface. |
q | Use old bolt for measuring radial clearance |
|
Piston ring dimensions in mm | New | Wear limit |
1st compression ring | 0.20...0.40 | 1.0 |
2nd compression ring | 0.20...0.40 | 1.0 |
Oil scraper ring | 0.25...0.50 | 1.0 |
|
Piston ring dimensions in mm | New | Wear limit |
1st compression ring | 0.06...0.09 | 0.25 |
2nd compression ring | 0.05...0.08 | 0.25 |
Oil scraper ring | 0.03...0.06 | 0.15 |
Note
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