SEAT Workshop Service and Repair Manuals

Assembly overview   Note Oil the support and slide surfaces before carrying out assembly work.

1 -	Securing ring

2 -	Piston pin

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

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

3 -

Piston

q	check → 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	Shift the gap by 120º

q	Remove and install compression rings using piston ring pliers

q	The mark “TOP” must face towards piston crown

q	Checking end clearance → Fig.

q	Checking piston ring side clearance → Fig.

5 -	Oil scraper rings

q	Carefully remove and install by hand the oil scraper rings made up of 3 parts

q	Checking end clearance → Fig.

q	The play between the rings and the grooves cannot be measured

6 -

Conrod

q	Renew as set only.

q	Mark cylinder assignment -A-

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

q	Piston axial guided

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	M7×0,75: 20 Nm + retighten 1/4 turn (90º)

q	M8x1: 30 Nm + retighten 1/4 turn (90º)

q

Replace.

q	Oil threads and contact surface.

q	To measure radial play, tighten to the applicable torque, without retightening

9 -	cylinder block

q	Checking cylinder bore → Fig.

q	Piston and cylinder dimensions → Chapter

10 -	Bearing shell

q	Do not interchange used bearing shells

q	Centrally align bearing shells on insertion

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 end clearance Special tools and workshop equipment required t  Calibre –  Insert ring at right angles from above into lower cylinder opening approx. 15 mm from edge of cylinder.

Piston ring Dimensions in mm	New	Wear limit
1. st compression ring	0,20...0,50	1,0
2ºcompression ring	0,40...0,70	1,0
Oil scraper ring	0,40...1,40	--- → Note

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

Checking play between the rings and grooves Special tools and workshop equipment required t  Calibre –  First clean piston ring housing groove.

Piston ring Dimensions in mm	New	Wear limit
1. st compression ring	0,04...0,08	0,15
2ºcompression ring	0,04...0,08	0,15
Oil scraper ring	not measurable

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

Check bore Special tools and workshop equipment required t  Internal dial gauge 50...100 mm –  Take measurements at 3 positions in both lateral -A- and longitudinal -B-. Difference between measured value and nominal value: max. 0.08 mm. Nominal measurement → Chapter   Note The measurement of the interior diameter of the cylinders cannot be done while the engine block is attached to the engine and gearbox support -VAS 6095-, as doing so may result in erroneous measurements.