SEAT Workshop Service and Repair Manuals

Note:

When stripping and assembling the engine it should be secured to the engine frame with engine bracket 3269.

• 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
• Piston
• ◆ Checking => Fig. 3
• ◆ Mark installation position to conrod and cylinder number
• ◆ High point of piston crown faces to centre of cylinder block
• ◆ Install with piston fitting tool 3278
  => Fig. 5

• Conrod
• ◆ Only renew as a set
• ◆ Mark cylinder number -B-
• ◆ Installation position:
  Marks -A- must be above one another
• Conrod bearing cap
• ◆ Note installation position
• 30 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Oil threads and contact surface
• ◆ To measure radial clearance tighten to 30 Nm but not further

• Bearing shell
• ◆ Note installation position
• ◆ Do not interchange used bearing shells
• ◆ The lugs on the bearing shells must fit tightly in the recesses
• ◆ Axial clearance
  New: 0.05...0.31 mm
  Wear limit: 0.40 mm
• ◆ Check radial clearance with Plastigage:
  New: 0.02...0.07 mm
  Wear limit: 0.10 mm
  Do not rotate crankshaft when
  checking radial clearance
• Cylinder block
• ◆ Checking cylinder bores
  =>Fig. 4
• ◆ Piston and cylinder dimensions
  =>Page 13-56

• Piston pin
• ◆ If difficult to remove, heat piston to 60 °C
• ◆ Remove and install with drift VW 222a
• Circlip

→ Fig. 1    Checking piston ring gap

• ‒ Push ring squarely from above down to approx. 15 mm from bottom end of cylinder. To do this use a piston without rings.

→ Fig. 2    Checking ring to groove clearance

Clean groove before check.

→ Fig. 3    Checking piston

Measure pistons approx. 6 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

• ◆ Measure bores at 3 locations in both directions -A- across the engine and -B- in line with crankshaft.
• ◆ Use internal dial gauge 50...100 mm.
• ◆ 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 3269, as incorrect measurements would then be possible.

→ Fig.5    Installing pistons with piston fitting tool 3278

Note:

If a new fitting tool (funnel) is used to install the pistons, first pass piston with oiled piston rings twice through the tool and then if necessary remove the resulting metal shavings. Only then install piston with piston rings.

• ‒ Oil tool and push piston in by hand. High point of the piston crown must face to the lug on the fitting tool -arrow-.
• ‒ Hold tool (with piston inserted) on upper edge and press piston in with both thumbs.
• ‒ Push piston in until it protrudes approx. 15 mm from the lower edge of the fitting tool.
• ‒ Place piston in appropriate cylinder bore. Lug on fitting tool -arrow- must face to centre of cylinder block.
• ‒ Hold fitting tool tight against cylinder block and push piston in.