Leon Mk2
| Assembly overview |
| 1 - | Piston |
| q | check → Chapter |
| q | Mark installation position and cylinder number. |
| q | Arrow on piston crown points to pulley end |
| q | Install using piston ring clamp |
| 2 - | Piston pin |
| q | If difficult to move, heat piston to 60 °C |
| q | Remove and install with drift -10-14- |
| 3 - | Circlip |
| 4 - | 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. |
| 5 - | Bearing cap |
| q | Do not interchange used bearing shells. |
| q | Insert bearing shells centrally. |
| Checking radial clearance with Plastigage: |
| q | New: 0.020 ... 0.060 mm |
| q | Wear limit: 0.090 mm |
| q | Do not rotate crankshaft when checking radial clearance. |
| 6 - | cylinder block |
| q | Checking cylinder bore → Chapter |
| q | Piston and cylinder dimensions → Chapter |
| 7 - | Conrod bearing cap |
| q | Rods divided by fracturing (cracking) can be fitted by the cap in only one position and only with the corresponding conrod |
| 8 - | Conrod bolt |
| q | M7×0.75: 20 Nm + 1/4 turn (90°) further |
| q | M8×1: 30 Nm + 1/4 turn (90°) further |
| q | Replace |
| q | Oil threads and contact surface. |
| q | To measure radial clearance, tighten to corresponding specified torque but not further. |
| 9 - | 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. |
| 10 - | 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. |
