Cylinder Block Assembly: Testing and Inspection

Checking cylinder bore






- Measure in direction -A- perpendicular to crankshaft, and direction -B- parallel to crankshaft.

- Measure at -1- 10 mm (0.039 in.) from top, -2- (center) and -3- 10 mm (0.039 in.) from bottom.
- Use 50-100 mm internal micrometer.
- Maximum deviation from nominal diameter; 0.08 mm (0.0015 in.)

CAUTION!

- DO NOT measure cylinder bore when cylinder block is mounted in VW540 holding fixture. Measurement accuracy can be affected by cylinder block distortion as it hangs down from the engine stand.

Piston and cylinder dimensions 07.95 1)






1) Flat top Piston with center combustion chamber recess


Piston and cylinder dimensions 08.95-07.96 1)

�6�:

1) Stepped piston crown with valve relief, installed in some m.y. 1996 vehicles.

2) Dimension stamped on piston crown. Add 0.015 mm (0.0006 in.) for actual diameter including phosphate layer.

Piston and cylinder dimensions 08.95 -> 1)






1) Flat top Piston with center combustion chamber recess