Cylinder Block Assembly: Specifications

Crankshaft Bearing Cap Torque 65 Nm + 90 (1/4 turn) further
For further information regarding bearing cap bolts, refer to Service and Repair. Service and Repair

Crankshaft
Axial clearance:
^ New: 0.07-0 23 mm
^ Wear limit: 0 30 mm
Checking radial clearance with Plastigage:
^ New: 0.01-0.04 mm
^ Wear limit: 0.15 mm
^ Do not rotate the crankshaft when checking the radial clearance
^ Crankshaft dimensions, Refer to Crankshaft, Engine, Specifications




Crankshaft dimensions
(in mm)

Connecting rod bearing cap torque
Always replace bolts
Assembly
Tighten 30 Nm (22 ft lb) + 90°
To measure radial clearance
Note:To measure radial clearance use old bolts
Tighten 30 Nm (22 ft lb) but NOT additional 90°

Connecting Rod Bearing shell
Axial clearance
New 0.05 to 0.31 mm
Wear limit 0.37 mm
Check radial clearance with Plastigage:
New 0.01 to 0.06mm
Wear limit 0.09 mm
Do not rotate crankshaft when checking radial clearance
Crankshaft toothed belt sprocket 90 Nm +1/4 turn (90°) further
Vibration damper/belt pulley 25 Nm
Camshaft Sprocket 65 Nm




Piston Ring Gap





Piston Ring Clearance





Checking cylinder bores
Special tools and equipment
^ Internal dial gauge 50 to 100 mm

- Measure bores at 3 locations in both directions -A- across the engine and -B- in line with crankshaft.
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 VW540, as incorrect measurements would then be possible.





Piston and cylinder dimensions (engine codes: AWP, AWV)
1) Dimension without graphite coating (thickness 0 02 mm). The graphite coating wears away.

Cylinder head for distortion Max permissible distortion: 0.1 mm