Cylinder Block Assembly: Specifications

Piston And Cylinder Dimensions

Piston and cylinder dimensions:

Cylinder Bores





Take measurements at 3 positions in both lateral - A - and longitudinal - B - planes, as illustrated.
Deviation from nominal dimension maximum 0.10 mm

Note:
Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with holding fixture VW 540 as incorrect measurements would then be possible.

Crankshaft
Axial clearance
New 0.07 to 0.17 mm
Wear limit 0.37 mm
Radial clearance
New 0.03 to 0.08 mm
Wear limit 0.17 mm

Crankshaft Dimensions

Crankshaft dimensions:

Crankshaft main bearing cap bolts 65 Nm plus 1/4 turn (90°)
Replace bolts

Connecting Rod Bearing Shell
Axial clearance
Wear limit 0.37 mm
Radial clearance
Wear limit 0.08 mm

Installation Position of Bearing Shells





Dimension - a - must be same on left and right sides
Maximum deviation 0.2 mm

Piston Ring Gaps





Ring To Groove Clearance





Crankshaft toothed belt pulley bolt 120 Nm plus 1/4 turn (90°)
Replace bolt
90° turn further can be done in several stages

Belt pulley/vibration damper bolts 10 Nm plus 1/4 turn (90°)