Cylinder Block Assembly: Locations

Assembly overview





1 - Piston rings
^ Offset gaps by 120°
^ Use piston ring pliers for removal and installation
^ "TOP" faces toward piston crown
^ Checking ring gap
^ Check piston ring groove clearance
^ Oil control ring, 2-part or 3-part, mixed installation is permitted

2 - Piston
^ Checking
^ Mark installed position and cylinder allocation
^ Arrow on piston face points toward belt pulley side
^ Install with piston ring compressor

3 - Piston pin
^ If difficult to remove, heat piston to 60° C
^ Removing and installing using a pilot drift VW 222 A

4 - Circlip

5 - Connecting rod
^ Replace only as a set
^ If connecting rods are to be reused, use a punch to mark each connecting rod and cap with the cylinder number at location - B -.
^ Installation position:
- Markings - A - point to belt pulley side

6 - Bearing shell
^ Note installation position
^ Do not interchange used bearing shells
^ Axial play
- New: 0.05 to 0.31 mm
- Wear limit: 0.37 mm
^ Measure radial play using Plastigage. Do not turn crankshaft during measurement.
- New: 0.01 to 0.06 mm
- Wear limit: 0.12 mm

7 - Cylinder block
^ Cylinder bore, checking

8 - Connecting rod cap
^ Note installation position

9 - Oil spray jet
^ For piston cooling

10 - Pressure release valve, 27 Nm
^ Opening pressure 1.3 to 1.6 bar positive pressure

11 - Connecting rod bolt, 30 Nm plus 1/4 turn (90°)
^ Replace
^ Lubricate threads and contact surface
^ Use old bolt to measure radial play





Checking piston ring gap

Special tools, testers and auxiliary items required
^ Feeler gauge
^ Inner bore gauge 50 to 100 mm
^ External micrometer 75 to 100 mm

Test sequence
- Insert ring into lower cylinder bore at a right angle from above, approx. 15 mm from cylinder edge.








Checking ring to groove clearance

Special tools, testers and auxiliary items required
^ Feeler gauge

Test sequence





- Clean ring groove before checking.





Checking piston

Special tools, testers and auxiliary items required
^ External micrometer 75 to 100 mm

Test sequence
- Measure pistons approx. 10 mm (3/8 in.) from bottom edge of skirt and at points offset by 90° to piston pin axis.
- Deviation from nominal dimension: max. 0.04 mm





Bearing shells - installed positions
Bearing shell - 1 - with oil hole - arrow - for connecting rod.

Bearing shell - 2 - without oil hole for connecting rod cap.
- Place bearing shells centrally into connecting rod and connecting rod cap.
- Dimension - a - must be the same at right and left. max. deviation: 0.2 mm.





Checking cylinder bores

Special tools, testers and auxiliary items required
^ Inner bore gauge 50 to 100 mm

Test sequence
- Measure bores at 3 locations in both directions - A - across engine and - B - in line with crankshaft.
- Deviations from nominal dimension: max. 0.08 mm

Note: Cylinder bore measurement must not be performed when cylinder block is secured to assembly stand with holding fixture VW 540. Inaccurate measurements will result