System Specifications

Crankshaft dimensions
(measured in mm)





Piston and cylinder dimensions
1) Dimension without graphite coating (thickness 0.02 mm). The graphite coating wears away.





Piston ring gap, checking





Ring to groove clearance, checking





Piston, checking
Micrometer 75 to 100 mm (2.95 to 3.95 inch)
Measure pistons approximately 10 mm from lower edge of skirt, at 90°angle to piston pin axis.
Deviation from nominal dimension max. 0.04 mm





Cylinder bores, checking
Special tools and equipment
- Internal dial gauge 50 to 100 mm (2.95 to 3.95 inch)
- Measure bore at 3 locations in both directions -A- across engine and -B- in line with crankshaft.
^ Deviation from nominal dimension max. 0.08 mm

Note: Do NOT measure the cylinder bores when the engine block is mounted on a repair stand using the VW 540 adapter bracket, inaccurate measurements will result due to the uneven bending of the engine block on the repair stand.

Crankshaft
Axial clearance:
New 0.07...0.23 mm
Wear limit 0.30 mm
Check radial clearance with Plastigage
New 0.01 0.04mm
Wear limit 0.15 mm
Do not rotate crankshaft when checking radial clearance
Connecting Rod Bearing
Axial clearance
New 0.05 0.35 mm
Wear limit 0.40 mm
Check radial clearance with Plastigage:
New 0.01 0.06mm
Wear limit 0.12 mm
^ Do not rotate crankshaft when checking radial clearance

Main Bearing Cap Bolts
Assembly
Tighten 65 Nm (48 ft lb) + 90°
To measure radial clearance
Tighten 65 Nm (48 ft lb) but NOT additional 90°
Main Bearing Tightening Sequence, Refer to Procedure
Service and Repair

Connecting rod bolt
Assembly
Tighten 30 Nm (22 ft. lbs.) plus additional 90° (1/4 turn)
To measure radial clearance
Tighten 30 Nm (22 ft lb) but NOT additional 90°

Belt pulley/vibration damper 40 Nm (30 ft. lbs.)
Camshaft Drive Belt Sprocket (Crankshaft) 90 Nm (66 ft lb) + 90°
Camshaft Sprocket 100 Nm (74 ft lb)

Cylinder Head
Maximum permissible distortion 01 mm
Cylinder head sealing surface dimension a = 132 6 mm minimum