System Specifications

Cylinder Bores





Difference between actual & nominal diameter not more than 0.10 mm

Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with engine bracket VW 540 as the resulting measurements would likely be incorrect.

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:

Connecting rod bearing shell
Axial clearance, wear limit 0.37 mm
Radial clearance, wear limit 0.08 mm

Connecting rod bolt 30 Nm plus an additional 1/4 turn (90°)

Piston and cylinder dimensions

Piston and cylinder dimensions:

Piston installation position and piston/cylinder allocation





Piston in cylinders 1 and 2:
Larger intake valve chamber toward flywheel end - arrows -.
Piston in cylinders 3 and 4:
Larger intake valve chamber toward belt pulley end - arrows-.

Note:
^ New piston allocation to cylinders is shown by a colored marking on piston crown.
^ Piston for cylinders 1 and 2: marked 1/2.
^ Piston for cylinders 3 and 4: marked 3/4.

Piston ring gaps





Ring-to-groove clearance





Crankshaft toothed belt pulley bolt 120 Nm plus 1/4 turn (90°) further
Replace

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