Cylinder Block Assembly: Testing and Inspection

Piston rings, checking

Checking ring gap

Special tools, testers and auxiliary items required
^ Feeler gauges

Work sequence
- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.





- Determine ring gap using feeler gauges.





Checking ring-to-groove clearance

Special tools, testers and auxiliary items required
^ Feeler gauges

Work sequence
- Clean ring groove before checking.





- Determine ring gap using feeler gauges.





Checking cylinder bores

Special tools, testers and auxiliary items required
^ Internal dial gauge 50 to 100 mm

Work sequence





- Take measurements at 3 positions in both lateral - A - and longitudinal - B - directions, as illustrated.
Difference between actual and nominal diameter: not more than 0.10 mm.

Note: 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.

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.