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Fitting Pistons

  1. Measure cylinder at 3 points: 3/8" (10 mm) from top and bottom, and at center of bore. Measure in line with and at 90° to thrust face. Wear limit is 0.003" (0.08 mm).
    NOTE: Do not measure when block is mounted in repair stand with adapter VW 540 due to possible distortion.
  2. Measure pistons 5/8" (16 mm) from bottom of piston skirt, 90° to pin bore. Subtract this measurement from that of corresponding cylinder bore and note piston-to-cylinder clearance. If clearance exceeds 0.0028" (0.07 mm), oversize pistons must be installed.
  3. Place each piston ring squarely into bottom of cylinder about 5/8" (16 mm) and measure end gap. Reading should be 0.010 - 0.020" (0.25 - 0.50 mm). Measure ring side clearance in pistons using a feeler gauge. Ring clearance should be 0.0008 - 0.0030" (0.02 - 0.08 mm) with a wear limit of 0.004" (.1 mm)
  4. Install rings on pistons with "TOP" mark facing piston crown. Recessed edge on outside of center ring must face toward piston pin. Oil scraper ring with spring can be placed in either way. Ring gaps should be spaced 120° apart. Use suitable compressor (US 1008 A) and install piston and rod assemblies.
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