Pistons And Cylinder Bore, Checking

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Checking Piston Ring Gap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required

Feeler Gauge

-- Insert the ring at a right angle from above, to the lower end of cylinder approximately 15 mm from the cylinder edge.

Piston Ring		Gap
		New	Wear limit
Compression rings	mm	0.20 ••• 0.40	0.8
Oil scraping ring	mm	0.25 ••• 0.50	0.8

Fig 2: Checking Piston Ring Gap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required

Feeler Gauge

-- Clean the groove in the ring before checking.

Piston Ring		Ring to Groove Clearance
		New	Wear limit
Compression rings	mm	0.06 ••• 0.09	0.20
Oil scraping ring	mm	0.03 ••• 0.06	0.15

Fig 3: Checking Piston

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required

Micrometer 75-100 mm VAS 6071

-- Take the measurement approximately 10 mm from the lower edge of the piston skirt and offset 90° to the piston axis.

Deviation from nominal dimension: Max. 0.04 mm

Fig 4: Checking Cylinder Bores

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The cylinder bore must not be measured if the cylinder block is secured to the engine stand with the engine lateral bracket T03001, or else results may be incorrect.

Special tools and workshop equipment required

Cylinder Gauge VAS 6078

-- Measure diagonally at 3 positions transversely -A- and longitudinally -B-.

Deviation from nominal size: Max. 0.08 mm.

Piston and Cylinder Reconditioning Dimension

Honing Dimension

Piston Diameter

Cylinder Bore Diameter

Basic dimension

82.465 ⁽¹⁾

82.51

⁽¹⁾	The measurement does not include the graphite coating, which is 0.02 mm thick. The graphite coating wears off.