1.9 DG Internals – Measurements and tolerances

[drjsmithwhite]

Hi All,


Firstly I have used the search function but couldn't find the answers i was after (im sure someone will now link a thread with all the answers to lifes questions below) so i apologies in advance for that


I will in the near future be stripping down and rebuilding my engine (1.9 DG)

What i would like too know is, what need replacing, whats within tolerance and what to change whilst im in there!


so where can i find measurements of the internals and there accepted tolerance

also any other advice of what too look for damage wise etc


reason for rebuild is negative results from compression testing

[itchyfeet]

All in Bentley manual which is basically taken from the VW workshop manual
I wouldn't bother starting without one.
There was a download doing the rounds but a hardcopy is best imo.


I put togeter some interesting rebuild links on tbis tgread, also a link to a 2.1 manual there which is similar in many parts to the DG but missing some data you will need.

https://club8090.co.uk/forum/viewtopic.p ... 93&start=0" onclick="window.open(this.href);return false;

if your oil pressure is good you may not need to do a full rebuild, just removed heads, piston and barrels and rebuild those.