Club 80-90 Forums

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

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.