Operation CHARM: Car repair manuals for everyone.

Cylinder Block Assembly: Testing and Inspection






Pistons and Cylinder Bore, Checking

Piston Ring Gap, Checking





Special tools, testers and auxiliary items 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 Groove Clearance, Checking





Special tools, testers and auxiliary items required

Feeler Gauge

- Clean the groove in the ring before checking.






Piston, Checking





Special tools, testers and auxiliary items 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

Cylinder Bore, Checking





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, testers and auxiliary items 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






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