1.8L - Block Assembly Repairs & Specifications (GROUP 13, NO. 82-10)

1.8L - BLOCK ASSEMBLY REPAIRS & SPECIFICATIONS

TECHNICAL SERVICE BULLETIN

1.8 LITER ENGINE - ENGINE BLOCK - DRIVE BELT SPROCKET - CRANKSHAFT OIL SEAL - CONNECTING ROD/BOLTS/NUTS - PISTON/PIN - CYLINDER - CRANKSHAFT

Model(s): Volkswagen Rabbit GTI

Group: 13 - Engine - Crankshaft/Crankcase

Bulletin No.: 82-10

Part Identifier: N/A

Date: November 26, 1982

ENGINE BLOCK

Refer to Fig 1 .

• cylinder bore diameter ............. 81.0 mm
• breather hole diameter (arrow A) ... 22.0 mm
• breather hole diameter (arrow B) ... 16.0 mm

DRIVE BELT SPROCKET

Refer to Fig 2 .

- Fit lug on sprocket (arrow B) into notch in shaft (arrow A).

CRANKSHAFT OIL SEAL, REMOVING

- Insert bolt of tool 3083 in crankshaft to guide seal extractor 2085. See Fig 3 .

- Remove oil seal.

CRANKSHAFT OIL SEAL, INSTALLING

- Slide sleeve of tool 3083 on crankshaft journal. See Fig 4 .

- Dip oil seal in engine oil and slide over sleeve.

- Slide thrust sleeve over guide sleeve.

- Press in seal with thrust sleeve and bolt until fully seated. See Fig 5 .

CONNECTING ROD MEASUREMENTS

Refer to Fig 6 .

Distance Between Bores a	Journal Bearing Diameter b	Piston Pin Bore Diameter c
144.0 mm (5.669 in.)	50.6 mm (1.992 in.)	20.0 mm (0.787 in.)

CONNECTING ROD BOLTS, IDENTIFICATION (STRETCH TYPE)

Refer to Fig 7 .

• A = thread length: 25 mm (0.984 in.) thread diameter: 8 mm (0.315 in.)
• B = center part: smooth finish
• C = bolt head shape: conical

CONNECTING ROD NUTS, IDENTIFICATION

Refer to Fig 8 .

• a = thread diameter M 8 x 1
• b = wrench size 14 mm with notches (arrow)

CONNECTING ROD NUT, TIGHTENING

- Lubricate contact face of nut.

- Install new stretch bolt and nut.

- Tighten to 30 N.m (22 ft-lb).

- Then tighten nut 1/2 turn (180°) more.

PISTON IDENTIFICATION

Refer to Fig 9 .

Compression Height (mm) a	Recess Depth (mm) b	Piston Pin Bore Dia. (mm) c	Piston Diameter (mm) d
22.2 mm	8.1 mm	20.0 mm	81.0 mm

PISTON PIN IDENTIFICATION

Refer to Fig 10 .

• a = 54.0 mm (2.126 in.)
• b = 20.0 mm (0.787 in.)

PISTON CYLINDER MATCHING

Size	Piston Dia. (mm)	Cylinder Bore Dia. (mm)
standard	80.98	81.01
1st oversize	81.23	81.26
2nd oversize	81.48	81.51

CRANKSHAFT JOURNAL SIZES (MM)

Stage	Main Bearing Journals	Max. Out Of Round	Connecting Rod Journals	Max. Out Of Round
standard	53.96 - 53.98	0.03	47.76 - 47.78	0.03
1st undersize	53.71 - 53.73	0.03	47.51 - 47.53	0.03
2nd undersize	53.46 - 53.48	0.03	47.26 - 47.28	0.03
3rd undersize	53.21 - 53.23	0.03	47.01 - 47.03	0.03