Liner protrusion too high @ 0.15mm ?

[DamirGTI 342]

Had to resurface the block base , and afterwards i'm left with what seems to be a little high liner protrusion measuring 0.15mm on all the 4 liners (measured with liners and base cleaned and without O-ring fitted) .

 

Haynes says maxi liner protrusion is 0.10mm , though i also found info (as well from the Haynes) that the 0.18mm is maxi ?!? ..

 

Anyways , is the protrusion measured at 0.15mm considered too high or not ?

 

D

[Thijs_Rallye 87 4 Cars]

If I remember correctly the inner two liners should protrude further than the outer ones and keeping in mind the difference between an outer one and inner one shouldn't be more than 0,05 mm. I'll have to look in my documentation tonight to have the exact figures unless someone beats me to it .

[DamirGTI 342]

From what i have found says :

 

0.08-0.15mm (in the 309 haynes)

0.03-0.10mm (in the 205 haynes)

 

For blocks up to a 1987 its - 0.08-0.15mm  , from 1987 its - 0.03-0.10mm .

 

... if that's right by OE .

 

I do not have any OE "material"/book which has liner protrusion data/chapter .

 

Thanks !

D

[Thijs_Rallye 87 4 Cars]

All measurements should be carried out without the o-rings under the liners.

 

Flatness: measure 4 points on top of the liner. Deviation max 0,02mm

 

Liner to liner protrustion: measure (top view) left liner at 3 o'clock and liner to the right at 9 o'clock. Deviation max: 0,05 mm

 

Deck protrusion: measure 3 points at top of the liner to the engine deck. Protrusion should be within 0,03 and 0,10 mm.

 

 

[DamirGTI 342]

... means i have 0.05mm more than maxi spec. on the liner-to-block protrusion .

 

Great ! now what to i do ?! mill the liners 0.05mm down ?

 

Anyone knows what effect might make this + 0.05mm more protrusion , is it still sufficient for the HG clamping properly on both the fire rings and oil/coolant passages or needs lowering the liner protrusion between 0.03 - 0.10mm range as a must ?

 

Thanks

D

[wicked 103 3 Cars]

I would just pop the head on...

 

1.6 GTI GrpA spec specifies 0.08-0.15mm

1.9 GTI GrpA spec specifies 0.09-0.11mm

205T16 spec specifies 0.27-0.30mm

 

Which would hint me that 0.15mm would work. 

Most important is that liner to liner diff is minimal/within spec.

 

Edited November 8, 2018 by wicked

[Thijs_Rallye 87 4 Cars]

It will likely work but it could become a headgasket eater. Combustion pressure is higher in a 1.9 and I think that is the reason they've specced the protrusion down. (to keep the headgasket deformation down) But these are all just gut feels :P.

As for the Turbo16, such an engine doesn't really compare since headgasket longelivety isn't really an issue because they get pulled apart after each event.

 

Anyways, you can either have the liners skimmed a little or re-machine the liner seats in the engine block.

 

 

Edited November 8, 2018 by Thijs_Rallye

[DamirGTI 342]

Think i'll fit the head on , and will see what happens ! .. with thicker "repair" 1.5mm HG .

 

.. as really no time nor money for machining parts now , and need to get the car going asap as it's my daily .

 

Thanks !

D

[Thijs_Rallye 87 4 Cars]

It'll likely be fine like Rolf said.