[Vwdiesel] cylinder bored too much by shop. now what??

[LBaird119 at aol.com]

  If it was bored .010" over the already .040" overbore then they 
either get you a custom set of 5th over pistons (you said second 
size but is that .25 mm steps or .5 mm?)  Aftermarket pistons 
come in 2nd and 4th oversize (for the 1.6 engines anyway) so I 
presume 1st and 3rd are dealer only.
  The only choices I can see would be a replacement block, custom 
pistons if the cylinder walls are still thick enough, or sleeves.
  I presume .001" is the called for clearance for your engine, same 
as the 1.5 and 1.6?  Geez. .011 is too much for most racing 
engines even (I think.)  Sounds like you get to have a "fun" talk 
with your shop.  :-(
  I had to literally SHOW the shop the called for clearance when I 
had a couple blocks bored.  They flat out didn't believe it and had 
been boring them to .018" because some other shop had them do 
it that way. (.024 is wear limit)  So those engines would be over 
half worn out before you even turn the key!
     Loren


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