Tech Tips

TT 15-09-02 Date: Nov 24, 2009

ALL Models with 2.0T FSI Engine – Oil Consumption –

Cylinder Bore Checking using Dial Bore Gauge

When checking an engine’s cylinder bores for wear for an oil consumption concern, it is important that accurate
measurements are obtained in order to verify the cylinder’s condition and ensure a proper diagnosis.

The recommended measuring procedures are located in Athe ElsaWeb repair manual (Engine > Crankshaft,
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Cylinder Block > Diagnosis) and in the Self Study swagen
Program (SSP) # 821003oes – Metrics for Mechanics, Section 9,
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pages 44 – 45 on ServiceNet under Training. d bThe following is a summary of gthose
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Cylinder
ss Bore Checking with Dial Bore Gauge

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Measurement Terms:
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Cylinder Out-of-Round
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Both types of measurements are By comparing bore diameter

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important ways of evaluating the measurements at different points

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condition of the cylinders and around the circumference.

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possible causes of symptoms
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such as low compression or oil Measure diagonally at 3 positions:
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-A- Transversely (across)
-B- Longitudinally

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Refer to ElsaWeb for “deviation

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Cylinder Taper
The difference in diameter between
the bottom of the cylinder bore and
the top of the bore just below the
ridge. Subtracting the smaller
diameter from the larger one gives
the cylinder taper.

Page 1 of 2
© 2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or
reposted to other sites, without the prior expressed written permission of the publisher.
 Service Information
Special Tools Required:
• US 1033/S Inside Micrometer Set
(18 – 100mm) or equivalent

• Dial Bore Gauge

A special type of dial indicator
with a mechanism designed for
measuring cylinder bores and
similar inside diameters.

The dial indicator portion of a dial bore

gauge functions just like any other dial
indicator. The zero point on the scale
can be adjusted as necessary as an
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nominal dimension specified for the

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bore. This way, the gauge will directly

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read the difference between the actual

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diameter at any point in the bore and

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the nominal value.

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The critical thing to remember about

using a bore gauge is that it must be
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positioned precisely in line with the

bore to measure true diameters at any
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point in the bore. Tipping the gauge,

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even slightly, will cause the dial

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bore gauge to measure a value

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larger than the actual diameter.

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The cylinder block must not be

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Page 2 of 2
© 2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or
reposted to other sites, without the prior expressed written permission of the publisher.
 Cautions & Warnings

Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.

•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.

•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen. retailer parts department for the latest information.
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•= Any time the battery hasdbeenby disconnected on an automatic gutransmission vehicle, it will be necessary
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running. y li
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
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battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
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become inoperable, even if the correct code is used in a later attempt.

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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
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goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
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•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
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•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.

Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
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 Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.

•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
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grinding, sanding, or by cleaning with acompressed agenAvoid
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Breathing asbestos can cause yserious ot g or cancer, and may result in death.
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Finger rings should be aremoved so that they cannot cause electrical shorts,
or get caught in running machinery, or be
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•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the

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instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only

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replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good

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•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
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might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.

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•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.

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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
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•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of his
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the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
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govern the disposal of wastes.

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The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
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serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
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trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
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automotive chemical refrigerants.

•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.

•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.

•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).

•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.

Page 2 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
 Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.

•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.

•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.

•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

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Page 3 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
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