Maximum Allowable Variance in Deck Height, Stock 2.0 Liter Four Options

[motorvated]

I'm in the process of re-assembling the top end of my stock 2.0 liter four, and I have measured deck heights as follows:
#1 - 0.036
#2 - 0.029
#3 - 0.037
#4 - 0.035

These measurements are with the cylinder base sealing rings in place and the cylinders torqued down snugly and measured with a dial gauge. To me it seems as if I need to add a shim to the bottom of cylinder #2 approx. 0.050 - 0.080 to increase its deck height to within the range of the others. I have a couple of used 0.080 shims, one of which I could add to cylinder #2 to bring it up to 0.037.

I have a couple of questions about this.

First, how much variance is permissible between the measurements? If the deck heights are all within 0.002 of one another, is that Ok or do they need to be exactly the same.

Second, can I re-use one of my 0.080 shims or should I source a new one.

And third, do I place the shim on top of the cylinder sealing ring, beneath it, or doesn't it matter. I was planning on putting it on top of the sealing ring.

Thanks in advance for your advice.

[yeahmag]

The individual deck heights are less of a concern than having each pair of cylinders even. I use to make a tool to do this, but you can probably work something out with a straight edge, some spacers, and the cylinder head nuts.

[Mark Henry]

The individual deck heights are less of a concern than having each pair of cylinders even. I use to make a tool to do this, but you can probably work something out with a straight edge, some spacers, and the cylinder head nuts.

I picked up one of your tools used. Were there any write ups or instructions on how to use it? I found the original pictures and see how it’s bolted up and seen how the plate locates over the pistons. What type of mounting is used for the dial indicator?

Aaron I think I inherited one of your tools, is it two machined alunimum bars with a keyed plate that drops in for measuring deck and 4 spacers?

I'm using it for the first time and have to say it's a nice piece of T4 kit. (IMG:style_emoticons/default/thumb3d.gif)

[motorvated]

The individual deck heights are less of a concern than having each pair of cylinders even. I use to make a tool to do this, but you can probably work something out with a straight edge, some spacers, and the cylinder head nuts.

I picked up one of your tools used. Were there any write ups or instructions on how to use it? I found the original pictures and see how it’s bolted up and seen how the plate locates over the pistons. What type of mounting is used for the dial indicator?

Aaron I think I inherited one of your tools, is it two machined alunimum bars with a keyed plate that drops in for measuring deck and 4 spacers?

I'm using it for the first time and have to say it's a nice piece of T4 kit. (IMG:style_emoticons/default/thumb3d.gif)

I was measuring at the edge of the piston, but 90° from the plane of the wrist pin, so I think a rocking piston gave me a poor reading. When I rotated the engine and measured along the plane of the wrist pin I measured the deck height of cylinder #2 at 0.037, a value consistent with the other three cylinders. This is after installing a 0.008 shim on the base of cylinder #2 and putting a straight edge across the top of cylinders #1 and #2 to make sure they are both the same height, which they are. Since I am installing head gaskets that measure out at 0.0035 thickness, my final deck height is right around 0.,040, which seems to be the safe target height. So it looks like I'm good to go. Thanks for advice and help on this. I really should have fabricated up a nice stable plate system to use with the dial gauge so my measurements could have been made more easily and at the correct positions. I'll do that for the next rebuild of my 1.8 liter.