Is the outside diameter of a bigbore 96mm jug the same as the stock diameter?

Aww, that's not what I was hoping this thread was about

A 96mm will fit in place of a 2.0 liter's 94mm without machine work to head or case. A 1.7 or 1.8 has a different answer.

OK so if I need to order seals for the head and block, I should ask for the 2 liter seals.
I have a 70 1.7

I'm learning this as I go but, No seals between heads and cylinders. You'll need your heads machined unless you are using 2.0 heads. I'm not sure if the 96s will fit the 1.7 case without machining. Others will chime in I'm sure.

You will need to have the heads milled out to fit the 96mm jugs. The case should work,
but it is a tight fit. I have done this twice. Both times I put the 1.8Ltr. Big Bore kit on a
1.7Ltr. case. With this set up, you get the thicker wall size on the cylinders, but the
heads must be enlarged.
74914LE

In my reading on the jug sizes, I've read a couple times that the 96s made for the 1.7s are junk (too thin) and that the 96s made for the 1.8 are the way to go on a 1.7 case. No experience, just passing on what I've read.

Sean... with 1.8 Heads you should be ok too... 1.8 jugs have the same o.d as 2.0 and the heads do not need to be flycut IIRC...

on the 1.7 heads you will have to cut for 96mm cylinders...

All cases have the same spigot size.

1.7 head registers are smaller than 1.8/2.0, which are the same.

Do not use the head seals - VW issued a bulletin to stop using them.

I have the 96mm installed already, I am getting an oil leak around the jug and case and I suspect blow by on the head. I want to put the seals in to try to stop these problems. I need to know if I should buy the 2.0 seals. Does any one know were I can get the seals? AA has lists just one size for about 6 bucks each.

Don't believe seas will fix this. However since you need to pulle the top end off the motor anyway have the cylinder lapped to the case and head. Then Apply the correct torque you will be fine. Little bit of orange/ copper permatex THIN LAYER at the case end. No more leaks.

I say it's false advertising! Where's Johnny Cochran when you need him?

-Dan