1600cc Barrel And Piston Kit - 85.5mm Bore Type 1 Engines - Mahle Forged Pistons

High-performance 85.5mm barrel and piston kit manufactured by Mahle, designed for all 1600cc Type 1-based aircooled VW engines. Featuring premium forged aluminium pistons, this kit is built for strength, durability and increased resistance to heat and load—ideal for fast road and performance applications.

The piston and cylinder assembly is critical to engine performance, creating compression and converting combustion into usable power. Under higher loads and temperatures, standard cast pistons can become a limiting factor. Forged pistons are manufactured using a high-pressure process that aligns the metal grain structure, making them significantly stronger and more resistant to cracking, detonation and extreme operating conditions.

This Mahle forged kit is perfect for engines running higher compression ratios, upgraded carburettors, performance cams or sustained high RPM. Precision-machined cylinders ensure correct tolerances, while the included piston rings provide optimal sealing for improved combustion efficiency and power output.

Designed to standard 85.5mm dimensions, this kit fits directly into stock 1600cc engine cases and heads without machining, making it a strong upgrade over standard components.

Specifications

• Manufacturer: Mahle
• Piston size: 85.5mm
• Engine size: 1600cc
• Piston type: Forged aluminium
• Quality: OEM / performance grade
• Quantity: Complete set for one engine

Kit Includes

• 4 x Barrels (cylinders)
• 4 x Forged pistons
• 4 x Gudgeon pins
• 8 x Circlips
• Full set of piston rings

Recommended Additional Parts

• Performance engine gasket set
• Heavy-duty or chromoly head studs
• Main, big end and camshaft bearings
• Pushrod tube seals
• Oil system upgrades (pump/cooler) for high performance builds
• Torque wrench and ring compressor for correct installation

To Fit

Aircooled VW

• VW Beetle (Type 1) – 1600cc engines (1968–1979)
• VW Splitscreen (T1) – 1600cc conversions (1963–1967)
• VW Baywindow (T2) – 1600cc engines (1968–1979)
• VW Karmann Ghia – 1600cc engines (1968–1974)
• VW Type 3 – 1600cc engines (1968–1973)
• VW Type 181 Trekker – 1600cc engines (1968–1983)
• VW Buggy / Baja – 1600cc Type 1 based engines

Note:
Forged pistons may require careful setup with correct piston-to-cylinder clearances and proper engine tuning for best results.