1200cc Barrel And Piston Kit - 77mm Bore Type 1 Engines - For 87mm Bore Case

Restore the performance and reliability of your classic aircooled engine with this replacement 77mm cast barrel and piston kit, suitable for all 1200cc Beetles, Splitscreen Buses, and Karmann Ghias built from 1960 to 1977, as well as the very late 1200cc Beetles from 1978–1979. Manufactured to OE specification, this kit provides everything required to refresh the top end of your 1200cc engine.

These 77mm cylinders are designed for engine cases machined with an 87mm spigot bore. This is crucial, as some late or replacement cases use a 90mm opening. If your crankcase has a 90mm cylinder opening, you will require part number 042198057 instead.

Featuring 18-fin cylinder barrels, this kit ensures excellent heat dissipation—essential for keeping temperatures under control during modern driving conditions. Each piston is cast to original spec, with correct dome shape and weight matching for smooth, balanced running.

This complete kit includes:

• 4 × 77mm barrels

• 4 × 77mm pistons

• 4 × gudgeon pins

• 8 × gudgeon pin clips

• Full set of piston rings

Suitable for engines up to code D525049 and from D1430281 onwards, this makes it compatible with the vast majority of 1200 engines produced during the classic aircooled era.

Perfect for stock rebuilds, everyday drivers, and restorations, this kit brings your engine back to factory efficiency, reliability, and smoothness. Pair with fresh gaskets, new pushrod tubes, and a honed or inspected case for the best results.

OE reference: VW part number 111 198 057A