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Date:         Sun, 23 May 1999 20:12:36 -0400
Reply-To:     Martin Jagersand <jag@CS.YALE.EDU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Martin Jagersand <jag@CS.YALE.EDU>
Subject:      1.9l Head torqueing. Was: 1.9l TD swap

Following the recent discussion on 1.9l Diesel swaps I'd like to add a note to those assembling their 1.9l TD engines. One of the more important and unobvious differences between the 1.6l and 1.9l Diesel is the head installation and torqueing procedure. Note that the 1.9l uses a stainless steel headgasket, has a different torqueing sequence and *no* after torqueing. This seems to be critical. At least one person I know got problems after using the 1.6l procedure on a 1.9l engine.

Cylinder head, installing.

Special tools:

Torque wrench (e.g. VAG#1332), guide pins (VAG#3070)

Notes:

Always replace cylinder head bolts. (They are stretch bolts)

When performing repairs, carefully remove seal/gasket remnants from the cylinder head and cylinder block. Ensure that no longitudinal groves or scratches are created.

When using abrasive papers, do not use grades coarser than 100. Carefully remove any abrasive or emory remains.

Do not remove the new head gasket from package until the moment of installation.

Handle the gasket with extreme care. Damaging the silicone layer or the indented area will lead to leaks.

Loosening cylinder head: Reverse the sequence below.

Re-torqueing after repairs is not necessary.

Procedure:

Before installing the head, turn crankshaft to TDC mark.

Then turn crankshaft against direction of engine rotation until all pistons are approximately equally located below TDC.

Place cylinder head gasket into position.

To centralize place guide pins (3070) into the outer threaded holes on the intake side.

Install the cylinder head. Screw in 8 head bolts and tighten by hand.

Remove guide pins with removal tool from 3070 kit, and install the two remining head bolts.

Tighten cylinder head bolts in four stages in a sequence as follows:

Head bolt sequence:

--------------------- | 10 4 2 6 8 | pulley | | Flywheel | 7 5 1 3 9 | ----------------------

Inj. Pump

1. Tighten initially with torque wrench:

Stage 1: 40 Nm (30 ftlb) 2: 60 Nm (44 ftlb)

2. Turn further with normal wrench: Stage 3: 1/4 turn (90 degrees) Stage 4: 1/4 turn (90 degrees)

After tightening the cylinder head, turn camshaft so the cams for cyl 1 points upwards. Turn crankshaft in direction of engine rotation to TDC before fitting toothed belt.

/Martin -- Westy 1.9l Turbo Diesel Quantum 1.6l Turbo Diesel

Martin Jagersand email: jag@cs.yale.edu Computer Science Department jag@cs.rochester.edu Yale University

Slow down and visit the VW diesel Westy page: WWW: http://www.cs.rochester.edu/u/jag/vw -------------------------------------------------------------------


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