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Thu Nov 20, 2008 1:06 pm

I am just about to embark on a head gasket change on my 1.6TD (JX) engine.

I have had a compression test done and it came back good, the engine is recon unit with less than 20´000km on it. The head gasket has failed leaking water out behind the injector pump but shows no signs of letting water in to the oil. It still drove without any smoke just used water.

So far i have taken of the turbo as that was knackered as well (I now have a shinny new one!) I have done loads of research on here and looked in my Benntly manual. My main questions are-

1. Can I leave the injector pump aloan - i.e I will not have to buy any special tools for timing etc?
2. Which type of DTI gauge will I need for working out my head gasket and in laymens terms how do i do this?
3. Should I have the head and manifolds skimmed. Who do i get my head skimmed with if i need to? (based in Surrey)

I am sure there will be loads of questions as i go but for now any pointers or help would help put my nervous at ease!

Thanks in advance.

87´ Syncro Westy 1.6TD

Thu Nov 20, 2008 2:27 pm

You can leave the injector pump in place. You will need to time the pump sprocket when you put the head and belt back on. You will need to check the head for straightness. Borrow a straight edge and a feeler blade set. Check in different places. If you have gap of .006" or more at any one place the head needs to be surfaced. VW did not want the heads to be resurfaced, but I have done some without ill affect. The intake manifold should be fine, you can put a straight edge on the exhaust manifold flanges to check for warp. I will get some boos. But if the correct notch head gasket was used last time, you can go ahead and get the same thickness. You will need some way to lock the cam at TDC when you put the timing belt one. Someone said you could use the 10mm wrench from the tool kit in place of the tool. Cheers

Thu Nov 20, 2008 2:37 pm

thanks....all great help

Thu Nov 20, 2008 3:16 pm

There are lots of ways that the headgasket can blow and each way results in different symptoms. Here's more explanation.

http://www.vwdiesel.net/phpBB/viewtopic.php?t=16699

If you already have the straightedge and feeler gauges for measuring the flatness of the head, then you can go ahead and measure piston protrusion with them and make sure the last person doing the headgasket didn't screw it up. If it is currently a three notch gasket, then I would most certainly measure it. Some unethical mechanics use the 3-notch exclusively as it is easier to stock just one size and with the three notch gasket, the risk of piston to valve contact is eliminated. The downside can be poor starting and inefficiency due to improper "squish" and "quench" area in the combustion chamber resulting in an improper burn.

There is no need to mess with the injection pump. The timing of the injection pump will not be affected by the removal and replacement of the head unless you use a new timing belt. That being said, you might consider using the a new belt and tensioner as you are in there already. You will however need to adjust the camshaft timing as that can change even if the same size gasket is used and no shaving is done.

Andrew

Fri Nov 21, 2008 1:39 am

thanks for that.

I am planning on changing the cam belt and tensioner as it makes sense to do it when I am in there. I have bought a DTI gauge so i can work out what head gasket I need. I think I will have the head and exhaust manifold skimmed as that way I will know they are flat.

my problems is ...
Leakage between a coolant passage and the exterior will result in coolant leaking out of the engine.
the engine is a recon unit that has covered about 20`000miles. we had it compression tested and it came back fine but it leaks coolant.

while changing the head gasket i decided that i would renew the turbo as when it was tested the guy advised us to use it as a door stop!! then I though why not chnage the timing belt and fan belt. from there the list has grown.
at the end of this all I am trying to achieve is a 1.6TD engine that is producing as much power as possible and is reliable.

if anyone has any more pointers or advice its always welcome as I am well in to unknown territory .... :shock:

Fri Nov 21, 2008 7:39 am

For power improvements head over to www.vwdiesel.net and check out the FAQ section along with the IDI Engine section. LOTS of reading.

Andrew