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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Sun Dec 05, 2021 5:50 am Post subject: Re: Swapping injection pumps in 1.6TD |
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Def not reversible, wasn't thinking. |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Sun Dec 05, 2021 10:41 am Post subject: Re: Swapping injection pumps in 1.6TD |
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With help from a friend, the engine is timed up. We used the Bentley, and he knew pretty much how to use the dial gauge, I didn't.
So, the valve cover gasket I got is rubber composite. Victor Reinz. Today all I find are old threads saying to always use a cork valve cover gasket. Is it that big of a deal? |
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old_man Samba Member
Joined: June 19, 2018 Posts: 1381 Location: Newfoundland
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Posted: Sun Dec 05, 2021 10:56 am Post subject: Re: Swapping injection pumps in 1.6TD |
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ndorian wrote: |
So, the valve cover gasket I got is rubber composite. Victor Reinz. Today all I find are old threads saying to always use a cork valve cover gasket. Is it that big of a deal? |
Mine is rubber like. Works fine for me. Worse comes to worse yours leaks and you have to replace it. Not exactly a difficult or arduous process. |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Sun Dec 05, 2021 11:37 am Post subject: Re: Swapping injection pumps in 1.6TD |
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True. Do you put grease on the head side and sealant on the cover side? Or how do you install yours? Thanks |
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?Waldo? Samba Member
Joined: February 22, 2006 Posts: 9752 Location: Where?
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Posted: Sun Dec 05, 2021 12:33 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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The rubber gaskets are much better than the 3-piece cork gasket set. The only downside is that there can be a mismatch between the inserts in the gasket and the shouldered studs of the valve cover requiring replacement of the shouldered studs with ones that do not have a shoulder. I use a drop of sealant at the places where the flat rubber meets the half moon and where it meets the strip that goes up and over cam cap #1. No grease or sealant on 99% of the gasket. |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Sun Dec 05, 2021 3:10 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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Thanks Waldo, looks like I messed that one up. Might have to redo. |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Sun Dec 05, 2021 3:16 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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Thanks for the info. Double post by accident. |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Thu Dec 09, 2021 4:24 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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I have a set of used fuel connection pipes. They are in the clamps and somewhat in position to be installed. Is it best to leave them clamped, and try to install them as a unit? Also I will spray brake cleaner on the threads because they look a bit grey. |
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AndyBees Samba Member
Joined: January 31, 2008 Posts: 2310 Location: Southeast Kentucky
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Posted: Thu Dec 09, 2021 5:00 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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Yes, the IP hard pipes should remain in the clamps and be installed in pairs! _________________ '84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003. |
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?Waldo? Samba Member
Joined: February 22, 2006 Posts: 9752 Location: Where?
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Posted: Thu Dec 09, 2021 5:31 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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AndyBees wrote: |
Yes, the IP hard pipes should remain in the clamps and be installed in pairs! as a clamped set of all 4 for the 1.6/1.6TD. |
FIFY |
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AndyBees Samba Member
Joined: January 31, 2008 Posts: 2310 Location: Southeast Kentucky
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Posted: Thu Dec 09, 2021 5:54 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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?Waldo? wrote: |
AndyBees wrote: |
Yes, the IP hard pipes should remain in the clamps and be installed in pairs! as a clamped set of all 4 for the 1.6/1.6TD. |
FIFY |
Thanks Waldo ....
I should have clarified ...
The big clamp on the hard lines at the IP end can be removed then install them in pairs beginning with Injectors 1 & 2. This makes it a bit easier installing the nuts at the IP as they are on the bottom and much easier to get the 17mm wrench on them. Proceed with 3 & 4 and then re-install the big clamp. This procedure also makes it easier to align and start the nuts in the Injectors. I've done ii both ways. _________________ '84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003. |
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?Waldo? Samba Member
Joined: February 22, 2006 Posts: 9752 Location: Where?
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Posted: Thu Dec 09, 2021 8:17 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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I never take any of the clamps off unless I need to replace a line. |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Fri Dec 10, 2021 2:33 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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Thanks guys, do I need to put anything on the threads? When I first got the van all the injectors, and or pipes leaked. I replaced injectors and pipes and have been ok except #1 still had a minor leak at the feed nipple. |
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AndyBees Samba Member
Joined: January 31, 2008 Posts: 2310 Location: Southeast Kentucky
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Posted: Fri Dec 10, 2021 4:01 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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No pipe dope or anything else is needed on the nut threads. The hard lines seal by compression mating to the Injectors. Sometimes you will need to tighten, loosen, tighten, etc., several times to stop a leak. Be careful to not strip the threads. _________________ '84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003. |
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RolandD Samba Member
Joined: January 15, 2017 Posts: 247 Location: Menomonee Falls, Wis
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Posted: Fri Dec 10, 2021 4:14 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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I like to put a drop of oil between the square shoulder of the line and the nut that bears on it. I want the nut to spin on the line, and not have the line twist with the nut.
Roland |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Fri Dec 10, 2021 6:40 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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Yeah, I was thinking about oil because these lines are used and a couple of the nuts have rust on the threads. |
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?Waldo? Samba Member
Joined: February 22, 2006 Posts: 9752 Location: Where?
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Posted: Fri Dec 10, 2021 8:47 pm Post subject: Re: Swapping injection pumps in 1.6TD |
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Push the flare into the injector or delivery valve on the injection pump and thread the nut by hand several turns before using a wrench. |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Sun Dec 12, 2021 6:56 am Post subject: Re: Swapping injection pumps in 1.6TD |
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So I got the lines installed. Seems that using a crows foot extension on a torque wrench changes the leverage and makes the real torque value much higher then the one set on the wrench. Luckily I realized I was over torqueing and stopped and found that out. |
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ndorian Samba Member
Joined: June 23, 2018 Posts: 760 Location: Virginia
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Posted: Sun Dec 12, 2021 7:03 am Post subject: Re: Swapping injection pumps in 1.6TD |
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Should the deck cut out for the td pump include the area over the accelerator lever? So far I cut out area over solenoid and cleared the foam out of the levers path. Still, the lever doesnt have much clearance, worried about someone sitting on the lid. |
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AndyBees Samba Member
Joined: January 31, 2008 Posts: 2310 Location: Southeast Kentucky
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Posted: Sun Dec 12, 2021 7:14 am Post subject: Re: Swapping injection pumps in 1.6TD |
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ndorian wrote: |
Should the deck cut out for the td pump include the area over the accelerator lever? So far I cut out area over solenoid and cleared the foam out of the levers path. Still, the lever doesnt have much clearance, worried about someone sitting on the lid. |
I had a custom cover made for my TDI install. I could have lowered the engine for more clearance, but with my plans, that was not an option. _________________ '84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003. |
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