Manual for 1.6TD?

Post by **joe75** » 28 Jul 2008, 09:31

Anyone know what manual we would need to buy to get the info for changing the head gasket on a 1.6TD engine?

Thanks

Joe

Post by **Ye Olde Syncrospares** » 28 Jul 2008, 10:35

mk2 golf diesel is closest,cj.

Post by **joe75** » 28 Jul 2008, 20:51

what years where the mrk2 golfs?

thanks

Joe

Post by **Russel** » 28 Jul 2008, 20:54

There is also a T25 diesel book by pocket mechanic.
Russel

Post by **dave friday** » 29 Jul 2008, 18:26

And Justkampers sell one for about £15.

Post by **HarryMann** » 30 Jul 2008, 09:42

Theres also some bits'n pieces under Diesel Engines in the Wiki about parts and procedures for the 1Y and AAZ (1.9 & 1.9TD) that apply generally to diesel head gaskets...

e.g. https://club8090.co.uk/wiki/Di ... re-fitting

Part Nos and torques for 1.9 diesels

https://club8090.co.uk/wiki/Parts_-_Part_Nos

Post by **joe75** » 30 Jul 2008, 12:43

thanks for the help.

the syncro made it from Cornwall to surrey ok. it lost about 2litres of water but run just fine. the engine is a German recon unit that has only done 20,000km ...

I have ordered a manual from JK and the rocker box gasket from brickwerks. I am going to try and re-torque the head down at the weekend to see if it has come lose. if this does not stop the leak then I will replace the head gasket and then we should back on the rd perfectly.

thanks for the help

joe

Post by **joe75** » 30 Jul 2008, 12:57

Any idea where to buy a head gasket as brickwerks has sold out?

Post by **HarryMann** » 30 Jul 2008, 15:22

Post by **Simon Baxter** » 31 Jul 2008, 08:47

joe75 wrote:Any idea where to buy a head gasket as brickwerks has sold out?

There are 3 thicknesses.
GSF only sell the thickest, the 3 notch.
VW sell them, but they are back ordered from Germany, and very expensive.
I'm slowly building up a stock of gaskets and I'm expecting the next delivery from Elring in the next day or so, but I am now away on holiday till the 11th of August.
I have on order, 1,2 and 3 notch head gaskets so the job can be done properly.
(did you know you have to measure the piston projection from the block to determind what gasket to use?)

.66-.86mm 1 Notch (1.4mm thick)

.87-.90mm 2 Notch (1.5mm thick)

.91-1.02mm 3 Notch (1.6mm thick)

Post by **joe75** » 31 Jul 2008, 09:34

thanks for the info.....will work out what I need and order when I have the info...

Post by **Simon Baxter** » 31 Jul 2008, 11:07

Isn't it funny that Elring don't stock and never have stocked anything other than the 3 notch gasket.
The idea of the different thickness gaskets is that you make sure the pistons don't touch the head and you get the best compression.
basically, you use the thinnest gasket you can get away with so you maintain good combustion pressures.
Just out of shear laziness most garages either replace what was on, i.e 2 notch comes off, 2 notch goes back on or just put a 3 notch gasket on.
Great for clearance, not so great for compression pressures.
If you are replacing a gasket there is a fancy VW special tool specially for the job but it isn't the cheapest item ( I have bought one because I do a few of them, and it will pay for itself in time) but you can get away with a DTI and a magnetic stand.
Make sure you test all the cylinders as they can differ.
It is common practice when an engine is reconditioned to "Deck" the block, meaning the top face is machined flat much the same way as a cylinder head is skimmed, so the piston protrusion, or projection in VW speak is a must in my eyes.

Post by **HarryMann** » 31 Jul 2008, 23:01

Thanks Simon, Wicked!

Post by **joe75** » 02 Aug 2008, 13:59

that info was really great. i asked the local garage if they could fit a head gasket and of course the answer was yes. when i pressed them about finding out what head gasket we would need they told me there was only one !! just shows you that they will use any gasket!

does any one have recommendations of garages in or around Guilford - Surrey that are T25/Syncro friendly?

thanks for all the help.

Post by **Simon Baxter** » 12 Aug 2008, 22:14

Sorry they took so long, been on holiday.
I've got stock and uploaded the details to the website.
Clicky
No probs if you got sorted, I needed a kick to get them done anyway.
De-coke sets due in soon, but inlet and exhaust gaskets are available.