Netters,

Prompted by the 1.9 TD conversions going on, I checked what the
VW TSB says about head re-torqueing for the 1.9l TD. Surprisingly
it seems to say that no re-torqueing is necessary. In addition
the whole head installation sequence is considerably simplified.
I'd be curious to know if the more complicated 1.6 l instructions
would actually give better results on the 1.9l TD also.

My TSB is from 94. Could people with different year editions please
check so this is not a mistake in the manual?

Does the 1.9 use the same head bolts as the 1.6? (Someone with
the fiches please check)

For your reference I copied the whole 1.9l TD instructions below.
The 1.6 (in summary) had: Tighten to: 40 Nm, 60 Nm and finally 75 Nm.
Turn 180 degrees. Run engine until warm. Turn 90 degrees. After
1000 miles turn 90 degrees. So these 6 steps have been replaced with
only
4 on the 1.9, with no after tightening whatsoever. I'm particularly
concerned about the aftertightening.

Thanks for any insights,
Martin
--
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
-------------------------------------------------------------------

-----------From W42 012 194 103, "1.9l TD General Engine Manual"----

Head torquing for 1.9TD heads.

Cylinder head, installing.

Special tools:

Torque wrench (e.g. VAG 1332), guide pins (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 TDV 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 cenatralize 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.