Thank you for this, Martin.  I shall file it away and use it soon I hope.
-Dana-

Martin Jagersand wrote:
>
> 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
> -------------------------------------------------------------------