[Vwdiesel] 1.9 hybrid motor mistory

[gary]

There are only two ways for the valve to come in contact with the
piston...

1) Cam not timed properly

2) Piston projection not figured correctly.

Based on what you said regarding only the intakes kissing the pistons,
my guess would be #1, they timed the cam wrong!

But I am confused...
The 1.6 and 1.9 heads are FLAT on the mating surface. If all the bolt
holes and water ports match up, then THERE IS NO MISMATCH!

Why two head gaskets? The gasket used is based on piston projection. A
single 1.9 gasket should have been all that is needed for sufficient
clearance. If they had such a conundrum dealing with piston projection,
something must be wrong here. Double check this, and compare with the
spec. 

On my 1.6's, I have always replaced the head gaskets with the thickest I
could get. Running a Rabbit diesel in SoCal didn't require such exacting
compression ratios.

Now, if the piston doesn't appear to be damaged, I would still drop the
pan and look at the rod bearings. Hell, just replace them. The mains
should be alright. The rod bearings are subject to much more stress.

I don't think you problems are because of the 1.9/1.6 hybrid parts...
this has been done before with success. 

I don't believe Overland set the engine up right to begin with.

Didn't you have issues with this engine from day one? Like low oil
pressure due to the head gasket on backwards or something like that?

-Gary
 



On Mon, 2004-02-16 at 18:08, 82 Diesel Westy wrote:
Snip...
> #1 intake valve was driven up and shattered lifter and
> blew off spring keeper.
> The piston is fine, the valve does not appear to be
> bent, just free moving in valve guide.
> #3 intake valve was driven up and cracked lifter.
> 
> There are marks on top of #1, #3 and #4 pistons where
> intake valve is kissing, but no dents or nasties.
> #2 has a ccarbonring build-up when intake valve comes
> close to piston top.
> IS THIS NORMAL ON A DIESEL?
> The motor had 2 head ggaskets a stock 1.9 and a
> thinner metal one to match holes.
> WAS THIS DONE BY OVERLAND TO POSSIBLE CREATE THE
> CLEARANCE NEEDED BECAUSE OF THE 1.9 - 1.6 MISMATCH?
> This motor ran on 3 cylinders after initial damage. 
> At first it felt like I blew a fuel line to a
> ccylinderuntil I heard the noise.  I was able to start
> and run on 3 cylinders, the VW dealer that I towed it
> to started it up and drove it into the shop!  It
> sounded bad but ran on 3 cylinders with a cracked #3
> intake lifter.
> 
> SO, DOES THIS RULE OUT A TIMING CHANGE OR BELT SLIP?
> Belt seemed fine, tension good.
> 
> WHAT COULD HAVE CAUSED THE CONTACT?
> 
> This motor has had a noise for the past 8K or so that
> seemed like a bad wwater pumpbearing, but swapping
> wwater pumpdid not get rid of noise.
> WOULD YOU THEN CHECK FOR MAIN BEARING ISSUE WITH #1
> AND #3?
> 
> 
> ANY HELP IS GOOD HELP?
> I will take some pics as well and post.
> I am thinking it might be better to start over with a
> real AAZ 1.9TD long block and get the intake manifold
> converter for my 1.6 stuff.
> Thanks again as always.
> Bryan Belman
> 
> =====
> Bryan Belman, Pt Pleasant, NJ
> 04 Jetta Wagon TDI, 100bhp, 5sp (had to have a car that starts when I need it)
> 82 Westfalia Diesel, 1.9L NA hybrid, under body restoration
> 90 Audi 200, 2.2L Turbo FWD
> 70 Type 1 Beetle, restored, QQ plates
>