[Vwdiesel] 1.9 hybrid motor mistory

[82 Diesel Westy]

Thanks for the feedback everyone.
Gary and all, the first thing I checked was to see if
the cam bolt was loose.  It does not seem to be but I
need to put the cam pully in a vise I guess and check
the foot pounds it takes me to loosen the bolt.
I hope that was the issue because that would be a good
explaination.  Timing, timing has been an issue with
this setup from day one, not oil pressure.
I feel that becuase this setup (using all 1.6NA parts
and belt) moves the pump, you must re-bend the fuel
lines and with all 3 timing locks in place the teeth
on the timing belt do not fall into place on the pump
gear.  I had 3 different people help me time the
motor.  All said that is not an issue, take the pump
lock out and set the stroke.  I feel that is the root
of the problem.



If anything, I had high oil pressure.  140ftlb when
cold and 60-70ftlb when motor was hot on the highway,
25-30 ftlb when idle.
When I questioned this, more oil pressure is better.
I did use a new 1.6 NA pump and Vanagon pickup because
my 1.6 NA pump and pickup were scored up pretty good. 
I was not able to buy just the pickup, had to buy
both.

Yes, there was a nice dusting of carbon on pistons,
maybe a bit much.
1.6 and 1.9 heads are ported the same, water holes and
oil flow, from what I have learned over the years.


Anyway, if I find the cam bolt not to be tourqued to
specs, then I will give the motor another try, but it
is a lot of time invested here.  Ahhh.

I will let you know, check it later this evening.

Thanks again.
Bryan Belman
Pt. Pleasant, NJ
--- gary <gbangs at cfl.rr.com> wrote:
> 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
> > 
> 
> 


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