[Vwdiesel] Head R/R Poll

[Rudy]

I always remove the Turbo, then take the Head off with the Manifolds on.
Helicoils work good for the Intake Manifold Bolts, I install it on the Head
on the bench in case any more Bolts strip out.  

Rudy 

-----Original Message-----
From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com] On
Behalf Of mikitka
Sent: Sunday, July 13, 2008 6:58 AM
To: vwdiesel at vwfans.com
Subject: [Vwdiesel] Head R/R Poll

Since I'm in the middle of replacing the head on my 91 Jetta I figured I
would ask.

 

How many of you pull the head with the intake and exhaust and turbo still
attached?

 

How many take everything off and then remove the head?

 

Granted the intake isn't that heavy but the exhaust and turbo add some
weight and trying to pull them up off the block isn't the easiest thing to
do but compared to having to get to all the mounting hardware while in the
car I feel it is better to pull them all together.  What brought this
question up was that I was talking to Val yesterday and he pulls the intake
and exhaust off before he pulls the head.

 

What has happened and I guess it is a good thing, while installing the
intake on the new head before I put it on, one of the intake bolts stripped.
What makes me mad is that it did it while I was using a torque wrench and
following the Bentley instructions, not just guessing how tight it should
be.  So now I got to find an 8 x 1.25 helicoil for it. Not fun in a small
town.

 

Oh and as usual, another problem. The water temp sensor that mounts in the
front water neck at the head that is the one on top with the blue white
wire, the wire broke off just at the sensor connector, so there isn't any
way of fixing it.  I take it to be a salvage yard item and not one that I
can get at the dealer?  

 

The carbon inside the head wasn't as bad as I thought it would be after
running WVO diesel mix. The outlet of the turbo seemed to have more black
carbon on it than I thought it should but other than that not to bad. On
further investigation on my old head, three of the cylinders while looking
inside the intake ports you could see the valves soaked from oil running
down the valve stems. So it seems that the shop that redid this head didn't
know what they were doing when they put the valve stem seals on, or if they
even put any on as wet as the stems were. This explains the serious smoke I
was getting on start up and first few miles running down the road. I'm
hoping this other head that I got from Aluminum Head Rebuilders will serve
me better.

 

I also found that the bolts to the IP bracket under the IP were lose that
mount to the front of the block, as well as the bottom bolt that connected
the front bracket to the side IP bracket fell out.  So all the bolts were
taken out, cleaned up with carb cleaner "Wal-Mart" brand works great and
isn't expensive plus dries fast.  Then they were installed with blue lock
tight.  I also was missing the little "L" bracket that connects the top of
the AC compressor bracket to the side IP bracket. I found one a long time
ago in the salvage yard and remembered to put it on this time around.

 

I'm also installing an EGT gage. I drilled a hole in the center of the
exhaust manifold right in front of the mount for the exhaust bracket bolt.
I have seen where I think Roger took out that mount stud and mounted his
probe there using it as a probe and mount.  I chickened out on that one. So
at least now I will have an EGT gage to go on since I have the Giles pump
with no govner and extra fueling. I guess I have been lucky so far not to
over temp it.

 

So with this new head, I'm hoping to stop my start up smoke, reduce my one
qt of oil usage in 2500 miles and get my oil pressure back.  

 

Nick

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