| HYDRAULIC LIFTERS |
Hydraulic Lifters On
1986 Volkswagen 1.6L (96.9 CID) Diesel Engines
Volkswagen 1.6L (96.9 CID) diesel engines used on the 1986 Jetta
and Golf are now equipped with hydraulic lifters.
In comparison to mechanical lifters, these hydraulic lifters do
not require valve adjustment as part of routine maintenance
service or after engine disassembly.
According to VW, intermittent valve noise is normal during
startup and does not require replacement of the lifter assembly.
Use the following procedure to determine when the hydraulic
lifter needs to be replaced.
Start the engine and allow it to reach operating temperature. The
cooling fan should come on at least once.
Increase engine speed to 3500 RPM, maintain this speed for 2
minutes. Allow the engine to return to idle. If lifters are still
noisy they should be replaced.
Remove the rocker cover and rotate the camshaft so that the lobe
above the lifter to be tested is at base circle (lobe facing away
from head). Using a wood stick or other suitable tool press down
on the lifter (see illustration). If the lifter can be depressed
by more than .004 replace the lifter.
(insert illustration)
The AERA Technical Committee
October 1987 - TB 462
##END## |
| CYLINDER HEAD GASKET SELECTION |
Cylinder Head Gasket Selection On
1981-86 Volkswagen 1.6L (96.9 CID) Diesel Engines
The cylinder head gasket used in the 1981-86 Volkswagen 1.6L (96.9 CID) diesel engines is available in three thicknesses distinguished by notches on the side of the gasket. The correct gasket is selected by measuring piston protrusion on all four cylinders and basing the selection on the highest piston height.
Protrusin should be measured as indicated in the illustration below by using Volkswagen tools VW382/7 and VW385/17 or equivalents. It is important that your depth gauge/dial indicator set-up not rest directly on the piston itself to
prevent possible distorted readings. Parallels placed on the deck surface next to each cylinder will provide a good base for measuring.
Use the following table for determining gasket usage:
Piston Height Identification Notches
.0260-.0339 1 (1.4mm thick)
(.66-.86mm)
.0343-.0665 2 (1.5mm thick)
(.87-.90mm)
.0358-.0402 3 (1.6mm thick)
(.91-1.02mm)
Additionally, be sure to install the cylinder head gasket with the side marked TOP or OBEN (on OE gaskets) facing up.
The AERA Technical Committee |
| CYLINDER HEAD THICKNESS ON WATER COOLED ENGINES |
Cylinder Head Thickness On
Water Cooled Volkswagen 4 Cylinder Engines
The minimum cylinder head thickness for Volkswagen 1.5L, 1.6L, 1.7L and 1.8L gasoline engines is 5.215 as measured from the deck surface to the valve cover rail. See illustration below. Although AERA members report following the above specification for 1.5L and 1.6L diesel cylinder heads as well, Volkswagen's official position is that the diesel cylinder heads are not to be
resurfaced. Heads warped more than .003 are to be replaced.
AERA members are reminded that the diesel engines have 5 different thicknesses of cylinder head gaskets identified by the number of notches located on a tab on the side of the gasket. The proper gasket is selected based on piston protrusion and size of engine, not cylinder head thickness. The table below indicates the proper gasket selection.
Piston Gasket Notches
Projection Thickness 1500cc 1600cc
.025-.032 .055 3 1
.033-.036 .059 4 2
.037-.040 .063 5 3
The AERA Technical Committee |
| CONNECTING ROD BOLT TORQUE CAUTION |
Connecting Rod Bolt Torque Caution For
Allis Chalmers 201, 301 & 426 Cubic Inch Engines
The AERA Technical Committee offers the following information on connecting rod bolt torque specifications for Allis-Chalmers engines. This information applies to both early and late style engines, as several different hardware combinations have been used. Previously published TB-2018 should be discarded as TB-2018R contains updated information.
Two different connecting rod and cap mating surface finishes were used and identification can be made by visual inspection. Early style connecting rods have a serrated mating surface between the cap and the rod. Middle and Late style connecting rods can be identified by smooth/machined surfaces between the cap and the rod.
ALL MODELS
When installing, use a light amount of engine oil on capscrew threads and on the underside of the capscrew head at the mating surface. Tighten hardware using a minimum of two incremental torque steps, three on higher torque hardware (7.0L). Non-serrated connecting rod caps MUST be aligned with the rod during installation. To do so, install hardware finger tight, use two feeler gauges between the rod/cap assembly and the side of journal to hold assembly snug to one side of journal. Tighten hardware in multiple steps and then remove feeler gauges.
Allis-Chalmers engine models: 2000 series, 3.3 and 4.9-liter series (2200, 2800, 2900, 433 & 649 types, etc.)
Early style rods use hex-head capscrew with washer. The rod cap bolt holes have a 30° degree chamfer. Capscrew size used is .375" ? 24 x 2.00" long, grade 8, tighten those capscrews to 50 ft/lbs.
Later style rods have the rod cap chamfer deleted and a new 12-point capscrew introduced. Capscrew size used is .375 - 24 x 2.00 long, grade 100, tighten those capscrews to 45 ft/lbs.
Note: Do not use later 12-point capscrews in early rods with chamfered holes or loosening of capscrews will occur. Early rods may be machined and balanced to accept later capscrews.
Allis-Chalmers engine models: 3000 Series, 7.0 liter series (3400, 3500, 3700, 3750 & 670 types, etc.)
Early style rods use serrated rod caps with hexhead capscrews and washers. Capscrew size .437 20 x 2.25 grade 8, tighten those capscrews to 85 ft/lbs.
Middle style rods use smooth machined rod and cap mating surfaces. Socket head capscrew size .437 20 x 2.156 long, grade 100, tighten those capscrews to 70 ft/lbs.
Later style rods use smooth machined rod and cap mating surfaces. 12-point capscrew size .437 20 x 2.156 long, grade 100, tighten those capscrews to 70 ft/lbs.
Note: Do not use middle or later type hardware in early-serrated connecting rods.
The AERA Technical Committee |
| REVISED VALVE RETAINER & KEEPERS FOR DIESEL HEAD |
Valve Retainer & Lock Changes On
Volkswagen 1500 & 1600 Diesel Engine
Perfect Circle engineers report that Volkswagen is using two different combinations of valve retainers and locks on its 1500cc and 1600cc diesel engines. Both combinations have been found on the same head at times with all the exhaust one type and the intakes the other type.
The single groove lock is used with the retainer that has an overall height of .375 while the three groove lock is used with the retainer having an overall height of .325.
Care must be taken to insure that the correct locks are used with each retainer to avoid costly damage to the engine. Valve breakage will occur if you intermix the retainers and locks.
The AERA Technical Committee |
| DRIVE BELT SPROCKET TORQUE VALUES |
Torque Valves On
Two Volkswagen Drive Belt Sprockets
The illustrations below show the two different versions of a
drive belt sprocket used on all water-cooled Volkswagen 4-
cylinder in-line engines (except the Vanagon Waterboxer). Note
that the newer design eliminates the slip-in keyway as well as
other differences.
It is important to use the correct tightening torque
specifications when installing the respective sprockets.
Always check the drive belt sprocket bolt torque after repairs
that may require turning the engine counterclockwise using the
sprocket bolt head.
(insert illustrations)
The AERA Technical Committee
October 1985 - TB 363
##END## |
| HEAD GASKET CAUTION ON 1992-97 1.9L VIN Z DIESEL |
Head Gasket Caution On
1992-97 Volkswagen 1.9L VIN Z Diesel Engines
The AERA Technical Committee offers the following information on head gasket caution on 1992-97 Volkswagen 1.9L VIN Z diesel engines. These turbocharged engines use one of the three different thickness gaskets available for each of the engines, TD or TDI. The correct gasket to be used depends upon the amount of piston protrusion measured before installation.
Measuring piston protrusion requires mounting a dial indicator to the block top and bringing each piston to TDC (top dead center). This measurement should be made directly above the piston pin. Observe and record the amount each piston extends above the top of the block deck. Use the highest value measured to select the correct cylinder head gasket to be used. The three different gaskets can be identified by the number of notches located on the
head gasket next to the part number.
Engine Part Number Notches Piston Protrusion
TD 028 103 383 BH 1 .036-.039 (.914-.990 mm)
TD 028 103 383 BJ 2 .040-.043 (1.106-1.092 mm)
TD 028 103 383 BK 3 .044-.047 (1.117-1.193 mm)
TDI 028 103 383 BL 1 .036-.039 (.914-.990 mm)
TDI 028 103 383 BM 2 .040-.043 (1.106-1.092 mm)
TDI 028 103 383 BN 3 .044-.047 (1.117-1.193 mm)
AERA is currently unaware of an aftermarket supplier for the above mentioned head gaskets.
The AERA Technical Committee |
| HEADS MODIFIED FOR 12MM CYL. HEAD BOLTS |
Modified Volkswagen 1.6L Diesel Engine Cylinder Heads
All Volkswagen-rebuilt 1.6L short blocks (complete with cylinder
heads) are supplied only with 12mm head bolts. AERA members
should be especially watchful for the following:
When the letter C is stamped behind the casting number on the
cylinder head, it indicates the head was modified for 12mm bolts
instead of 11mm bolts and spacers. Volkswagen part #068 103 377A
or equivalent must be placed on each bolt.
When the letter C or S is cast in the cylinder head, a 4.5mm
spacer (Volkswagen part #N 901 157 01 or equivalent) must be
used.
The AERA Technical Committee
January 1984 - TB 307
##END## |
| TIMING CHAIN REPLACEMENT ON 2.0L DOHC VIN 9A VW ENGINES |
Timing Chain Replacement On
1990-93 2.0L DOHC VIN 9A Volkswagen Engines
AERA members have reported limited information available on the timing chain for 1990-93 2.0L DOHC VIN 9A Volkswagen engines. This chain is used to keep
the two camshafts in proper sequence in the cylinder head. When cylinder head service is required, this chain is removed to access components.
During normal rebuilding processes it is common to evaluate a components condition and determine whether it may be placed back into service. To properly evaluate a component, specifications must first be obtained in orfer to compare your evaluations. However, the manufacturer of this engine has not
provided reuse specifications for this camshaft timing chain.
AERA has contacted Volkswagen of North America at their rebuilding facility and their recommendation is to replace this chain anytime it has been removed for cylinder head service. Currently, obtaining a new chain has only been successful through dealership sources with Part #077109120.
The AERA Technical Committee |
| TURBOCHARGER FAILURE DUE TO LACK OF LUBRICATION |
Turbocharger Failure Due to Lack of Lubrication On
1998-99 Volkswagen 1.8L VIN AEB Engines
The AERA Technical Committee offers the following information regarding a turbocharger failure on 1998-99 Volkswagen 1.8L VIN AEB engines. This failure may occur more often on vehicles that lack scheduled oil maintenance and/or experience continued high engine operating temperatures.
Engines that are subjected to either of the above-mentioned conditions may exhibit supply oil line coking, which can restrict or stop oil flow to the turbocharger. Lack of oil flow will eventually damage the turbocharger.
To reduce the frequency of the above condition vehicles manufactured beginning with VIN number XE000100 have a heat shield, Part #058129585B installed. These shield and oil lines, Part #05845778 are suggested to be part of failed turbochargers on engines built before the above VIN number.
The AERA Technical Committee |
