|
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 |
|
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## |
|
CYLINDER HEAD CRACKS ON 2.8L AAA ENGINES |
Cylinder Head Cracks On
1993-2001 Volkswagen 2.8L VIN AAA Engines
The AERA Technical Committee offers the following information regarding cylinder head cracks on 1993-2001 Volkswagen 2.8L VIN AAA engines. Visible cracks in the cylinder head combustion chamber have been reported during inspection on this engine. Those cracks reported are located between valve seats or between valve seats and spark plug threads.
It has been determined that those cracks are insignificant to the service life of the head if they do not exceed .020 (.500 mm) in width. It is advised that the cylinder head be pressure tested to confirm the cracks do not allow coolant or combustion leakage. If the crack/s are wider than the amount stated above, the cylinder head should be repaired by welding those cracks before returning to service.
The AERA Technical Committee |
|
COMPONENT REPLACEMENT CAUTION ON VOLKSWAGEN ENGINES |
Engine/Component Replacement Caution For
All 1990-2004 Volkswagen Engines
The AERA Technical Committee offers the following information regarding engine/component replacement on all 1990-2004 Volkswagen engines. This information should be considered anytime the cylinder head or block requires service work.
It has been reported that engine damage has occurred after installation of an engine into the vehicle. This includes a long block assembly and service work to the cylinder head.
Engine damage may be caused by debris from the previous damaged engine lodged in assemblies, which are transferred from the damaged engine to the replacement or assembled engine.
If the original engine fails and pieces of metal (debris) are distributed or ingested throughout the engine, some debris may end up in the intake manifold and become lodged there. Those pieces, if not removed, can remain stationary for an unknown period of time after the engine is restarted.
During engine replacement or reassembly, when parts must be transferred from a damaged engine to a replacement engine it is imperative to clean all the associated parts. The parts include; intake manifolds, turbochargers, hoses, fittings oil lines & etc. They must be checked and cleaned for contamination or debris from the damaged engine.
This cleaning caution is especially important to do in V6 or VR6 engines with variable intake manifolds where debris can become lodged in the inner parts of the manifold until the manifold port changes length, at which time the debris may loosen and travel into the engine.
CAUTION! Engine damage caused by failure to clean and remove debris from assemblies that are transferred to a replacement/reassembled engine will not be covered by warranty.
The AERA Technical Committee |
|
CYLINDER HEAD CRACKS ON GAS & DIESEL ENG. |
Cylinder Head Cracks On
Volkswagen Gas & Diesel Engines
When reconditioning cylinder heads for Volkswagen gas and diesel engines, be sure to look for cracks between the valve seats or between the valve seats and the spark plug hole.
Volkswagen reported that if the cracks are no larger than .5mm (019), the head can be reused without reducing engine performance.
Cracks in the spark plug hole cannot be any deeper than the first
coil of the threads.
The AERA Technical Committee |
|
NEW CYLINDER LINER O-RINGS |
New Cylinder Liner O-Ring Seals On
Cummins NH/NT 6 Cylinder Engines
Cummins Engine Company has released new O-ring seals for the cylinder liners in NH/NT 6 cylinder engines. The new seals are made of an EP material and have a smaller diameter cross-section.
The new seal replaces both the old center seal #3008998 and the old lower seal #183049. The new seal carries Cummins part #3032874 and is black in color with one blue dot.
The new O-ring seals are not to be intermixed with the former seals on the same liner. Cylinder liner deformation will result. You can use the former seals and new seals in the same engine as long as they are used in the correct combinations on each liner. The illustration below shows the correct combinations.
The AERA Technical Committee |
|
OIL IN COOLANT |
Oil in Cooling System on
VW 1.5L & 1.6L Diesel Engines
AERA members have reported instances of engine oil in the cooling system on VW 1.5L diesel engines. According to AERA sources, the problem is related to a crack in the cylinder head bolt hole located near the oil gallery feeding the cylinder head.
The oil feed gallery in the block is located on one side of the center head bolt hole and a coolant jacket is on the opposite side of the bolt hole. Pressurized engine oil is diverted through a slot in the head gasket and is feed up the side of the head bolt to the cylinder head. The oil also follows the bolt back down to the bottom of the bolt hole. Should the crack in the head bolt hole extend to the coolant jacket, oil can mix with engine coolant.
This problem is generally found on engines equipped with 11mm head bolt holes. Later design engines utilize 12mm head bolts and do not exhibit this defect. At the time of this writing no successful repair procedure is available.
The AERA Technical Committee |
