Well, after changing out the head gasket it appears that it did not work out so well perhaps because of the gasser head bolts. I have an 85 jetta non-turbo and found a receipt showing a used 1981 motor was installed it 2003. I pulled the head and there was major corrosion on 2 or 3 of the coolant passages in the head which was allowing pressure to enter the coolant systems and slight steam out of the exhaust. Ran great and started very easy. I had the head professionally welded up and resurfaced and installed a german head gasket and t seemed fine until I came to a large hill this morning and it started getting hot so I pulled over. Could see coolant sprayed around underneath the reservoir and I checked the oil fill cap on the valve cover are there were a few chocholate shake bubbles on there but the oil was not chocholate shake. I really like this little car and am willing to do whatever needed to have a reliable diesel commuter car so I am going to use the correct bolts this time and redo the head gasket (which having just done it should go rather quickly) and if that does not work, I am going to get a longblock for it so I came across qualitygermanautoparts and saw that they have used motors listed on the website.
Did you come to the conclusion that the head was bad? I am going to retry the HG replacement but check the level of the head on a granite check plate and obviously use the correct headbolts this time. If it fails again I am just going to fork out the $$$ to get a proper head or entire rebuilt motor. I hate not being able to drive this car becuase it just feels really nice to drive and know that you are much more fuel efficient that all the other cars around you. In the meantime I have to commute with my 93 F350 7.3 diesel which is 14-15 mpg!!!!!! Do you have any reccommendations for quality head gaskets and/or heads and motors?