Head questions

[carraca]

Hi,
this is my first post after introducing myself.
I found a lot of answers in the forum, but I still have a couple of questions.

Well, my engine is a 1.6TD, code CY, and it goes into a Passat 32b (quantum).

I noticed compression going to the cooling circuit, so I decided to check the head/gasket.

There was some pitting in the water passages and the machinist soldered it.
As you can see from the picture, after soldering, the water passages became narrower (right side in the pic). Should I enlage them to their original size with a dremel?

Also, the head gasket blocked two water passages (the ones in the middle, inyector's side). Is that ok?

Thanks!!



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[carraca]

Any input?

[sparkoid]

First of all welcome to the forum.  I'm a fellow newb, so get some additional opinions and take an average. 

If that were my cylinder head, I would indeed reopen those coolant holes to their original sizes.  First of all, these little engines are not very tolerant of overheating, especially the c. head.  With your restricted openings, you will get less flow through the head, and possibly run hotter as a result.  Second, those excess metal ridges may induce turbulence in the flow, which is probably not a good thing.

You should be able to eyeball the original opening dimensions by slowly grinding out the ridges until you see the end of the weld bead further in the opening.  Or, make a template: take a piece of paper, tape it down to the *block*, rub lightly around the coolant and the bolt holes to emboss the paper slightly.   Cut the embossed areas out with a razor blade, line it up on your head (remember the side you rubbed on will go against the head), and use a marker to highlight the excess.  Hope this helps.

[R.O.R-2.0]

leave the passages small like that, then it will take much longer for them to corrode away next time..

i see no problems with that..

[carraca]

Hi,
thanks for the replies!

I have already installed the head.
After further inspection, I realized that the water passages are a lot smaller in the head gasket than in the head it self. I am not very familiar with water cooled engines, but that doesn't make any sense to me. Neither the fact that both old and new gaskets blocked two water passages.
Anyway, I transfered the gasket patern to the head and opened them only to the size of the head gasket holes (which are in fact a lot smaller than they were before soldering).

Now I'm stuck with the crankshaft sproket bolt. I have a quite big oil leak and my suspects are against the crank seal. No luck until the moment with my not-big-enough cheater bar. Keep triying...

Is this bolt reusable? I know in that later TDIs it is a one-use bolt.

regards,
Marcos

[Blocksmith]

Yeah, pretty sure it's a one-time use bolt.

[damac]

my 85 jetta bently manual doesn't say the crank bolt is a one time use?  i think the newer ones are though?

i sure hope it isn't because i have been driving on an engine daily with the old bolt/old torque for months now

[pointynoggin]

If the torque spec added a portion of a turn after a torque value than you need to replace the bolt.  It will have been deformed during the first install and every install after the bolt will be weaker and more brittle.

[theman53]

The bentley I have most certainly makes it clear. IIRC it says if you have a 6 point bolt, you use a certain torque and it is reusable. If you have the 12pt bolt you use a different torque and 1/4 turn and it is not reusable.

This is from memory, but I am pretty sure it is accurate. The new stretch type is supposed to hold better, so I would buy one and use that either way.

[carraca]

Tranks for the replies,
I have the 6 point bolt. I've just received my bentley and it says "torque to 200Nm". No angular tightening and it doesn't mention bolt replacement.
Time to look for such a torque wrench...

[R.O.R-2.0]

Tranks for the replies,
I have the 6 point bolt. I've just received my bentley and it says "torque to 200Nm". No angular tightening and it doesn't mention bolt replacement.
Time to look for such a torque wrench...

the stock 6pt bolts are said to be weaker..

dunno how true that is tho..