1993 1.9 Passat head gasket change

[Skippy594]

Hey guys, I used the search site using the search bar for a step by step walk through for a head gasket change on my 1.9 litre AAZ engine but I cant find one. Can someone please point one out or, tell me step by step how to do it? Pics would be fantastic too. I have a repair manual but it wants me to take the cam shaft out, intake and exhaust manifolds off and all that. Theres got to be an easier way, right?

Thanks in advanced,

Rick

[vanbcguy]

You CAN leave the manifolds on the head but it makes it heavy and hard to lift. You CAN leave the cam shaft in but then you can't put down the head without risk of damage to the valves.

The book you've got sounds like it has the right procedure, I assume it tells you that you need to replace the head bolts and has the proper torque sequence and tightening order.

[jhax]

http://vwts.ru/page02.html

[ORCoaster]

Skippy, the removal of the head is sooo much easier if you have all the extra parts off of it.  It is a bit more work but if you don't have a lift wrestling the head on with all the extra weight but more importantly the stuff has to align without moving the head gasket about.  Sure you can tack it down with Holomar or something like it but there is just no better way than to align it on a couple cut off bolts and just slide it down in the right place first time. 

I work up from under the back side to get the nuts on the exhaust tight and then the hex or Torx head bolts on the intake tight.  I have some stuff in the way but I don't have trouble with a 3/8 in ratchet and a couple short and medium sized extensions. 

[the caveman]

As others have said ,you can do it either with the turbo etc installed or not, but if it's just the head gasket to be changed, leave all those parts on. The head can then be removed by one person, but you will need someone strong enough to help you place the head back on so that you don't damage the new one. It has to be carefully dropped straight down onto the block so as not to scratch ot

[Skippy594]

Thanks very much for all the replies. I appreciate them. My problem has gotten deeper and now Its going to need a motor swap. I've been searching since my initial post for an AAZ but, man.... There isnt one anywhere near me for sale.

My next question I guess is, does anyone have a good AAZ for sale for a reasonable price in or around Ontario, Canada? I'm willing to take a whole car for the motor and, I'm willing to drive some distance to pick it up.

The next question I have after that is, I've heard and read around on the internet that I can swap in an AHU engine if I reuse my AAZ injection pump. Is this correct? The VW mechanic I know really well says I can only replace the AAZ with an AAZ but, again.... Everything I read online says I can swap in an AHU with my injection pump. Which is it and, if I can, whats involved in the swap?

Thanks again for all the helpful info!

[rodpaslow]

If you want an engine that will run properly a AAZ pump will not run an AHU/TDI properly as the pump needs modifications to produce the correct injection pressure, etc.  As said  many times on many questions about this, in this forum, if you want a TDI without the hassle of wiring, a Rover 200 or 300 TDI pump is the way to go. Almost a bolt on.