~My 91 GLI to 1.6TD conversion build up~

[53 willys]

Not exactly what I was saying.  What I meant was that I would have more faith in it if the large hole in the metal gasket was made even bigger so that the perimeter of it extended around the coolant channel in the head and block.  Then if the plug was made to fit closely it would be a complete seal of the coolant hole rather than have the seam of the two gaskets run through the middle of the coolant hole.  I don't know if there is enough gasket between the coolant channel and the cylinder for that, tho.

Andrew

yes VERY good idea....I will have to see what I can do when I get the gasket in hand....

[53 willys]

well I retorqued it today...this is what I did

block heater was one all night so everything was warm...
torqued studs to=90ftlbs(some pretty loose studs I might add)
then I warmed the engine to op temp..
retorqued studs=95ftlbs
then went back trough the pattern and did
100ftlbs... :shock:


took it for a drive I railed on it pretty hard!! it ran GREAT!! took it to 20psi and she was just a shining!!!
   

got home never got hot at all....I thought I had it until I popped the hood and saw coolant still seeping from the head and block...(right under the top radiator hose outlet...

guess I will pull the head and wait for my MLS...least then I can inspect it all and make sure nothing else is wrong..


NOTE If a guy is using fiber gasket I would recommend a retorque after a day or so.....I wounder if I would have retorqued sooner if it would have held??

[Quantum TD]

Hmmm.

So, it didn't puke out the coolant reservoir???

I'd say that you're almost there, or you've solved the problem

Are you sure it's leaking out of the HG, or is it just running out of the coolant flange gasket and dribbling onto the HG where the notched tab is? I had that problem on a recent rebuilt. The fiber gasket was so ***ty, it seeped coolant out and it collected on the HG tab. I thought the HG was blown, despite the fact that there were no symptoms of a blow out.

I see your car has the aluminum front flange, some of which used that fiber gasket. I'd look into it before/while you're getting ready to pull the head for the HG. Basically, I'm trying to be upbeat here, but also relying on the evidnce. If you ran the car hard, and it didn't force coolant out of the chamber, then it wasn't bulding pressure via lost compression into the cooling system. So, you seem to have resolved that issue. That means at least PART of the HG is sealing properly after the retorque.

I guess it could still leak OUT of the HG, but the flange is a convenient place to look in order to rule out all possible option while you figure out how you'll actually mount the MLS gasket.

Again. good luck!

[53 willys]

well it did puke some coolant from the looks of it...but it seems like it was less then before....I think it is still leaking slightly??

yeah I checked the top hose flange a few times to make sure it was not running down...the flange is dry as a bone
o well....least HG on these engines are easy! worst part will be getting to the turbo bolts!
maybe I will get some studs for that while I am at it?.?.?.?

[53 willys]

well I got the head off.....the hg was blown in a few spots!!!!!! :cry:  :shock:
dang fiber gaskets!!!
now I'm waiting for myke to call me back so I can get a MLS for it!
dang fiber!!!

[TurboJ]

Yeah, those fiber gaskets are donkey sh*t and nobody should use them  :cry:  Surprisingly mine was intact, though, when I opened up my 1.6.

[53 willys]

Yeah, those fiber gaskets are donkey sh*t and nobody should use them  :cry:  Surprisingly mine was intact, though, when I opened up my 1.6.

yeah I knew they are crappy...but lots of guys have had some ok luck...least I thought.....I was worried about the MLS mod...but if I cant even get 200 miles on my car and the HG is blown in at least 2 spots..then I dont wanna mess with it, I will take my chances with the MLS mod...
talked to Myke my gasket is on it's way!

[AudiVWguy]

Heres what the plug looks like that I showed you earlier. This is two years later and about 30K on it so far.Currently I am installing a Performance Diesel SuperPump and new injectors. As you can see the gasket sealer has worn away from washing the engine, but still no leaks.

[53 willys]

Heres what the plug looks like that I showed you earlier. This is two years later and about 30K on it so far.Currently I am installing a Performance Diesel SuperPump and new injectors. As you can see the gasket sealer has worn away from washing the engine, but still no leaks.

thanks for the pic buddy!!!! and I hope you dont mind that I posted pics of your mod...I feel it's good info to get out there..it seems like a great way to mod/run the MLS gasket...


Is that coolant seeping in this pic? kinda looks like green coolant??

[AudiVWguy]

Nope, being obsessive-compulsive every seventh time I open the hood.

[53 willys]

well I got some more parts to install...
I bought all new control arm bushings to rebuild the arms
I read about lots of guys who had poly bushing fail pretty fast...i will be driving this car everyday and I dont want to tear the arms off every other year to replace poly arm bushings so I went with the R32/Audi TT rears and Stock fronts....
I also picked up some ball joints, tie-rod ends, new hydro rear engine mount and I also picked up a poly sway bar bushings....I was thinking the sway bars would not wear out as fast as arm bushings?? so I thought I would try them...I may just go back to stock if these dont hold up.
since I was paying shipping I figured I would grab some of the rear axle bushings inserts....they are cheap so I figured I would give them a try...


finally found a Turbo Volvo at the wrecking yard with a oil cooler and T-stat sandwich adapter....I picked it up for $15..it came with the stock lines cooler and T-stat adapter plate.
it had some oil on it so I pressure checked it last night to make sure it was not leaking...it passed the test...no leaks



maybe I will get lucky and my HG will show up today so I can install it this weekend!....fingers crossed

[TurboJ]

Looking good!

[53 willys]

thought I would post a couple pics of my waterjacket mod...(sorry for the low quality..I just snapped the pics with my phone)
taped off the head to keep any shavings out..I just used green painters tape..




tape removed...1/8" holes drilled..


since I had the head off I decided to peen the prechambers some more...I only penned them in 2 spots the first time..but I was still kinda scared they might drop so I gave them some more peens...


shot with the 1.9AAZ MLS gasket on...I'm not using the 1.9AAZ now tho..I'm getting a custom made MLS gasket for the 1.6 CY,ME,MF




now I gotta wait 2-3 weeks while my gasket is made

 

[zukgod1]

Well at least when you do get it back together you know it will be good.

I'm concidering having you get me a 1 notcher so I have one for next time....

[53 willys]

Well at least when you do get it back together you know it will be good.

I'm concidering having you get me a 1 notcher so I have one for next time....

wait I thought you needed 3 notchers?? on your engine?
is this for your spare engine??