1981 1.6D rabbit freshening

[bigger daddy]

The headis re-assembled and keepers were easier than I thought, cleaned the deck off and removed a few more brackets in prep for taking it out and cleaning all the gunk off it. I also chased all but 2 bolt holes in the deck in prep for the studs

[bigger daddy]

Did a little cleaning today.....holy cow!

Before



After



Looks like a completely different car!

[bigger daddy]

Need to know the torque specs for ARP studs on the engine....anybody out there got them

[bscutt]

I have seen them referred to on this forum but didn't write it down. :~(
I will have the same issue when I get around to putting the head back on my 81 1.6. Have you tried a few searches for old postings?

[bscutt]

try this link: looks like 80 ft-lbs using their lube

viewtopic.php?f=8&t=8876&hilit=+11mm+stud+torque


If I got the link right, this is from member Green79

I have about 200 miles on the rebuild now. No idea on mileage yet.

I double checked the ARP head stud torque values after reading some info on another forum, and found out that ARP put the wrong instructions in the box. I had only torqued mine down to 60 ft-lb, but it should've be 80 ft-lb (with ARP moly lube) ! With 30 wt oil, the torque is 85 ft-lb. ARP has no specs for VW diesels with the 11mm studs, so these are the gasser values. Luckily, I had no headgasket leak yet.

[surfcam]

I'm not say 85ft-lbs won't work but I would be careful about over torquing. VW has designed that torque with the gasket ,head and block in mind not APR. What can happen is the gasket can get crushed around the stud. Because the gasket isn't crushed as much between the studs it's like a teater todder effect on the head. There will be less force at the midway point between the studs with over torquing than the proper torque if the gasket crushes. VW may have over design their head and gasket or maybe not? It would be interesting to know just how much torque people are getting away with.

[Fatmobile]

Hard to believe that beautiful tan engine bay was under all that black
stuff.

Feels like I should ask what product you used

[bigger daddy]

I used a combo of 2 cleaners Greased Lightning and Simple Green an 1600PSI power washer and a toothbrush for those hard to get at spots. Lots of elbow grease and it came out awesome

[bigger daddy]

did a little work on the engine, and installed the studs.


and put the head on. I also need a new IM shaft pulley as this one is breaking all around the edges.



more later

[Fatmobile]

Pic of the I-shaft pully.
Later on the factory ground the lips off even with the surface.

[bigger daddy]

If that is the case I can salvage this one, since its the lips that are chipping off

[bigger daddy]

When putting the flywheel on a complete longblock, like I will be doing this week when I do clutch ,PP etc and mate the tranny to it. Is there only one way it will go on so as not to mess up timing or TDC on the flywheel? I have not done a diesel before and would be happy to not have any surprises. TIA! BTW it is a diesel flywheel

[tylernt]

When putting the flywheel on a complete longblock, like I will be doing this week when I do clutch ,PP etc and mate the tranny to it. Is there only one way it will go on so as not to mess up timing or TDC on the flywheel? I have not done a diesel before and would be happy to not have any surprises. TIA! BTW it is a diesel flywheel

The PP will only go on the crankshaft one way (bolt holes irregularly spaced). However, the flywheel can be put on wrong. There are alignment dowels in the flywheel that match up to holes in the PP, but it's easy to mess them up (yes, I've done it). You can rotate the crankshaft to TDC and then verify the flywheel timing mark is pointing upwards (hard to tell exactly, because the pointer is on the transmission which you haven't installed yet), but this plus paying close attention to the alignment dowels should get you in the right spot.

[bigger daddy]

cant tell if its at TDC as the head is on (no camshaft so valves are closed) I will pay attention to the dowel pins

[tylernt]

cant tell if its at TDC as the head is on (no camshaft so valves are closed) I will pay attention to the dowel pins

If your injectors are out, a thin flexible wire can be poked down in beyond the prechamber to feel where the piston top is.