$400 USD/85 Jetta 1.6TD/My Rebuild Journey

[nicknack2]

Guys, here you will find some pictures of the intake manifold and the turbo on the exhaust side.

[nicknack2]

I'm sure Hagar's turbo does not look anything like the one above, Hagar if you get around to it, could you post pictures of your turbo, after all the "hillbilly TUNING" your exhaust must be lean w/o much soth, your turbo must be looking nice and clean!

[nicknack2]

two more pics my engine on my "hillbilly" engine stand and my intershaft bearing/ 1/2 water pump with broken studs..


engine on "hillbilly" stand!

[nicknack2]

All accesories have been remove from the engine, Other than the crankshaft sproket and clutch stuff, all Head bolts are off minus one, the head on the torx got striped, Im still thinkering on how to remove the last head bolt, so I can separate the head from the engine and proceed with the lower end disassembly and finally send the engine to the machinist.
here are some pics of the cam.
#s 1-2 Lobes


#s 3-4 Lobes


Full Cam

[nicknack2]

here 3 more pics of engine and head.
Front

Rear

Mechanical Head

[CoolAirVw]

all Head bolts are off minus one, the head on the torx got striped, Im still thinkering on how to remove the last head bolt

Just use a drill bit the same size as the shaft of the bolt you probably have 12mm head bolts???? Drill into the head of the bolt till the head of the bolt falls off then after you get the head off use vise grips on the bolt or weld a nut on it or use a stud extracter.


OOOPS! other pics showed you got the head off. I'll leave above info up for future generations. How did ya end up getting the bolt out?

[nicknack2]

Coolairvw, the head is not off, the picture was taken from the top, the engine still attached to it

[Wolfsbur]

You posted "the head on the torx got striped"

Did you use a Torx or triple square to remove the head bolts?



The pump bolts have always busted for me as well--on VW gassers too. I spend the few extra dollars for the pump AND housing.

Keep at it!

[nicknack2]

I meant to say the head bolts(which are torx) came all out but one, which I striped, I used torx to remove them(try any ways) I dont think they are triple square are they??

[CoolAirVw]

I meant to say the head bolts(which are torx) came all out but one, which I striped, I used torx to remove them(try any ways) I dont think they are triple square are they??

Mine are triple square.

[Fatmobile]

Mine too

[nicknack2]

can you guys post a pictures of the head bolts??? could I be wrong?, but all the other bolts came off with the Torx, I tried drilling it all day today with no luck, I think that I just going to take it to the machine shop and have them remove the last bolt and split the engine from the head...

[nicknack2]

can u guys post/take a picture of the triple square tool, that way I'll know what u guys talking abouty/what the triple square tool looks like.

[Wolfsbur]

http://en.wikipedia.org/wiki/Triple_Square_screws

This will give you a good idea of what they look like compared to Torx.

The 12 point (or Triple Square) is what VW used before Poly-Drive and after internal Hex Head for head bolts.

12 point is also used on your inner CV to trans flange bolts.

[nicknack2]

Guys, no wonder why I striped some of the CV bolts too!, I have been using a Torx it only has six points... , I think that my best bet is to weld a 15 or even a 17 MM bolt to the head of the stripped head bolt and remove it that way