Technical Stuff
Here is a list of what was checked and obtained:
Settings:
Injection pump checked at 1.03mm.
Piston height above block (inches):
| #1 | #2 | #3 | #4 |
| .033 | .036 | .035 | .035 |
Parts:
I purchased most of my used and new items at Small Car Connection: http://www.chrisvolkswagen.com
A used piston and rod for #1 cylinder
Piston rings: Cofap (std. Size) P/N ND.6184 (VW # 068 198 151 CBR)
Rod Bearings: Kolbenshmidt P/N PL-87 464 600 STD (VW 068 198 501BR)
Head gasket: 3 notches Elring P/N 323.757
Head Bolts: 12 mm VW P/N 068 103 384A
Timing Belt: Contitech Timing Belt
Tensioner: SKF P/N VKM11010 (VW 068 109 243F)
V-belts: Contitech AVX 10x965 & AVX 10x740
Thermostat: Wahler P/N 143 0640 (VW 056 121 113A) 80C
Air Filter: Autobahn P/N 069 129 620
Oil Filter: Mahle
Glow plugs: Bosch P/N 80010 (VW 0 250 201 032)
Front Grill
Remanufactured 12mm mechanical head from Jack Ewald: http://vwdieselparts.com
Tools:
¼” drive x 7/16 deep socket 12 point (Craftsman) – used for the injection pump lock pin.
12mm x 1.75 Tap – to clean the head bolt threads.
I was going to use the used bolts to clean up the threads. But Nate (vwdiesel listserve) warned that if any oil was left in the bolt holes, a bolt tightened down to the bottom of threads could cause the block to crack. The bolt would act like a ram and the oil like hydraulic fluid exerting a lot of pressure on the block. I opted to spend the $5 for a tap which has relief’s cut into it to prevent debris and oil from being trapped below the threads.
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Last updated: 18 April 2011