mk3 1.9 TD Head gasket

[ckelly0172]

Hello all from a newbie.....
It seems my head g has failed, or so 2 mechanics have told me. I was quoted £250 just to have the head removed and see if there was any further damage adn £350 to replace the gasket if no further work was required!!!
So i thought I'd have a go myself!
The haynes manual mentions having a camshaft locking tool and a locking pin btu I can't seem to track them down anywhere. Does any know where I could pick them up? or preferably if there is anything else i could use instead?
Many thanks

[adamss24]

Go to a Euro Car Parts and see one of the camshaft locking kits from SEALEY. Also get a genuine cam belt + belt tensioners and a water pump. Did the car overheated very bad, is it difficult to start, smokes on idling ?

[ckelly0172]

It has been losing a little coolant for a while then the retaing clip that holds the bottom hose to the stat housing must hve failed as the hose was disconnect, thus all the coolant drained off. Now the car will start when cold but not when warmed up, its lost power and smokes like a bugger when started. Also if the expansion tank cover is off and the engine is revved, coolant is pouring out of the tank, but not on idle.
Is is worthwile replacing the water pump also?
Is a locking kit definately required, or can you just ensure that there woudld be no movement in cam, crank and injector?
Cheers

[thefoolmccool]

I have changed two head gaskets now on D Golf Mk3s. It gets easier every time!

You definitely need a looking pin for the injector pump sprocket and a locking plate for the cam shaft. Impossible without this. The cam shaft sprocket has to be removed to release the backing plate of the timing case.

This locking plate can be made up by yourself using the description listed in the haynes manual. But it must be made quite accurately as feeler gauges have to be used at either side to line the plate and camshaft up. The tolerances are so tight on a Diesel engine. This is the only way of timing the engine so there isn't much room for error.

As for the injector pump sprocket, depending on what size the locking pin hole is, you may be able to use a small drill bit of the correct diameter or if it is of the larger type, you will need the proper timing pin.

You will also need to make a tool to stop the camshaft sprocket moving when loosening the retaining bolt. Again this can be made using the specifications in the haynes manual and is really a crude device able to be made in about 15 mins. You will also need a large selection of sockets and spanners from 8mm to 22mm. A 6mm (I think) hex socket is needed to get the bottom pulley off the crankshaft and the inlet manifold bolts off.

If you want to buy a VW specific timing tool kit it will cost you about £100 new or you might be able to get one on eBay. This is where I sold the kit I used. This includes all of the above mentioned tools.

The head gasket must be matched to the gasket that is already on the engine. Thsese are identifiable by small notch cut out on the front of the head.

This is a difficult task and there are various things that can (and probally will) go wrong. Such as exhaust studs shearing off etc etc. But if you take your time and use plenty of WD-40 it is possible. It took me about 8 hours the first time and 5 the second.

Do replace the timing belt and tensioner prefarablly using VAG (about £80)parts but don't worry about the water pump, it runs on the ancillary flat belt, so wont cause failure if it siezes.

The whole front bumper, slam panel, radiator assembly is removable quite easily and I would advise this to be done. If the haynes manual is used and care taken and the correct tools used this job can be done. Although I have never tackled a TD just a D engine I believe these two engines are very similar and all the above instructions are accurate.

Any other questons you can email me: thefoolmccool@hotmail.com

[ckelly0172]

Hi mccool, many thanks for a detailed response. I was hoping to do it without the VAG tools but since I aint done a head removal since I was 14 on marina... its probably best i do. Seen the kit fro £80 on ebay or 100 from GSF.Did oyu get a good price for yours when you sold it on?
If I get stuck part way through, woudl you mind receiving an email or 2 picking your brains?????
Thanks again
Craig

[thefoolmccool]

Yeah no problem will try and answer any problems you have. As for the kit I got about £75 for it on ebay. This was a 15 piece kit though so it wasn't as specialised and in fact could be used in petrol engines as well. So it had a few applications

[ckelly0172]

Hi mccool,

Struck a problem, i've sent you an email, be grateful of a bit of advice.
Cheers

[thefoolmccool]

Hi,

Any developments, how are you getting on

[ckelly0172]

Hi,

Goings been a bit slow, been on nights til yesterday. Nearly got it all back together, just the altenator ad power steering pump, oil and coolant to add.
A bit worried about the timing, is there any way of checking the injection timing?
Also, after I cleaned the piston heads i noticed slight valve markings in the crowns, is that normal?
Cheers
Craig

[adamss24]

Hi, looks like your car had a broken cambelt at some point as there shouldnt be contact between pistons and valves. All tdi engines are interference type and when cambelts breaks, valves stay open while the pistons still travels up and down because of drive transmited trough transmission. Some guy in USA machined had some custom made pistons with a deeper recess to avoid interference and ended up with a average compression of ratio of 12:1 and started asking on forums why his car lacks performance(i wonder how it even started with that compression !!!). I bet its just a made up story.