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#1
03-10-2019, 05:51 PM
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While the engine was in the car I R/R the head with the exhaust manifold detached but the intake manifold still attached. It was manageable with two people.
Main difficulty was that I made the locating dowels too long and made the head interfere with other components during installation. Like you, they were repurposed old head bolts. I cut them down further to ease the installation.
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1985 744 gle d24t 1985 745 gle d24t 
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#2
03-10-2019, 06:34 PM
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ngoma--I cut slots in the ends of the dowels to fit a flat tip screwdriver. Right now I'm trying to figure out how the coolant pump is used to adjust the timing belt tension.
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#3
03-11-2019, 12:34 PM
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Yes, that seems to be the common method for fabbing the head locating dowels. My suggestion was just to not make them too long.
Two of the mounting holes in the waterpump are slotted in an arc, which allows it to pivotally swing in and out to tension and detension the TB. Don't make it too tight. Should be able to twist the TB almost 90deg by using just a few fingers.
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1985 744 gle d24t 1985 745 gle d24t Last edited by ngoma; 03-11-2019 at 09:38 PM. Reason: Correction: Two, not one, slotted mounting holes.
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#4
03-11-2019, 04:27 PM
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Got it. I loosened the three bolts but didn't get any movement. Guess I'll figure it out when I get to that step. Now I'm fabricating a counterhold (5187) for the dampener. Does anyone know the length of the extension arm of the wrench for the center bolt (5188)?
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#5
03-11-2019, 09:26 PM
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Correction: Two of the waterpump mounting holes are slotted.
As long as you have all three bolts out, you should really remove the waterpump and replace the sealing o-ring especially if it's not recently fresh. I've had leaks from there before. PIA to get everything buttoned back up and the timing set, only to find it's leaking from that o-ring. 
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1985 744 gle d24t 1985 745 gle d24t
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#6
03-20-2019, 02:26 PM
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I now have the heat shields, injectors, new timing belt and harmonic balancer installed. The engine block is cleaned up including head bolt holes and mating surface. Now getting ready to install intake and exhaust manifolds and torque center bolt for balancer. I fabricated a counter hold, now need to make the wrench 5188.
Questions: Can't seem to find a source for the water pump O-ring. would it be ok to use RTV sealant or similar with old O-ring? I have intake gaskets, but do I also need exhaust gaskets? Does anyone know the dimensions for harmonic balancer wrench 5188? I'm most concerned with the length between the socket and hole for the torque wrench.
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#7
03-20-2019, 06:40 PM
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This is where I got the heat shields for $1.15 a piece: https://www.fcpeuro.com/products/vw-...al-068130219my
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