Little red pickup

This is a place for us to share progress on and upgrades to our vw diesels.

Moderator: Fatmobile

Fatmobile
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Posts: 7444
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa
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Re: Little red pickup

Post by Fatmobile »

If he sells the engine separate I can get the factory TD Rabbit body for $500.

I played with the injectors.
I have some mildly abrasive stuff for stropping the razor and tried using it to lap the injector needle.

Put the needle on a drill and spun it.
Tried it a few times.
I got it to chatter a little but it was still peeing too much.

So I put a new brazilian bosch insert in there.
I was wrong earlier when I said the new indian ones were junk.

The indian ones were good.
This batch of new brazilian ones don't spray as nice as they should.
It chatters nice but if I hold it right before breaking I can get it to pee.
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
2, '84 GTI projects cars
sgnimj96
Diesel Freak
Posts: 148
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

I've tried that needle in the drill trick, helped but no cigar.
Next time I mess with injectors I might try adding polishing compound on a bad one to see what it does.
It is a sham that so many of the new bosch nozzles are like that, if you need 4 - buy 5 or 6 ?
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
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Posts: 7444
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa
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Re: Little red pickup

Post by Fatmobile »

Here's picture of the old oil pan
and the cracked oil pump pickup.

Imageredpickuppandent by vwfatmobile, on Flickr

That's about where it sits in the pan.

Machine shop still has the head.
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
2, '84 GTI projects cars
sgnimj96
Diesel Freak
Posts: 148
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

I saw someone on the 300d forum talking about grinding paste or even toothpaste on the needle valve in junk injectors and it making a difference.

Dang, that cast pickup tube looked nice.
Vw didn't seem to put any thought at all into protecting mk1 diesel oil pans, guess they figured only an idiot would want to lower one so they thought is was a non-issue. At least the steel ones are pretty cheap or easy to hammer back out.
I don't think a cheap pan would have survived that blow without hemorrhaging.
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
Global Moderator
Posts: 7444
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa
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Re: Little red pickup

Post by Fatmobile »

Yeah, I'm glad I had another pickup tube for one with the early metal pickup.

Head is done.
I picked it up yesterday.
Some parts to clean then it goes back together with new seals.
They did a great job, the valves have almost no side-to-side movement.

I gave them a new 12mm headbolt so they would know what size to make the bolt holes.
I forgot to grab it with the head,.. should have given them an old one.
I'll pick it up next trip into town.

Off topic side post:
Now that the MK2 MTDI is running good, and I have my first Mk4 project (2000 Jetta) running
it might be time to take the old VNT-15 Rabbit (Pa)Tina off the road.
There is oil in the coolant, an oil leak on the front of the engine
and it needs some body work.
I want to build stainless rocker panels for her, to match the stainless floor pans.

It'll be nice to have my hoop building work space back.
I was tired of waiting and did the MK4 steering rack swap outside.
1 week of really nice weather for that job.

I might also be getting my own Rabbit pickup project after this one is done.
He keeps making the deal better.
Now it's $1800 with all the parts it will take to get it on the road,..
and a MK4 panzer plate for protecting the underside of a MK4 TDI.
And maybe I can get a nice topper for it.
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
2, '84 GTI projects cars
sgnimj96
Diesel Freak
Posts: 148
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

Stainless floor pans? wow

Mark 4's are the new mk1's, everybody wants them because they're "simple" :lol:
I like the days when the check engine light was just a timer.

btw, great project
I don't know what's going on with this forum, but kinda get impression that people think that
more than 2 people here might be some kind of conspiracy... :roll:
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
Global Moderator
Posts: 7444
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa
Contact:

Re: Little red pickup

Post by Fatmobile »

Yeah, I should probably link this post to the vortex or something.

Got to putting it together today.
The shop even put the valve seals in.

Not happy with the cam clearances.
Most are at 2 thou of an inch.

2 is the max,.. they should be 1 thou or less.
I'm rubbing the cap flats with sandpaper on glass until they are tighter,..
that's going to slow things down a little.

The headbolt was in a bag, along with some injector heat shields.

I agree the Mk4s have the reputation of the Mk1.
Easy to work on, fuel efficient and reliable.
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
2, '84 GTI projects cars
Fatmobile
Global Moderator
Posts: 7444
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa
Contact:

Re: Little red pickup

Post by Fatmobile »

Had to grind down the washers.
Took 40 thou off the width.
From .9" to .860".

Valve cover set screws blue loctited in.
Getting ready for the rubber gasket.
Hard grey sealant was chipped from the valve cover so it's clean and ready.

#1 cam cap has a light smear of formagasket 2 on the flat. It never hardens.
Since it's metal on metal
oil can seep out from around the cam seal if these surfaces aren't sealed.
I always had an oil leak around the cam until Andrew taught me this trick.

Picked up the new duraterms at the PO box today.
So those are in.

Both waternecks were rough
needed to be rubbed on sandpaper on glass.
Front one is on.

I want to just put the old injectors back in,
they spray so nice.
But they look like crap.
The one I did open had bunches of the same crap inside it.
I want this to be reliable and injectors are important.
So I'm going to risk having them leak and having to repeatedly take them apart and lapp sealing surfaces until they don't.

Head is on and torqued down.
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
2, '84 GTI projects cars
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