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: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

One step forward,..
The head has an M at the end of the part number.
I thought that meant it was from an '85 or'86 VW diesel.
Not so.
One step back.
I tried to put the 12mm headbolts through the holes.
Some, they would fit, tightly.
Some, they wouldn't go through at all.
It's an 11mm head. So the 12mm headbolt washers won't fit down in their space either.

I took it to the machine shop today.
He doesn't think he can machine the larger washer space.
Also says it's going to be 3 weeks before he can even look at it.
I might try a different machine shop for the washer lands.
Maybe use one of my adjustable reamers and/or the drill press to make the holes bigger.

Probably a good thing the head needed taken apart.
Looks like the exhaust valve guides are going to need replaced.
The intake valves are tight.
While/since it's all apart;
might as well get a couple new guides, seals and maybe valves.

Meanwhile on the other end of the engine:
I also got the transaxle cleaned.
The clutch kit has arrived.
So I can work on that.

Have to fix the steering rack rattle with a delron bushing before thee engine goes back in.
Pump also needs resealed.

Then if the head isn't done I can put another head on it just to get the engine installed.
So there is some other stuff I can do but not a months worth.
I might do the machining myself just to get it done faster.

The engine I'm using has all the guts and head from my TD engine that developed an external crack and leaked oil.
Since it was my engine, I drilled the 6 extra holes in the block, head and gasket.
"Steam" vents near the corners of the cylinders, I'll post a pic but it's just like the 1.9s have.
So when I put my head on this engine I drilled the holes to match the head.
I don't want to drill these holes in someone elses head.
Just scared to mess with a head that's in such good shape and belongs to someone else.
So this engine won't have the steam vent upgrade.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

And the clutch is going to need surfaced.
Both the machine shops that used to do this for me are closed.
I'll have to check the few remaining.

Because of the inside corner it's more difficult that other flat flywheels.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

Found a shop that even pulled a jig out for a VW rabbit clutch.
Hadn't used it in awhile.
Been awhile but I used to get it done for $40 or $50.
This new shop wants $95 but they said it will be done tomorrow with a diamond grinder.
I might bring the head to them and see if they can do it.
So I can work on the clutch/trany/pump/steering rack.
While they work on the head.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

This has the old FN trany.
Doesn't have the green seal holder.
I've been reading on the vortex about people having a hard time finding the fat output flange seals.
And when they do they are $16 plus shipping.
I've been wondering what I would do with all of mine.
I must have enough for 4 cars.
So this one is getting new flange seals.
One was leaking badly, the old seals didn't leave a bad grove where the seal rides
that was good to see.
The stash of parts didn't have a mainshaft seal in it
but there were a couple pushrod tube seals and bushings.
Those are swapped, new clutch release bearing came with the set
along with a new end cap.
I kept the green VW endcap,
it's not rusty but it's not pretty and the guys on the vortex like original ones with the VW on them instead of some chinese symbol.
Maybe he'll want to repaint it and use it.

One flange seal replaced.
I need to drain the trany fluid.
I tipped it and some came out the vent hole.
It looked red,.. I thought someone loved it enough to use Redline in it.
On second look it's redish brown and just old.
The machine shop got the flywheel done and the guy paid them.
I'll pick it up tomorrow and drop the head off.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
sgnimj96
Turbo Charger
Posts: 259
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

A 020 rebuilder told me those early 80's gearbox's were the best for not getting SMS, but main bearings are NLA.
Maybe because they never wear out. :)
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

That's good news about the old tranys.
I think up to a point they were made from magnesium instead of aluminum.
I don't think they have as much limited slip as the later ones.
One wheel seems to spin easier.

I got the motor mount from parts geek, it was the weak upside down man one instead of the HD one.
Last time I dealt with them, trying to buy a heater core.
They sent me one for a big block GM vehicle.
I sent a picture, it was obviously the wrong one.
SO they sent me another one,.. for a big block GM, now I have 2 GM heater cores, ha.
They didn't make me send them back and gave me a refund.
Hope it goes that well this time.
I'll try carid for the right part.
I hate to use good parts from my stash before I know I can replace them with the same part.
I found one of those upside down mounts in my stash too,
I should have filled it with the leftover windshield urethane last windshield I did but forgot I had it.
Next time...

Here's the brackets attached:
Image
I like to put all these together at the same time so they all sit well with each other.
See my HD motor mount,.. and the 6 extra "steam vent" holes in the block.
This was a good engine to rebuild. It didn't die from a broken timing belt or over heat.
They put a new head on it but didn't adjust the valves right and one exhaust hung open.
Image
From an '84 four door Rabbit.

Some sludge in the trany when I pulled the green cap:
Image
The fluid was a little dark and smelly with some sparkle to it.
It's not near as bad as some I've seen but the fluid got drained.

Trany is all cleaned up with nice new green seals:
Image
Always a nice picture to see.

And the clutch stuff all machined, new and ready:
Imageredpickupclutch by vwfatmobile, on Flickr
The pressure plate fit very tight. I sanded the crank and pressure plate but it had to be drawn on with the bolts.
Caught myself saying, "I wouldn't want to be the guy who has to take that off".

Transaxle is all bolted up now and head is at the machine shop.
The delrin steering rack bushing is probably in my P.O. Box.
I have an injection pump seal set and ordered the cold start bushings from the dealership.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

Got the steering rack bushing in.
So I can set the engine in while waiting for the head to get done.

I had an injection pump seal set that I had been robbing parts from.
As I took the parts I ordered a few extra of those separately.
So I was able to reseal the pump with this partial seal set.
Except for the mainshaft seal, I didn't have any of those in the stash.
I'll head up and get some extras from the local bosch guy.
He's the person who sent this pickup here so he got thanked when I ordered parts.

Next time I'll have a whole set ready.
Including the cold start lever bushings I ordered from the VW dealership.

Taking a quick look at one of the injectors showed it was eroded around the tip.
I'll look them all over and test them on the old kent-moore injector tester.
But it look really worn, I don't expect a good spray pattern.
Might need to install new nozzles and set the pressures.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
sgnimj96
Turbo Charger
Posts: 259
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

wow, new cold start bushings - nice. I didn't know there was such a thing, they're always gone. Thought was just a silly design for that thing to be loose.
Good thing they didn't put me running the star trek transporter.
.
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

Right, and the bosch guy doesn't know what I'm talking about.
VW dealership is the only place I can find those bushings.

I got the engine bolted back in with 3 engine mounts,
both ends and the rear.
Axles are hooked up,
wheels are on and it's back on the ground.

The head is still in the shop.
It's easier to torque down with the engine bolted in place anyway.

The list:?
I still need to test the injectors.
And I can get alot of things hooked up while I'm waiting for the head to get done.
I have a few things to swap to the new block;
alternator, vacuum pump and oil filter mount,
front motor mount/bracket/starter
before I put the radiator back in.

Oh yeah better put some new trany fluid in it.
He brought lots of fluids for it, I'll see if there is trany fluid.
Engine oil and a new filter,.. oil might have to wait until the new head is on.
...and parts to clean.

Now he has the old vacuum pump vent port on the front of the block with a hose coming from it.
He has switched to the newer vane-style pump that doesn't need this port.
I might have a MK2 block off plate that goes with his pump.
That would clean it up some.

He put new glow plugs in it before he brought it.
Autolites :cry:
I want to put duraterms in while the pump is out,
at least the 2 difficult ones behind the pump.
Sooo good progress.
2 or 3 more days work and it should be running.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

The dreaded lower timing belt cover:
Imageredpickuplowertimingcover by vwfatmobile, on Flickr

Almost impossible to find a good one and almost all of them are messed up.
A good used one is about $80 everyplace I look.
No new ones available.
The old Rabbit 1.6's use the 068 109 127A.
The MK2s used the one with a B on the end.
I checked ECS and he said they have to get them from Germany,,
checked further and found they couldn't get them at all.
It was a B cover anyway.

I guess this one isn't too bad.
Usually the pullys or belts cut holes in them.
The other mounting holes look great.

I can rebuild it
I have the technology. :twisted:

I want to use plastic epoxy but am not sure it can handle the heat.
Might be a job for JB weld.
Heating paper clips and melting them through the plastic should give it a lattice to grab onto.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

Got the repair started:
Imageredpickupbeltcoverrepair by vwfatmobile, on Flickr

Got some JB weld plastic epoxy.
This should help hold it in place.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
sgnimj96
Turbo Charger
Posts: 259
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

Sometimes it's not thinking inside or outside the box, just being able to glue the box back together. haha, Cheers!
Epoxies have come a long way and can stick permanently to almost anything, except HDPE (or most any other Polyethylene)

fiberglass cloth helps to give structure and prevent cracking, even in the putty types that don't saturate the fibers.
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

I'm not sure what kind of plastic this is.
But this glue seems to stick to it.

I brushed some LPS-3 on his old block and
set it on end.
Image
That worked. It didn't stick to the block.

Trimmed it up.

Imageredpickupcoverdone by vwfatmobile, on Flickr

Cover is on so the pullys can go on,
alternator is on and tensioned.
Radiator and horn and some wiring
In,,, doh forgot to bolt the radiator in.
This early style has 2 bolts on the bottom
so radiator is almost in.

He bought new glow plugs,.. autolite.
I want to put duraterms in
at least in the 2 hard to get spots.
Then when the slow glow autolites burn out he can replace them easily.
That's what I do with my used glowplugs.
The new ones go in 1 and 2.
#4 almost always has a used glow plug in it,..
but they are still used duraterms.

I'll check with him.
I think they are about $11 each.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
sgnimj96
Turbo Charger
Posts: 259
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

slow glow? haha, the only thing good about those is for describing how "vintage" your diesel engine is to get the collectors salivating.
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

I took a look at the injectors today.
Imageredpickupinjectors by vwfatmobile, on Flickr

I cleaned up the 2 on the outside.
They all looked nasty.
I was expecting worse but 3 of them tested real good.
They popped real nice didn't piss a stream even when close to breaking.
They all popped within the recommended 100psi of each other.
Lowest was 1825 highest was 1900.

Just 1 pisser. even kind of pissed while popping.
It's the one without the breaking pressure painted on it.

One new injector when 3 are used seems weird.
I found a good used injector that sprayed nice.
It's inside on old lucas cav injector or something so I'll have to swap it in and set breaking pressure.

Besides I'm not real happy with the new injector nozzles/inserts.
They piss when new.
The old German ones were good, the ones made in France were real good,
then brazilian ones sprayed nice,.
this current batch of Indian made Bosch injectors,..
I swear half the damn Indian made ones piss when new.

These old injectors spray real nice.
They pop cleanly.
Had to be one that gave me a hard time.

I have about 24 hours into it @ about $20 an hour.
and $1010 in parts including the rebuilt short block.
Plus the injection pump reseal at about $160. It really needed it, the seals were getting brittle.
The head isn't back from the shop yet.
A little under $1500 so far.

In a busy year I bring back a couple of someone elses old VW diesels a year.
Building one for myself to drive then sell usually takes a couple years.

Most people drive out of here for around $1200.
But they don't need a rebuilt block and head.
'91 Golf gasser converted to a 12mm pump, M-TDI.
'84 1.6TD Rabbit with a VNT-15 turbo, still setup to run on vegetable oil.
'84 GTI with 1.7TD pistons and intercooled.
2003 TDI wagon
2000 TDI Jetta.
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