Little red pickup

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

Moderator: Fatmobile

Fatmobile
Global Moderator
Posts: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

I think so.
It's hard to believe a reservoir cap would cause a blown head gasket before it blew a radiator or coolant reservoir.
It still starts rough when not plugged in but I sent it home with him.
He'll clean the reservoir and see if any more oil gathers there.

I pulled all the glow plugs and tested them.
They are all glowing in 6 seconds.

I'll probably put another engine together this winter,
test it then put that in his truck next year.
I'd like to put the head on another engine and see what happens.
'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: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

He called today and said it started just fine at 58F.
Maybe the ride home cleaned out an injector.
'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: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

The tragedy truck continues.
He did a compression test.
490 on 3 cylinders and 350 on #1.
I took it back apart and cylinder #1 was scored bad.

So that pop going down the hill was probably a head gasket blowing again.
Made it home parked it and went to start it the next day and one cylinder was bad.

So looks like the high pressure in the cooling system shoved soapy water into cylinder #1.
Washed all the oil away.
Started it back up ran it into the shop to change another head gasket.
Figured it was #4 again.
But all the cylinders still looked good after this short drive,..
at this point I still didn't realize it was the coolant reservoir cap causing all these problems.

Still had one cylinder bad when I started it after this head gasket but smoothed out.

Second over pistons so the block can't be bored again. It's trash.
Along with one ruined piston.

Fortunately I just bought a stash of engines.
Two 1.6s, one is 12mm with pistons that hit the valves.. and about 2 1/2 TDIs for $100.
Also got the vaned vacuum pump I was looking for.

So these pistons crank and rods, etc are getting swapped to another engine.
They originally came from my 1.6 Rabbit that had an external crack form on the front of the block
near the oil pump and was bleeding oil.
I've been looking for a set of new oversize KS pistons for him but no luck.
Found one new 2nd oversize KS piston.
So that's the plan.
Bore another block and put everything in that.
He's paying for it.

Everything wrong with the truck is sorted out.
No more gasoline in the tank and a good coolant reservoir cap.
It was running great after a short warmup.

Of course with hindsight I wish I hadn't offered to help get this truck running.
I'd have a great block with 490 on all cylinders ready to swap into one of my cars.
And all the time could have been put into my many projects.
But that's spilt milk.
I can't abandon him now and we all learned something from it.
It should be a good runner in about a month,.. depending on the machine shop time schedule.
'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: 220
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

crazy a stuck rad cap could blow a HG.
Duel rad caps would be sweet. Mine had that, but I modified a vanagon cap to make an overflow to the reservoir.
Back to just one cap
Made it run a lot cooler, I may have some issues.
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
Global Moderator
Posts: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

So got a pile of engine cores. TDI and 1.6.
There was a 12mm block in there.
It's a CR block, so there was one CR block that was 12mm and one CR that was 11mm.
It has the old school real real keyway on the crank.

New Kolben Schmidt pistons. Took some time to find them in the US. Got the last ones QGAP had for $320.
Got new bushings in the rods. They also sized the bushings real good and balanced them.

It's together and ready to bolt to the trany and maybe
(I hate to pretend I can predict the future)
I'll get it put in the truck today.

There was no dipstick tube so I had to make one.
It's about 10mm OD which isn't an easy pipe to find.
Just straight pipe, about 4"
Now I'm glad I saved all those old AC lines, ha.
They are odd ODs and have been handy for stuff like this and turbo oil return lines.

The pump is still at the Bosch shop.
The mainshaft was a little sloppy.
It should be ready by Friday.
Maybe I'll have everything else done by then.
'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: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

It's in and axles are hooked up.
Only mistake I made was not torquing the crank bolt before I installed in.

It's a CR block with the normal keyway so it's only 120ftlbs.
So I was able to put the locker on the sprocket and torque it with the engine in the car
and me on my side.
Would have been easier with the locker against the ground with me standing up but it's coming right along.

Should have my work space back and be back to working on my stuff again soon.
'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: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

So the injection pump is at the bosch service center.
Was supposed to be done today, so I called.
Nope not yet.
3 out of 4 delivery valves were crap.
There were some in Atlanta so he ordered them. they didn't place the order and now there is only one.
So I went through my stuff and brought him up 6 used ones.
Bound to be 3 good out of 6. Just looked at a couple but they were much better than the ones in the pump.

I got to discuss delivery valves with him.
He knows just by looking at them with an eyepiece.
What he was looking at, was of course the ridge where is seals but also,..
the "collar" just below it.
This collar sucks fuel back out of the line so the injector spray will snap shut.
What he was looking for was how it wears.
If it's shiny it's worn. There should be small machine marks going around the collar.
And not scratches from it going in and out.
It was a good school day.
It should be done next week.
He's going to call and let me know so I can go up and see it on the bench tester before I pick it up.

Side note. Only political post I'll make, promise:
Remember to watch the people's convoy nightly driver wrap up meeting live on rumble around 7 central.
my favorite live convoy streamer got kicked off utube:
https://rumble.com/user/WYSIWYGTVLive
bring a hanky, it's pretty moving to hear their stories and watch people peacefully fight for our freedom.
If you don't catch it live, it sometimes doesn't get reposted so set your alarm.
oreo express and sasnak are good too and they are still on utube but often censored.
'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.
colby
Site Administrator
Posts: 101
Joined: Wed Jan 29, 2014 9:46 am

Re: Little red pickup

Post by colby »

Politics aren't banned here, I actively encourage it. The problem today is you can't have your own opinion. I don't censor, nor will I ever. For sure, our freedom is in jeopardy. I just wish more people realized that.

You never did mention, were the delivery valves you took good enough to pass muster?
Fatmobile
Global Moderator
Posts: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

Thanks Colby, when I saw you posted I was expecting a scolding, ha.
The daily wrap up meeting is at 7pm. I'm sure daylight savings time will mess with that.
There won't be sound before they start because of music copywrites. But when the speakers begin the sound comes on.
If you don't catch it live, it might not get reposted because some of the medical info or something might be branded misleading.
A nurse looking for work was up there talking about her "vax" religious exemption and how the hospital wouldn't except it.
She straightened them out about I think it was her rights under title 7 and how what they were doing was illegal.
Stood her ground, they called back and hired her. So proud of her.
A black preacher/poet/author, oh can't remember his name, recited a great poem about America and the freedom it stands for.
Looks like he has it up now,.. but the rumbles were twice that last night.
Have a hanky ready if you watch.
Had to hit pause then play to get it playing:
https://rumble.com/vx7j3t-the-peoples-c ... 11-22.html

Right, the first ones he looked at weren't just better than the ones in the old pump.
He was very happy with them.
He didn't look at all of them but it sounds like out of the 6 he would get enough good ones.
He only needed 3.
Glad I kept them in the pump parts jar.
Never know where the next supply chain issue will show up.
I used to stock up on parts, then let some of the supply dwindle.
I've been building it back up again lately, I don't just buy one of something now.
Just got the last 3 sealed power I-shaft bearings from Summit.

It was a nice delivery valve lesson on how they work
and I was glad to see it doesn't take a $pecial tester to find out if the delivery valves are good.
Just got to know what to look for.
'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.
colby
Site Administrator
Posts: 101
Joined: Wed Jan 29, 2014 9:46 am

Re: Little red pickup

Post by colby »

Sadly I can't even find the 80s-90s in this area that aren't all rotten or driven into the ground. Its been years since I have owned one. I have a broken leg right now so I couldn't drive one anyways, but I keep my eye out for them.

I would never scold anyone for having differing political views. Believe me, its a subject of contention with one member of my family. We are on polar opposite sides when it comes to politics, freedom, etc. I believe the country as a whole is in trouble. I wish more people realized that, but it doesn't seem they do.

I said from the onset, if you want the vaccine, get it, or don't, I believe in the ability for a person to make their own choice. Just don't force your views or beliefs on me. Its been total chaos and anarchy all over, and I wish I could say it didn't keep me up at night. I'll just keep hoping it gets better.

Glad you have some spare parts left over. I don't have anything other than whats in my brain for knowledge. In these parts, it isn't worth much because nobody is even driving them anymore. I'm not much a fan of the TDI's either, even though the earlier ones weren't terrible. I hate computer controlled anything. Maybe some day, it'll be in the cards and I'll own another. I figure I'll have to travel quite a distance to find one.
sgnimj96
Turbo Charger
Posts: 220
Joined: Thu Feb 20, 2014 2:08 pm

Re: Little red pickup

Post by sgnimj96 »

Thanks for sharing the delivery valve lesson. That's real gold there (the link too)

I don't think anybody, except a rare few, can deny that what is happening in the world
and in many countries right now is on purpose. I lot more can be said, but it isn't hard
to see that the few that are gaining more market share from it, are not trying to help the many.

With fuel now (quickly) rolling past $5/gal, a running vw diesel will be even more rare to find for sale.
All I see now, for a good price, is stuff that needs serious work.
But there still are a few like these https://tampa.craigslist.org/pnl/cto/d/ ... 63910.html
I use this sometimes just to see what's out there https://www.searchtempest.com/

The mk4 ecu can be sent out to defeat the immobilizer for a bit of simplicity.
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
Fatmobile
Global Moderator
Posts: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

My MTDI is the best of both worlds.

I got everything done underneath and set it on the ground today.

Got the headbolts torqued.
When they start popping it's scary. Broke my 1/2" drive, 6" extension.
It split lengthwise.
I backed the poppy ones off then tightened them again to get them to move smoothly.

Put oil in it then primed everything with a drill though the vacuum pump hole.
Added some old coolant.
I want to have everything else done so when the pump is ready that's all that needs done.
Plug in the block heater for awhile, start it up and go.
'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: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

Pump is done and home.
Fun to watch the bench tester stuff.
See how much fuel it pushed at what RPM,
the timing advance moving,
internal pump pressure 73psi @1500 RPM and about 45psi @1000 RPM.
He didn't really have a number for 1000 engine RPM but at 414 pump RPM was supposed to be around 40psi.
A little more coolant, injectors and NEW heat shields need to be installed.
Pump on and everything timed.
Might be running tomorrow.
'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: 7519
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Little red pickup

Post by Fatmobile »

Up and running.
Took first trip into town yesterday.
Did real well.
Has a slight tick that I don't like but the timing is spot on.
I might check the lifter clearance again.

My pulse detector was not working right last time I tried it.
Flashes constant when I touch it.
Won't flash the light until RPMs are higher than idle.
I've been spoiled by it, makes timing so easy.
I'll try it again.

First start without the block heater today.
Rough cold start, even with the CS lever pulled out.
White smoke, Seems like it could use some advance.
'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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