Project: 1978 VW Rabbit

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

Moderator: Fatmobile

What should I do with the 1978 Rabbit?

Cut losses & get rid of it- you bought a lost cause!
0
No votes
Get a inexpensive running diesel engine & get the Rabbit hopping again!
4
50%
Get a rebuildable engine & rebuild it (only way to be sure) & get the Rabbit hopping again!
1
13%
What were you thinking buying it in the first place!? You should have looked closer at it!
0
No votes
It's a CLASSIC VW diesel! Get it HOPPING at all COSTS!!!
3
38%
 
Total votes: 8

VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Post by VanBoy »

Fatmobile wrote:If you surface it, you will probably find that the cam rocks in the journals.
The head will still be high in the center and the cam will rock like a teeter totter.
A local place bends the heads back straight and line bores it,
before a rebuild begins.
How much is it warped?

I didn't have the stuff to check it myself. Shop said it was (I trust them). So, does that mean I'll have to inline bore where the cam sits.... :shock: I was just planning to swap in the other cam, assuming it is smooth....
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Post by VanBoy »

Still working on the project..... farm work has taken the place of working on the Rabbit. Head is still a friend's friend's machine shop. No rush....
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Post by VanBoy »

Head needs valves and guides...
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Post by Fatmobile »

Pretty common,
especially the exhaust valves.
The trick is to end up with valves set so the adjustment shims aren't too thin to adjust later.
You might end up getting some new seats too,
just to get the valves to sit lower and allow a fatter adjustment shim.


does that mean I'll have to inline bore where the cam sits
You will probably have to line bore the cam journals if you've surfaced the head. Check the cam teeter when you get a chance.

When going with a used, warped head; it's best to have it bent straight then line-bored,..
then valves installed; shim thickness checked and new seats installed if the shims are so thin they won't allow adjustment as the valves/seats wears.
Then peen the prechambers in and surface it.

I have heard of people wrapping the cam with a layer of sandpaper and using it to "line-bore" the cam journals,.. claimed it worked well and I can see how it would.
,.. it's the middle ones that need it the most.
'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.
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Post by VanBoy »

Well, since I took the cam out, I might give it to my buddy to give to the machinist. If not, I'll get a new cam and have him install it.
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Post by VanBoy »

Project s l o o o w l l l y y y going...... :shock:

Heads been back.... but have yet to install....
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Post by VanBoy »

As I said before, it got new valves. But I didn't include the new cam..... so valve adjusting will be needed. I have yet to read up on how to do that....


(Trying to get a grape harvester ready for harvest (and other associated equipment). Last minute stuff :roll: , but all my friends say I'm a last minute person. Oh well.... One slave show and I'm the slave.... )
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Post by VanBoy »

Okay.... I know I asked this sometime before but forgot..... I think.... head studs still needed...

So..... question: Undercut studs or regular??
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Post by Fatmobile »

I'm not sure it matters.
I think the 11mm headstuds I've been using aren't undercut,
and they seem to work fine on the 1.5 engine,..
I hit 20psi a couple times tonight, I like leaving semis far behind,
in my smoke.
'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.
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

HAPPY NEW YEAR!

Post by VanBoy »

Okay- Project Update


Things are going slow on the project, but the head studs finally arrived. Been busy and keep forgetting to order. The head is over at a buddies and he's adjusting them. Now just have to get the car over there, get a head gasket....

That reminds me, I know that the general rule is to get the same gasket that was on there (look at the notches). But what happens when you put a different head that has had a new valves put in? Good idea to check for clearances or just get a head gasket and go.....
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
coke

Post by coke »

Gaskets are determined by piston protrusion above TDC.
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Re: Project: 1978 VW Rabbit

Post by VanBoy »

THE RABBIT LIVES!! :D

More details later..... And she fires up when cold (32F) too!
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Re: Project: 1978 VW Rabbit

Post by VanBoy »

Well, the old Rabbit runs now. There was a knock & buddy who put her together thought it was the lower end. But it seemed to be an injector...went away after a while & putting cleaner In fuel system seems to make it better. glow plug system seems to be working in its current form (original). Do you wait for the light to go off like most diesels? Seems a loooong time being on.

As stated, 11mm ARP head studs used. Water pump leaks, but not an issue. Diddto w/ heater valve, seeps. Car wont be used for winter for now, project. Not sure if the "crack" I saw on the backside is a crack or what....no leaks from there as far as I can tell. pO said tranny is a 5 speed.....whats the shift pattern? Cant find 1st gear....hope it is a simple issue....linkages vs internal tranny issues.

Is the correct starting method to gp for xx seconds, press throttle down 1/4 and crank? My Ford idis say thats how to start those.....

Is there any place to get old VW resto parts? i need a blower assembly/motor. pO wired in a computer fan for the defrost/heater fan. PAssengerside A pillar has rust hole.

an owner in the past put full guages in, but not sure where the senders are. This car has oem idiot lights. At some point, i want the guages hooked back up, plus i might put a manual over ride for the cooling fan. I think it works..heard it when buddy dropped it off. The Rabbit is a slow "restoration" project.... Usable one that is.

And all of you were right. the Rabbit has "procreated"....bought a 81 VW pickup w/ diesel early 1.6 w/ 11mm head bolts. Head gasket is bad, says buddy. Damn you all, :mrgreen: this is addictive !!
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
Fatmobile
Global Moderator
Posts: 7564
Joined: Wed Oct 30, 2002 10:28 pm
Location: north central Iowa

Re: Project: 1978 VW Rabbit

Post by Fatmobile »

When using duraterm glowplugs, I wait about 7 seconds before starting in summer.
Sometimes as much as 20 seconds in the winter.

Probably just need a shifter bushing kit to find reverse,.. or if you want to drive it; push down and act like you are heading for reverse but only go part way before shifting into first.

Used body parts can be found on the vortex.
'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.
VanBoy
Cetane Booster
Posts: 82
Joined: Thu Apr 01, 2010 12:38 am
Location: Pacific Northwest, USA

Re: Project: 1978 VW Rabbit

Post by VanBoy »

Image

Ebay says that's the heater fan assembly for my Rabbit.... I'm missing the fan completely, so I have no idea what it is suppose to look like.
1999 E350 ClubWagon 7.3L Power Stroke
1990 E350 ClubWagon 7.3L IDI x2
1977 Kenworth K100 Cummins NTC-350
1977 IH Transtar II Cummins NTC-290
1977 IH Transtar II Cummins Formula 290 (ongoing project)
1978 VW Rabbit 1.5L (ongoing project)
And a few other gas rigs....
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