1981 1.6D rabbit freshening

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82vdub
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Re: 1981 1.6D rabbit freshening

Post by 82vdub »

On a 1.6, it's really, really easy to tell where TDC is located.

If you look at the front crank pully, look for the dimple. If you align the dimple so it's at the 7:30 position with the two corresponding bolt holes aligned to run straight up the cylinder bore of the block, that is TDC.

See the pic below. If you counter clockwise rotate the crank just a tad to get the dimple to align at the 7:30 position, that's TDC (note that the dimple is currently at the 9:00 position).

Image
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bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

This is a CK 1.5 is it the same?
bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

Did an interesting thing today

Image

I'm not entirely sure it will act correctly but since it's going to have my rear disc setup gotta have my NOS 3/15 proportioning valves:laugh: Now the big question is will the stock "Westy" fender mounted prop valve cause me any problems. I know they can be tuned down, I just cant remember how.
the vegenator
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Re: 1981 1.6D rabbit freshening

Post by the vegenator »

How did you wash out your engine bay? Pressure washer with a specific solvent or cleaner?
- Mike Harpring

'85 VW Jetta NA Diesel/WVO
bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

a combination of Simple Green and Greased Lightning and a pressure washer Oh and a toothbrush
bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

Image

Engine in! woohoo
bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

Homework from today
Image
82vdub
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Re: 1981 1.6D rabbit freshening

Post by 82vdub »

Did you find if the dimple in the front crank pully on the 1.5's align's the same for TDC as the dimple location on the 1.6's? I would believe so, but have never worked on a 1.5.
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bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

It appears to be in the same spot, I am not 100% on the mark on the flywheel but very very close. Crank always seems to move just a hair when I tension everything. I'm not hitting anything but the pointer on the tranny is very slightly to the left of the 0 on the flywheel. Hopefully it eill fire when the time comes
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Re: 1981 1.6D rabbit freshening

Post by Fatmobile »

Leaving the injection pump pin in when tightening everything up?
'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.
bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

Yes injection pump is in while tightening it all down
Fatmobile
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Re: 1981 1.6D rabbit freshening

Post by Fatmobile »

pump pin ya know the pump sprocket locking pin.
'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.
bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

Yeah Fatmobile it is in, but no matter how hard I try it wants to do this
Image

I also re-worked the rear disc setup so that it would clear the shifter mechanism

Image
82vdub
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Re: 1981 1.6D rabbit freshening

Post by 82vdub »

bigger daddy wrote:Yeah Fatmobile it is in, but no matter how hard I try it wants to do this
Personally, I've never concerned myself with a flywheel moving this little bit when tensioning the belt. It is ever so close to TDC, that in reality, it probably doesn't make much of a difference in the real world. Just make sure you rotate the engine at least two revolutions with a wrench on the crank bolt before using the starter to turn it over. Make sure there's no hard resistance inside the engine with valves/pistons hitting each other.
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bigger daddy
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Re: 1981 1.6D rabbit freshening

Post by bigger daddy »

I may leave it as such (although I'd love it to be perfect) Everything rotates clear no valve/piston hanging
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