Little red pickup

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Fatmobile
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Location: north central Iowa

Little red pickup

Post by Fatmobile »

A guy called me.
Said the local bosch service center guy gave him my number.
He has a nice red rabbit pickup,..
that runs like crap.
He was right, never seen one that runs so bad.
Didn't think it would make it into the hoop shop.
Smokin and chuggin.

It's running through the coolant.
I can smell it in the exhaust.
That isn't usual.
I can usually see air spurting into the reservoir when the head gasket goes.
But have never seen it so bad it comes out the exhaust.

So I started opening it up today.
Damn people who glue the valve cover gasket on.
I can almost hear them saying, "Wouldn't want to be the guy who has to take that off."

It has an M head,.. M at the end of the part number.
12mm head.
But it has the 11mm allen head, head bolts.
Most people know the 11mm head bolts are too short and put too much pressure on a small area.
Known to crack the block or pull the threads out.
I'm thinking the block is cracked.

Stay tuned.
'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 »

Man, you could make a TV show out of this one.
I hope the owner has the motivation to fix it right, which means fix or replace everything.
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
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 »

I have mixed emotions on this engine.
The bad:
1. It is an 11mm block.
Since it's an 11mm block I will need head studs to put the head back on.
I won't use the stock head bolts without written permission and owner taking responsibility for cracked block or threads pulled out.
I was kinda hoping I would find cracks near the headbolts/cylinder so I could sell him a good 12mm block.
I have a couple good ones sitting around.

2. The coolant leak was on cylinder 4 only and that cylinder was scored.
Almost no crosshatching remains in the cylinders. Some scoring on 4 and less on others.
Image

3. Before I pulled the belt I tried turning it by hand.
It turned over too easily, way too easy.
This one bugs me. It turned over real easy by hand.
Indicates it doesn't have much compression, under 325 by my experience.
I'm surprised I could even get it to start at 40 degrees.
Probably had to lay on the starter for 15 seconds
after it started to fire,.. before it started to run.
Wasn't sure it would catch and run without the starter engaged but it did.

4. Looks like pistons hit valves at some previous date.
Probably why the head was changed.
Didn't hit too bad, not a game ender.
No current marks on the valves.

5. The I-shaft seal was pushed out.
This to me indicates a high internal block pressure.
I thought maybe a previous mechanic set it a little farther out
so it wouldn't ride in the same groove on the I-shaft.
But there wasn't another seal wear groove, just the one and
the o-ring was so brittle it's been a long time since that seal/o-ring was changed.
Hasn't set like that for long,.. not as long as that seal has been in there.

The good:
1. Hey maybe the intermediate shaft bearing will be toast and the engine will have to be pulled.
Might as well put a better engine in then in right?
Nope the intermediate shaft bearings look real good
and the shaft turns slightly hard so they are tight and should provide good oil pressure.
2. There was no oil in the intake, really clean, that was weird.
3. almost no ridges on the cylinders.
4. I-shaft and pully look great.

Good and bad:
The timing belt was running to the right.
Close to the edge.
That's a good thing.
But the shaft has alot of play in it. "tinkatink"
Enough that I'm surprised it wasn't running toward the outer edge
or off the outer edge.
That's bad.
Haven't checked if the mainshaft seal was leaking but it did seem wet around there.

Something small bounced around in the cylinders at one time.
Image

Took a picture of the exhaust ports:
#4 is the only one that is wet.
Imageredpickupexhaustports by vwfatmobile, on Flickr

The head is in nice shape. Looks like it was surfaced at some point but they didn't take off much.
Haven't checked it for flatness yet.
Notice no cracks between the valves. None at all :shock:
Image

My camera isn't good with closeups but you can kind of see that
the metal ridge has split and coolant is flowing through the closest hole in through the cracked metal
into the cylinder.
Image

I get the feeling that if I put a good head gasket on, it will run.
But after all the money he would have to put into it
I don't think it will be a good reliable engine that will start in the cold
or not be a smoker.

If it was my truck I would swap in one of my good 12mm blocks.
'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 »

I reckkon the ante is pretty high. New engine and a new IP is just to open the can of worms. Probably needs injectors done too.
That NLA rusty fuel tank, abused 40 y/o 020, pathetic stock wiring, the old unibody born without a subframe, etc... steering, bearings , etc...
Unless the owner is quite an eccentric, I'm thinkin' he'll fold.
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 »

Besides the engine, I noticed the normal rattle in the steering wheel and no ebrake.
Hope I know when to stop working on it, ha.
He has put alot of good parts on this truck.
New control arms, struts and caps,.. and the brake fluid looks really clean.
The body is in great shape rust wise.

Sooo I called him with the good and bad news.
I have an engine I built last year.
Using the TD pistons from the engine that was in my rabbit trip across the country.
The block cracked in a weird place and started pushing oil out the front of the block.
I pulled the pistons and rods because they only had maybe 60,000 miles on them and looked great.
I put them in a freshly bored block with new bearings.
I told him he could have it for $600 with a new belt/tensioner and I'll put his good head on it.
He told me to put a good clutch on it while it's out.
So it's going back together right and should be a good, reliable, cold weather starting truck.

As far as the injection pump goes.
The belt is riding in a good spot and if it's not leaking from the mainshaft seal it might be OK for awhile.
We'll see if he want's that bushing fixed now or later.
'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, Cindarella story - out of nowhere, you're doing magic most people think is a myth.
VE pump bushings? That custom reaming is so tricky people won't even talk about it - but if he lets that go the IP mainshaft snapping is likely IMO. He should splurge and get a good pump to go with that 12mm runner, then he'll have plenty of time to fix everything else.
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 can ream the bushings. I charge a couple hundred to dig that deep and reseal them.
Have messed up a couple and made them too tight,.. so I know my limits.
Can't find your limits until you exceed them right, ha.
The local bosch shop is real good at setting them up right. They charge about $200 for that.
Main problems caused by loose mainshaft bushings is leaky seals and the belt likes to ride off the outer edge of the sprocket.
That's why it surprised me. The belt is tracking great,.. but there is alot of movement.
Better to fix it now than after it soaks the timing belt with diesel.
The belt doesn't like diesel.

I bitch about bolts that don't budge,..
the intake bolts wouldn't come out so I had to lift the head with manifolds attached.
If I did record it and put on utube,.. the language would have chased all the advertisers away, ha.
Damn heavy and aukward.
But I really do like working on these old Rabbits.
I know what wrenches to grab,.. usually
this one had a 17mm crank bolt. Long time since I've seen one of those.
I have a nice stash of parts that need to get put on something.
This one has a messed-up lower timing belt cover. Top left bolt hole crumbled.
Those are NLA so I'll have to figure out a fix for that.

There are many things to do around here
but when someone can't find anyone to fix their MK1 or Mk2 diesels,
it's hard for me to leave them hanging.

These cars aren't real popular with most people right now,.. but like you've said
gas prices are going to go back up, fast it seems.
And more people will appreciate them.
'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 »

There is an increasingly unique feeling to having an all mechanical vehicle these days that also gets good mileage. Your holistic approach to understanding and mastering the handful of technical difficulties are worthy of subscription. What's weird is that there are way more engines and drivetrains available out there than good chassis's to put them in. That is a whole other problem, but as people continue to get burned by the dealers for things like $400 to get a key made, these 20th century machines will continue to gain value as an economic and esoteric refuge.

I bought a 5-gal jug of SP-400 a few years ago and keep some in jar with a brush. Any areas that start to rust, but aren't worth painting, get a quick rust treatment ending with a coating of the wax/oil goo. On areas that will get painted some day, a careful dab on rust spot will keep it from getting worse.
I think the only reason that stuff cost so much is that it lasts so long, but I imagine a similar product could be made by heating any non-acidic oil and melting wax into it to make it thicker, The SP-400 does dry out over time, but is thinned with just about anything - diesel, gasoline, paint thinner... so that's part of the mix too. After it's painted on, it dries into a waxy O2 barrier that's good for a while (2 years).
Here in Florida, a lot of IDI's and early TDI's that "ran when parked", have been destroyed by rust. The lucky craigslist ads are mostly buckets these days.
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 »

Yep, after this I have one more good 1.6d engine to put in something.
If I can find a good body.

I like the SP-400 too.
I did end up with a gallon of LPS 3 which is pretty close to the same thing.
I brush it on too.
'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 »

If the part # is correct... 1.6D lower timing cover can be still had, with a delay (Latvia?)
https://www.ecstuning.com/b-genuine-vol ... 068109128/
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'll have to call them and see if that's the right one.
If it is I might order a couple at that price,...
combine shipping.

I got the engine out:
Here's the trany.
See it? That little broken spring perched on the trany?
Image

Changing the clutch was a good idea.
Image
Good thing this engine got pulled.

Here's the 2 engines side-by-side:
Imageredpickupengines by vwfatmobile, on Flickr
Along with my other spare engine. The engine I pulled from the MK2 Golf for the MTDI project.

Time to order some parts.
Gonna need a new p-side motor mount bushing.

The injection pump isn't leaking and even though the mainshaft moves a little the belt doesn't ride in a bad place.
Probably just see if he wants it resealed.
The cold start bushings are gone, that's usually a sign it's been awhile since it was last sealed.
'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, the great odometer reset going on for the LRT! As strange as all that is to look at, balanced on your shop floor- compared to todays dealers where they charge $250 to ONLY plug in their OBD2 reader, it's a revelation of a truth people are being conditioned to be afraid of. Truth is simple, evil forces complicate truth to hide the freedoms they destroy.

My "new to me" (years ago) 1.6d clutch had broken springs flying around in the bellhousing, too. The flywheel friction surface was discolored from heat, i guess. Got a clutch kit from RockAut and hand sanded the flywheel despite people saying it had to be "resurfaced" - worked fine. Thanks to having got a new pushrod when I got the input shaft seals, I compared and saw the old one was worn down (that was the cause of gear grinds),
https://www.hansautoparts.com/020141741 ... shrod.aspx

This guy fixes the bosch IDI injectors if you ever want to farm that out to save time. https://dieselfuelinjector.guru/
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 »

Gotta agree.
In times of universal deceit; truth is a revolutionary act.

Balanced, ha.
They won't sit pretty like that on their own.
It takes is a 4x4 to get them to sit up straight.

I got the old p-side motor mount cut out today.
Even had a heavy duty V bushing for it in my parts stash.
So I was able to go over to a friend's place, "Mr Burned Rabbits", ha.
And use his press.
I can get some stuff done on that end while waiting for parts.
I can only find the heavy duty p-side motor mount bushings at one place so far;
partsgeek has/had 1 and it was $35 + shipping.

Took the cam off and lifters out to see if the cam teeters in it's journals.
Not one bit.
Looks like a great head, haven't checked the surface for straightness yet but that was encouraging.
I think I found a straight bar to check it with.

Trying to figure out what can be salvaged from the old engine.
Maybe oil pan???
Nope. It was way banged up.

Checked the steering rack for slop in the p-side end.
yep, sloppy.
So I ordered up one of those delmar bushings off ebay.
Way easier to swap with the engine out.
'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 »

...dang, the rabbits. A moment of silence for those lost that terrible day. :cry:

I would be tempted to fill the left and right mounts with loctite PL roofing caulk from the hardware store. Takes almost a week to really cure but makes a rubber almost as stiff as the 3m windoweld.

Speaking of mounts, on my old manual steering rack, wheels on the ground, I video'd the side to side flex with my phone and was suprised at the amount of movement of the entire rack, mounts were fairly new..
So I got a poly mount, did only one, the larger (and easier) pass side one, https://www.ecstuning.com/b-powerflex-p ... 5-230~pfx/ and it helped with responsiveness, like dodging potholes.

Those big suppliers like partgeek seem like they source everything from other venders, too many parts
www.carid.com seems to have the hd mount and oil pans for a little less - says ships the next day.?
Maybe they're actually the same company :roll:
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 »

If it was the "upside-down man" motor mount I would feel like it needs some filler to make it solid enough.
I think the heavy duty V mounts do pretty good on their own
without causing too much body vibration.
I checked carid for the motor mount and it IS a little cheaper $31.67.
I'll have to put that on my list of suppliers.

Got the head all cleaned.
Damn, it's got to be the straightest head eveh.
Getting the head on and the injection pump belt tracking straight is something I can do while waiting for parts.
I keep extra gaskets in my parts stash,..
but no clutches.
'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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