$400 USD/85 Jetta 1.6TD/My Rebuild Journey

[nicknack2]

Guy I wish I had started earlier posting about my project, he is a 85 Jetta 1.6TD, I pulled the engine out of the car already, while doing that I striped all the inner CV joints bolts so I ended up grinding them off well thats a different story, the engine has been striped from all accesories already, and yesterday I removed the turbo and the intake from the back of the engine, I was not able to remove the exhaust header, seems like my 13MM wrench/sockets (even the 1/4 drive) is too big for the bottom part of the header. After I removed those parts Im starting to think that I did not need a rebuilt, I don't see lots of oil in the intake, but engine did smoked alot and I could see the blowby blowing hard from the valve cover, I did not do any testingbefore startin the tear down, but the car ran... in the front of the engine the cam and its pulley are off, the intermediate shaft is off... I see some damage on the bearings... I" post pictures tomorow if you guys got any recomendations let me know I will be posting daily on the progress of the process.. and by the way I paid $400 USD for the mighty Jetta

[Fatmobile]

Sometimes rusty nuts can get smaller.
Try some 1/2" 6 point tools on them, that should fit tight.

The word "header" is confusing me. I'm not exactly sure which bolts you are talking about,... the ones holding the exhaust manifold to the head? I think those are 12mm,... most of the time.

[nicknack2]

I meant the exhaust manifold nuts, the problem I'm having is that I can't fit the wrench nor socket between the nuts and the exhaust manifold(Im talking about the nuts on the bottom, the nuts on the top/upper nuts are already out) seems like the nuts are too close to the exhaust manifold...

[ahistand]

Sounds like you and I are into approximately the same projects. If you look below your post you'll see my Caddy project with 1.6TD. I'm in the process of rebuilding.

If you say the motor had lots of blow-by and smoke, it probably needs rebuilt. Especially if you took the intermediate shaft out and saw bad bearings there already.

My motor had lots of blow-by, and some smoke, and when I tore it apart, I found it to have totally worn pistons, cylinder wall clearance .009" out of spec, and valves that had hit pistons at some point. Compression was crap. So its getting new everything. However, my rod and mains had virtually no detectable wear, but the intermediate shaft bearings are shot.

[nicknack2]

I" post pictures later, but I remember talking to Jack and he mentioned that usually the bottom end of the engine stays in good shape after many many miles just the cylinder walls, pistons and some head work is required. for the re build, have you bought a rebuid kit? Im sure you can get lots of help down in the Houston area, Im originally from Odessa, tx and lived in El Paso before coming to Nogales,AZ

[nicknack2]

[img][http://pics.tdiclub.com/data/3804/mediu ... 19.JPG/img]

[jackfrost1031]

Those would be classicly shot bearings.

[nicknack2]

I was trying to post some pictures

[nicknack2]

guy how pictures can be posted I been scratching my head for two days and still can't post...

[nicknack2]

Jackfrost 1031, how did u do that?, the picture was there and then went away...

[jackfrost1031]

Jackfrost 1031, how did u do that?, the picture was there and then went away...

It looks like TDI club found out that it was linked to on here and they didn't like it. I would suggest an account with photobucker (http://photobucket.com)

The syntax for pixture posting is this:

[ img ] http://yourwebsite.com/image.jpg [/ img ]

Take out the spaces so that the img and brackets are closer together and it should work.

[nicknack2]

[Fatmobile]

Good picture.
What are we supposed to be looking at?
The chipped out I-shaft bearings,... or the broken waterpump bolts?
How many miles on this engine? 168,000?

[nicknack2]

Fatmobile.. you can see a little of both the broken studs of the half pump and the messed up intemediate bearing , I actually have a better picture of both that I be posting later, is just that I just learned how to post pictures, thanks to jackfrost1031. the Jetta has to have well over one hundred thousand miles, as we all know the odometers of this cars break about 90,000 miles in my case I bought my project with a broken odometer reading abot 95,000... hey Fatmobile Im going to need all the help I can get making this Jetta as lovely as some of the ones I seen in the forum I won't stop till he is like new and I heard you are a "head" guru/master... please help me ok??

[Fatmobile]

Welll,... I am the Global moderator and all,... but there has been some people beating me to the punch when it comes to helping people out here lately.
I'll try to help you out, but there is a good chance someones going to come on here and help you out before I get a chance .

Learning to post pictures is a great step.... and once you learn, it's easy.