Advice needed before installing take-out 1.6NA

joesco90vw · Post by **joesco90vw** » Thu Aug 27, 2009 4:35 am

Any help and advice is very much appreciated. I am about to install a 1985 1.6NA (non-turbo) VW diesel in a Suzuki Samurai. I purchased the engine from a salvage yard yesterday and before it was removed from the Jetta I had them run it for 15 minutes. It has 100k miles, started right up, showed no leaks, oil was clean and engine temperature was fine. So it appears to be a solid engine!

Before installing it next week, I am going to pressure test it and replace the water pump, timing belt/tensioner, glow plugs, IP return lines and valve cover gasket.

Keeping on budget with this project are there any other repairs that I should complete while the engine is in the engine stand???

Thanks very much!!!!!!!!!

82vdub · Post by **82vdub** » Thu Aug 27, 2009 8:46 am

Look for signs of where oil leaks and possibly replace those seals before you put it into the vehicle. While you're replacing all those other parts, you may want to freshen up the injectors as well.

odie · Post by **odie** » Thu Aug 27, 2009 9:04 am

I'd pull the intake & ex manifolds and clean them up and new gaskets. Probably a ton of gunk in the intake. with the engine pulled you are never gonna get an easier chance.

pull bottom/pan off and clean it out.

Post by **Fatmobile** » Thu Aug 27, 2009 9:37 pm

You have to pull the intermediate shaft and look at the bearings, while the engine is out.

Josh · Post by **Josh** » Wed Sep 02, 2009 9:47 pm

I agree with Fatmobile, you may as well replace the IM shaft bearings. If the outer looks great I'd sure like to see a picture! (Support the shaft at the back end via the vacuum pump mounting hole; with it removed you can get a finger on it and keep it from flopping around)

I'd also change the oil seals despite the fact that it's not leaking now; they're cheap and easy to do. They're old and may have been sitting. Do the camshaft, IM shaft, and front and rear main seals. You'll need an O-ring seal for the IM shaft too.

I'd put one of those rubber thingies on that go under the valve cover to prevent runaway and decrease oil consumption through the breather if the 85 doesn't sport one. They're about $20.

I'd drain the Inj pump right now and fill it with Diesel Purge and let it soak, and run a can of that through the engine when you're first up and running. It may have run fine on the stand, but until you drive it or pressure test the inj pump you don't know for certain whether the timing advance is functional. Honestly I'd spend the $125 or so and have the inj pump resealed, or save some cash and DIY. I'd spend money here before working on the injectors, honestly. Others may have other opinions.

Check the valves unless 85 was the transition year to hydraulic heads, I don't recall and am away from my books!

joesco90vw · Post by **joesco90vw** » Thu Sep 03, 2009 2:42 am

The engine arrived yesterday and in one piece. Work begins on Friday. Thanks for all the suggestions guys!

joesco90vw · Post by **joesco90vw** » Thu Sep 03, 2009 3:38 pm

BTW Guys can you purchase Diesel Purge locally at NAPA, AutoZone?

ad · Post by ad » Sat Sep 05, 2009 9:08 pm

Put a new engine block heater in before installing the engine.

joesco90vw · Post by **joesco90vw** » Sun Sep 06, 2009 3:58 am

Block heater is in. Some pic on Monday. Thanks!