Author Topic: My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!  (Read 40512 times)

June 05, 2008, 10:49:07 pm

riddleyo

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« on: June 05, 2008, 10:49:07 pm »
Last November I found a 1.6 N/A Diesel sitting outside in some lady's backyard. I bought it quickly and AAA towed it to my house. I dismantled the engine and found that the solid lifters were welded into their bores in the cylinder head! I also found the plastic thermostat housing was cracked open. This led me to believe that the engine lost all of its coolant and overheated. I bought a new cylinder head and thought I could get the thing running within a week or two. I started looking at VW GTD and VW vortex and found I was over my head in the work to come:

Here is the car soon after I bought it becoming a storage shed:


Out with the old cylinder head:


No valve-piston contact, good!


The new (used) cylinder head I bought. I didn't know it was 11mm and mine was 12mm until I started searching through VW GTD! So I had a machine shop enlarge the holes and washer recesses:


Went to home depot and bought some metal to make my own valve spring compressor:


Cylinder head is dissassembled:


All cleaned thanks to simple green, paper towels, and an ebay ultrasonic machine:


Using a gasket, a needle, and a marker to start porting the cylinder head:


Using a die grinder to port the cylinder head:


Took the cylinder head to a machine shop for new valve guides and a valve seat job:


Reassembled and used a dremel, scouring pad, and simple green to clean it up:
« Last Edit: June 19, 2009, 08:16:44 am by riddleyo »


1985 VW Golf Diesel 1.6L N/A
My Build Thread: http://www.vwdiesel.net/forum/index.php?topic=14607.0

Reply #1June 05, 2008, 11:00:47 pm

riddleyo

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #1 on: June 05, 2008, 11:00:47 pm »
Now it is time to install the new cylinder head:

But first, ARP head studs for a ford cosworth and a new headgasket (the headgasket is on upside down in this picture, I fixed this after taking the picture):


The rusty ip bracket just doesn't cut it:


Hex bolts instead of allen bolts and newly painted brackets:


After finding out my timing belt was not tracking correctly, I fixed it (you can see how in this thread: http://vwdiesel.net/phpBB/viewtopic.php?t=13496)


Got some 1.6 turbo diesel injectors with mercedes nozzles:


Head installed and cam splash guard goes on:


At this point, I tried starting the engine and it would fire then die once I released the key. So I rebuilt the injector pump thinking that was the problem (pics in the next post). It turned out to be just the glowplugs. The previous owner completely screwed up the glowplug wiring so I just tore it all out and redid the entire thing the right way. I used a push button switch because my relay had a mind of its own.

Vince Waldon's site helped me pimp my glowplugs with separate fuses, a ford starter relay, individual wiring, and a push button switch:


Done with wiring up the glowplugs and installing IP. Put on an unpainted G60 valve cover (haven't painted it yet):


Windage tray goes in, cleaned out all the hair  :shock: from the screen of the oil pump:
1985 VW Golf Diesel 1.6L N/A
My Build Thread: http://www.vwdiesel.net/forum/index.php?topic=14607.0

Reply #2June 05, 2008, 11:14:37 pm

riddleyo

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« Reply #2 on: June 05, 2008, 11:14:37 pm »
So I thought my car wouldn't start because of the injector pump being rusted inside or something. So I rebuilt it using biodiesel seals just in case I want to run biodiesel in the future. I had no idea what an injection pump was or how it worked until I found a post here in french showing how to reassemble it. So I followed the pictures and took some of my own.

Before the rebuild:


This is part of the cold start/dynamic advance assembly. I took out the bottom left shim in this pic thinking it would increase my dynamic advance. Now my cold start doesn't really work. Is this mod worthwhile or should I put the shim back in?


Feed pump looks good:


I wet-sanded every flat surface I could find in the IP:


Re-assembling:


Pump goes in:


Getting ready to put the delivery valves on:


Almost done rebuilding:


I put the IP back in the car, timed it to about 1.05mm and started it up. No oil pressure. Turns out I didn't tighten the bolts on the oil pump and they vibrated loose. :oops: Fixed that and took it for a drive. The brakes were NON EXISTANT! Did I take it back home and check to see if there was brake fluid in the master cylinder? No! I rebuilt all the brakes including the drums. And then when I went to bleed the brakes, I found that there wasn't a single drop of brake fluid in the system... :oops: I have never done drum brakes before. It took me a long time and you can see in the next post...
1985 VW Golf Diesel 1.6L N/A
My Build Thread: http://www.vwdiesel.net/forum/index.php?topic=14607.0

Reply #3June 06, 2008, 12:07:14 am

Possum79

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #3 on: June 06, 2008, 12:07:14 am »
Nice post. I like. I wish i had the money to treat my car better to rebuild a bunch of stuff. :lol:
1979 VW Rabbit Diesel L
My car may be ugly but im addicted to it.

Reply #4June 06, 2008, 01:26:15 am

Vincent Waldon

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #4 on: June 06, 2008, 01:26:15 am »
I like the glow plug wiring.   :wink:
Vince

Edmonton, Alberta, Canada
2001 silver TDI Jetta Malone Stage 1.5 , 2001 blue TDI Jetta SBIII 216s Malone Stage 3, 1970 Bay Window bus

Gone but not forgotten: 1969/1971 Beetles, 1969/1974 Westies, 1979 Rabbit, 1986 TD Jetta, 1992 gas Jetta, 1994 TD Jetta

Reply #5June 06, 2008, 01:57:53 am

Vincent Waldon

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #5 on: June 06, 2008, 01:57:53 am »
Vince

Edmonton, Alberta, Canada
2001 silver TDI Jetta Malone Stage 1.5 , 2001 blue TDI Jetta SBIII 216s Malone Stage 3, 1970 Bay Window bus

Gone but not forgotten: 1969/1971 Beetles, 1969/1974 Westies, 1979 Rabbit, 1986 TD Jetta, 1992 gas Jetta, 1994 TD Jetta

Reply #6June 06, 2008, 09:11:57 am

riddleyo

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #6 on: June 06, 2008, 09:11:57 am »
Quote from: "libbybapa"
Nice looking work.  I like the gasket matching.  

Your headgasket is upside down in the picture.  If it's run that way, it will starve the head of oil.

Andrew


Haha yeah. I just threw it on there for the purposes of picture taking. I fixed it later  :wink:
1985 VW Golf Diesel 1.6L N/A
My Build Thread: http://www.vwdiesel.net/forum/index.php?topic=14607.0

Reply #7June 06, 2008, 10:23:49 am

riddleyo

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #7 on: June 06, 2008, 10:23:49 am »
So I took the wheels off and I saw the axles were wound up and tangled with weeds and grass:


All fixed up (the rattle clips are installed wrong in this pic, I fixed them later):


After taking a sledgehammer to the rear tires to get the rusted drums unstuck, here is how it looked:


New drum hardware, took me a while to figure out how drum brakes worked. I've never worked on them until now. My emergency brakes were stuck so I put new ebrake cables in. (I ended up replacing the wheel cylinders after I took this pic because the bleeders had broken off):


Packing the bearings with bearing grease:


Using a big hammer and an impact socket to install the new bearings in the new drums because I don't have a press:


Rear drums all done:


Time to put the wheels back on:


That is pretty much where I'm at now. Cleaning the inside (it is full of grass and pine needles) and installing new gauges in a homemade gauge mount is next.
1985 VW Golf Diesel 1.6L N/A
My Build Thread: http://www.vwdiesel.net/forum/index.php?topic=14607.0

Reply #8June 06, 2008, 06:54:23 pm

bevboyy

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #8 on: June 06, 2008, 06:54:23 pm »
My hats off to ya! Great job, doing it right! 8)
1987 Jetta Mk2 - daily driver, MZ 1.8 goodness. TJ auto trans..

Gone but not forgotten:
1985 Mercedes 300d Turbo
1987 Olds Delta 88 Royal Brougham
1992 Mercedes 190e 2.3
1984 Mercedes 190e
1983 Quantum TD
1992 Jetta TD
1983 BMW 533i
1982 BMW 320iS
1979 Mercedes 300D (non turbo)
1977 BMW

Reply #9June 06, 2008, 10:23:48 pm

riddleyo

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #9 on: June 06, 2008, 10:23:48 pm »
Thanks for the comments!

So today I got a lot done. I finished my homemade gauge cluster and did some wiring and cleaning. The car had been sitting in the previous owner's backyard that hadn't been mowed in a long time:


After some vacuuming:


Got some presents in the mail!:


Now it is time to start work on a template for the gauge cluster. I didn't want to shell out big bucks for one from 42draftdesigns, so I thought I would make my own.


Transferring the template to some plexi-glass. I hate working with plexi-glass. If I were to do this again, I would use some other type of plastic sheet that isn't so brittle.


Being very careful not to crack the plexi-glass while drilling holes:


Spraying the first coat:


I used a dremel to cut out the plastic where the stock tape player was. Then I test fit the plexi-glass:


The previous owner had a rat's nest of wiring that I had to fix:


After a lot of test fitting, cutting, and finished painting, it is finally complete:


Here is the last moment of my clock cluster:


Tach cluster in (Somehow my car instantly racked up 99,000 miles!):


All done:


I started up my car and the TACH DOESN'T WORK!!!  :evil:   :x  :evil: I tested continuity from the W plug to the tach pinout and there is indeed continuity in the wire. So I gave up for the night. I think it is either the guy from vortex sold me a broken cluster or my alternator's W output is broken or something. Anybody have ideas why my tach doesn't work? It should be plug and play right?
1985 VW Golf Diesel 1.6L N/A
My Build Thread: http://www.vwdiesel.net/forum/index.php?topic=14607.0

Reply #10June 06, 2008, 11:16:31 pm

riddleyo

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #10 on: June 06, 2008, 11:16:31 pm »
Quote from: "prothe"
Very impressive!

I wish I had all that time to work on my projects!

Where did you get that tach cluster in mpg?


Thanks. I saw it on ebay and turned out to be a guy from vw vortex so I bought it: http://forums.vwvortex.com/zerothread?id=3846258
1985 VW Golf Diesel 1.6L N/A
My Build Thread: http://www.vwdiesel.net/forum/index.php?topic=14607.0

Reply #11June 06, 2008, 11:32:29 pm

zukgod1

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #11 on: June 06, 2008, 11:32:29 pm »
Good job man!!

Keep it up, we need more old school vw diesels on the road..
dan

99 Golf TDI (now CNG powered) , 82 TD Caddy

Reply #12June 07, 2008, 07:31:51 am

burn_your_money

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #12 on: June 07, 2008, 07:31:51 am »
Good job. Very impressive amounts of work you are doing

Check the wires for the W terminal. They like to corrode.
Tyler

Reply #13June 07, 2008, 10:33:25 am

theman53

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #13 on: June 07, 2008, 10:33:25 am »
I don't really know where beavercreek is but ohio isn't that big...when your dun with your project how much do you charge for other  :lol:
where did you get the guages? I like them. I was going to go cheap for some of mine, but those might have me turned around. Great work...I'm serious on the hiring deal :twisted:

Reply #14June 07, 2008, 12:20:37 pm

Turbinepowered

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My 1985 Golf 1.6 N/A Build Thread - No 56k! Picture Time!
« Reply #14 on: June 07, 2008, 12:20:37 pm »
I'd second the suggestion to check the W terminal for corrosion. I think I've still got a QTD alternator around here somewhere if you end up needing a new one. Sell it to you on the cheap.

You make me jealous with the speed of your build. My poor Fox has languished in the garage for six months, dash apart and engine-less.  :cry: