converting a 1991 Jetta GLI to a 1.6 TD?????

[53 willys]

I emailed you the info on the Totalseal rings 53 willys..

I'll be ordering a set here myself SOON.

We better take a look at this block ASAP to see what it's going to need. Maybe we can order 2 sets at the same time and save some shipping. Not like rings are going to cost allot to ship but hey..

dan I was just reading the spec on those rings and it says
"Gapless second ring. Not recommended for use with nitrous or forced induction. 10.5:1 or lower compression."

are you sure these rings will work/last??

[zukgod1]

Yup, will be fine

I even talked to one of the tech guys at TS, that's where I got the actual part #.


Worse case we save a couple bucks and go with OE however, every comment I had read about the Total Seal rings has been good so I personally think I'll be using them.

 :twisted: Your call though..  

[53 willys]

Yup, will be fine

I even talked to one of the tech guys at TS, that's where I got the actual part #.


Worse case we save a couple bucks and go with OE however, every comment I had read about the Total Seal rings has been good so I personally think I'll be using them.

 :twisted: Your call though..  

man I feel a little overwhelmed after all the info I was trying to absorb from our meeting last night!!
my list of things to buy seems to have grown!!!....a lot!
can you send me a link to your parts guys?
thanks
and thanks for all your help too.
I love your car it's even coooler in person!!

[zukgod1]

Yup, will be fine

I even talked to one of the tech guys at TS, that's where I got the actual part #.


Worse case we save a couple bucks and go with OE however, every comment I had read about the Total Seal rings has been good so I personally think I'll be using them.

 :twisted: Your call though..  

man I feel a little overwhelmed after all the info I was trying to absorb from our meeting last night!!
my list of things to buy seems to have grown!!!....a lot!
can you send me a link to your parts guys?
thanks
and thanks for all your help too.
I love your car it's even coooler in person!!

Relax, it's easy

Link sent to your PM and thanks for the comments.

[53 willys]

timing belt kit
water pump
engine reseal kit?
head gasket..notch? wont know till I measure piston protrusion.
new piston rings
both motor mounts.(rubber)
injectors rebuilt or new?
stronger clutch..what was the clutch place you said was online??
36mm oil pump

what else am I forgetting??

ARP studs



I am off to the power washer right now!!
 :evil:

[zukgod1]

timing belt kit
water pump
engine reseal kit?
head gasket..notch? wont know till I measure piston protrusion.
new piston rings
both motor mounts.(rubber)
injectors rebuilt or new?
stronger clutch..what was the clutch place you said was online??
36mm oil pump

what else am I forgetting??

ARP studs



I am off to the power washer right now!!
 :evil:

Tensioner for timing belt
Your GLI may have the solid rubber mounts already
Clutchnet.com, better off calling them but need to wait till we decide what trans you are going to be using. There are different spline counts and no need to get a disk to find out later it wont fit the new trans.
Other than that I'd say your good.

And ya, I wanted to wash that thing before you came over but I didn't want to give it to you with water in it either, figured it would be better if you put the water in it  

[53 willys]

ok so whats the word...
ARP main studs?
ARP connecting rod bolts?
ARP oil pump bolts?
should I get them or not??
knowing me I will probably make some big power with this motor so building it to last is ok by me even if it's a little over kill...
so should I only do ARP head studs and call it good or should I do the full blown ARP pimp out?

[53 willys]

Dan I also noticed the center Freeze pug was missing on this engine??
will you parts source have freeze plugs??


I also noticed the IP was leaking out of the front seal.  so should I rebuild it  myself?(never rebuilt a IP before) or should I send it to industrial injection?? or should I send it to Gilles(sp?) or?




Dan I pretty much torn the whole engine down today!!
looked pretty good inside..still has the crosshatching on the cylinder walls.....I still dont know what to think about the washer I found on top of the #4 piston!!!!!!! :shock:

[zukgod1]

Dan I also noticed the center Freeze pug was missing on this engine??
will you parts source have freeze plugs??


I also noticed the IP was leaking out of the front seal.  so should I rebuild it  myself?(never rebuilt a IP before) or should I send it to industrial injection?? or should I send it to Gilles(sp?) or?




Dan I pretty much torn the whole engine down today!!
looked pretty good inside..still has the crosshatching on the cylinder walls.....I still dont know what to think about the washer I found on top of the #4 piston!!!!!!! :shock:

There was probably a block heater in that hole, that's what I would recommend you put there anyway. You know how warm it is around here in the winter  :shock: Parts for Imports in Orem has them in stock or can get it next day.

How can you tell the IP was leaking? Was there trace?
Anyway, we can reseal it easy enough and do a couple mods while we are there or if you have a "G" to throw at it send it to Giles you wont be sorry..

That washer could have fallen down through the open ports sense it didn't have manifolds on it.

Text me your address and I'll come by on the way home tomorrow and take a look and help you make a good parts list.

[53 willys]

trannys are the same or atleast interchangeable??

Yes, 16V will be a close ratio transaxle but is probably a 2Y with a 3.67 final drive and 0.91 5th gear. It will bolt up to the engine, It will also have 100MM Axles, use those too. As far as the best transaxle, I love the ASF but, anything with a .75 5th gear and 3.67 Final would be ideal so, AON, ACN, ACL too. When rebuild time comes I'll probably have a .71 5th gear put in the ASF for even lower Highway RPMs. For transaxle codes, gear ratios, and RPM calculations go here

do the ASF AON ACN ACL trannys have the bigger 210mm clutch??
like my 2y does??

[zukgod1]

I belive they have the smaller clutch but it's easy to adapt.
Clutchnet makes a 210 mm clutch disc with small splines so any 020 trans will work once you find the gear ratio you want.

[53 willys]

I belive they have the smaller clutch but it's easy to adapt.
Clutchnet makes a 210 mm clutch disc with small splines so any 020 trans will work once you find the gear ratio you want.

I was using the RPM calculator and it seems like the ASF or same ratio trannys are the way to go....I would be doing 3712rpm@75mph with the stock 2Y trans...if I swap to a ASF or similar it would be 3059rpm@75mph ....none of the other trannys have any thing as good as the ASF....

[zukgod1]

ok so whats the word...
ARP main studs?
ARP connecting rod bolts?
ARP oil pump bolts?
should I get them or not??
knowing me I will probably make some big power with this motor so building it to last is ok by me even if it's a little over kill...
so should I only do ARP head studs and call it good or should I do the full blown ARP pimp out?

I just realized I didn't respond to this.

Mains, not necessary but your call.
Rod bolts? Toss up. I'm using OE
Oil pump bolts, if they are cheap then sure other wise OE is fine here as well.
Head bolts yes, regardless of what gasket you use they are better.

I say rod bolts and head bolts and save your money on the others.

[Ziptar]

I was using the RPM calculator and it seems like the ASF or same ratio trannys are the way to go....I would be doing 3712rpm@75mph with the stock 2Y trans...if I swap to a ASF or similar it would be 3059rpm@75mph ....none of the other trannys have any thing as good as the ASF....

I wouldn't take the calculator as gospel, have a look at this I took that somewhere near Baltimore on I95 when I drove up from Florida, Its the ASF trans with a set of 195/60-14 Michelin Pilot Exalto A/S tires I had put on just before leaving Fla.

The RPM calculator says I should be at 2989 RPM at 75MPH. At 75MPH I am ~2750 and don't get close to 3000 until 80. I suppose my Speedo could be off by a few MPH and maybe there is a margin of error.

If I swap in a 0.71 5th gear it'll drop the RPMs about ~160 at 75MPH.

[53 willys]

I was using the RPM calculator and it seems like the ASF or same ratio trannys are the way to go....I would be doing 3712rpm@75mph with the stock 2Y trans...if I swap to a ASF or similar it would be 3059rpm@75mph ....none of the other trannys have any thing as good as the ASF....

I wouldn't take the calculator as gospel, have a look at this I took that somewhere near Baltimore on I95 when I drove up from Florida, Its the ASF trans with a set of 195/60-14 Michelin Pilot Exalto A/S tires I had put on just before leaving Fla.

The RPM calculator says I should be at 2989 RPM at 75MPH. At 75MPH I am ~2750 and don't get close to 3000 until 80. I suppose my Speedo could be off by a few MPH and maybe there is a margin of error.

If I swap in a 0.71 5th gear it'll drop the RPMs about ~160 at 75MPH.

I picked up a ASF today at the pick n pull for $65...how hard is it to swap to a .71 5th gear??