Jetta project 200

[TurboJ]

I also wanted to get started with the engine.



It's been a really long way, and I really don't know how it will run - there are so many custom parts etc. But other people's results have been encouraging to say the least.
Really, I'm just as eager as a young boy with his toys to get this thing running.

Oh, and the assembly is so much fun! But it does remind me of the countless hours of preparing the parts. I have even treated quite many parts that eventually did not end up on my car.
Next time, I will do more planning ahead!     (but it seems like I've done so much of it already....)

Misc engine parts ready to be fitted:



Oil sandwhich fitted - I will run a front mounted air-to-oil cooler and have ditched the original heat exchanger. There's a thermostat in there as well to keep oil temps at optimum.





The rear engine support is on:



...as well as the cam belt back plate and pump support:



I sourced all three aluminum water flanges for this engine - no more broken water flanges for me... Two of them on this picture (coated with silver hammerite, of course...)

[theman53]

There are stock manifolds and stock manifolds...   

Some variants have been used on 1.9's developing well over 300 hp, but some are quite poor.
For example, the stock 1.6 TD exhaust manifold doesn't work well at all.

My engine will (according to today's knowledge) indeed use a modified stock exhaust manifold.
There are one or two secrets to make them work, and as you will see on the end result, some are
rather surprising.

I need to know, what are they? I am for some reason guessing that it is making the runners smaller, but let us know.

[TurboJ]

PM sent 

All of you VW guys, though, anyone have info on this:

Someone know the tightening torque for VR6 top mount's lower nut? Oh, and the top one too come to think of it...

It's difficult sometimes having only the mk2 Bentley manual...

[Smokey Eddy]

Not trying to hi-jack your thread here so maybe messaging me would be best but: Where did you find these fittings?!

My plastic ones are warped and leak *most* of the time.

[Alcaid]

Has the pump been bench tested? How many CC did it deliver and what is max RPM? I'm guessing at least 12mm piston to be able to support those 270hp on paper?

[R.O.R-2.0]

Not trying to hi-jack your thread here so maybe messaging me would be best but: Where did you find these fittings?!

My plastic ones are warped and leak *most* of the time.

those are mk1, or early mk2 GASSER flanges..

the top one wont work well.. the bypass hose connection points DIRECTLY at the end of the injection pump..

it is best to find coolant flanges off a mk1 diesel engine..

[TurboJ]

They are indeed out of a '86 Jetta GLI.

Good thing that you pointed out the problem with the pump clearance! Somehow I assumed the flanges were the same on gassers and diesels.
I'll have to dig a little deeper for a mk1 diesel flange or else I have to cut and weld the present one...

Hey, anyone have a good picture of a standard 1.6 D / TD water flange so I can see what the correct angle is. Thanks!

[RabbitJockey]

[TurboJ]

Thanks!

Much appreciated.

[TurboJ]

I think it's time I started posting full pictures so you guys won't have to right click so much 

I fixed the water flange problem by sourcing a Transporter water flange:




....and some clean up of the pump mounting parts:




Then I could test fit the VE pump for the first time. There are some final touches to be made on it still.

[TurboJ]

Fuel tank is only missing one hose clip and it's ready to be fitted:

[TurboJ]

The e-brake cable guides were looking very poorly.




But that's not a problem to a wire brush..





I also cleaned and painted with stainless steel spray the rear heat shield of the exhaust system:

[TurboJ]

Time to continue working with the braking system then.

[TurboJ]

The rears:






Very soon I will post some interesting stuff considering my new fuel pickup and the whole fuel system really!
I'm having a blast working on the Jetta now and I believe this is finally the autumn it will run. It will, it will!

Meanwhile, there's a great opportunity for you guys too. My old intake and exhaust manifolds are for sale ( http://www.vwdiesel.net/forum/index.php?topic=31935.0 )
...help me out and help you out at the same time, no?

[TurboJ]

Has the pump been bench tested? How many CC did it deliver and what is max RPM? I'm guessing at least 12mm piston to be able to support those 270hp on paper?

Yes, it was bench tested. Unfortunately I don't have the prints with me.
11 mm Bosch head in there, but apart from that, all internal pump parts have been modified.
Some have been replaced altogether with other types of parts.
I won't go into more detail just now - I want to see how it runs first