1.9TD Coupe Project

[zagarus]

cruised around and took some photos with a buddy in our dirty cars.  Mine is the grey Carat.





Wil also be doing a lot of work on the coupe tomorrow.  Will try to finish up as much of the lighting wiring as I can, install radiator which showed up yesterday, hopefully my other brake pads arrive tomorrow which will allow me to get all the brakes installed.  Then all thats left to do is get the oil cooler lines sorted out (need to get some fittings) install the turbo (once the manifold spacer shows up) and prime the fuel.  Intercooler will be installed and whatnot after I have the car initially running.  I really just want to hear this thing come to life.

Anyway will update with more pictures tomorrow 

[Smokey Eddy]

I found with my build my oil temp barely changes. i got the cooler but never plumed it because my oil temps never rose... i guess if I were doing a hill climb or a rally i'd need one
nicely done. Your pictures really make me want to pull out my interior and lay down tons of sound proofing

[zagarus]

Apparently this fatmat is more for dampening then it is for sound proofing.  Meaning hopefully fewer squeaks and creaks but more awesome diesel sounds! 

[zagarus]

Slowly getting things done. It's amazing how many things go unnoticed once you start putting things back together.  Like missing grommets, or damaged seals, or brake pads that don't fit  . Still plenty of work left ahead of me.   

One thing that I found neat was the brake booster vacuum line from the pump.  The original 1.9TD line did a huge massive loop up and over, looked ugly in my opinion.  So while at the junkyard yesterday I noticed a mk3 gti 2.0l and its vacuum line.  It ran nice and close to the head and turned 90 degrees into the front of the intake manifold. I thought to myself, "hmmmm if i just rotate it 90 degrees again it'll go straight down into the vacuum pump!"   Low and behold its perfect!  You can see in my pictures below.   Other then that I just tinkered away at coolant hoses, wiring, and other small things while i wait for more parts.





Volvo oil cooler I will be using.



Pump for my AWIC system.



Metal housing and new parts!  (Don't ask me why i'm so happy for a metal housing, just am)



Well as you can see wiring is still being worked on but I should have that all lengthened and loomed up to my liking within the next few days of work.  More to come!

 

[Smokey Eddy]

im in kamloops quite often, could we meet up and you show me this masterpiece?? you can see my abomination of a car too.

[zagarus]

Sure would be sweet.  Would have to be any day but a Sunday because the storage unit isn't open on Sundays

[starrd]

PD150 intake on it's way! will be building one of these in the future for sure!!!

So how much does one of these cost?  Would be really nice on my build as well.

[Vincent Waldon]

Metal housing and new parts!  (Don't ask me why i'm so happy for a metal housing, just am)

Hell ya... metal housings rock.  My daughters learned several new words back in the day of plastic housing.  

[rallydiesel]

Nice build.

[zagarus]

So I had a brilliant idea on how to relay my headlights.   

At first I was going to use two of these (one for low beams one for high beams). They are fully weatherproofed relay holders I got from Lordco.



But I didn't want to mount them in the engine bay because I'm trying to keep it nice and clean.  So then I noticed a heated seat wiring harness I had laying around and went "hmmmmm!!"



So now this means I will have an oem mount and location for my relays 

[zagarus]

Oh here's a question for the gurus.   I used a vacuum hand pump to prime the fuel pump and the lines.  Hooked it up to the return line and sucked fuel through the pump.  Well my question is how can I get the injector lines primed without actually cranking the engine over?   I tried sucking from the end of the tiny return lines that go from injector to injector but with no success.   There must be a way. 

[Kantdrivefast]

inline lift pump?

[vanbcguy]

There's not really any way I can think of to prime the injector lines WITHOUT cranking the engine over.  Standard operating procedure is to loosen the injector lines at the injectors and crank the engine over till fuel seeps out.  With the lines loosened the injectors won't reach their pop pressure so the engine won't start.

[zagarus]

ya that's how I did it last time.  alright guess that will be how it's done then.

[zagarus]

Manifold spacer came in today as well as the pin for the fuel pump throttle cable.   Managed to get the turbo and down pipe on, got the lighting wiring harness all sorted out (going to loom it up at home). 

Another question for the gurus.  The diesel tank I pulled from the wreckers was still full of diesel, now I don't know how long the car sat there but I do know for a fact that the fuel is pink.  It kind of looks like grapefruit juice.  Now would this have to do with it being really old diesel or is it possible it's marked diesel?   All I know is im going to siphon as much out of the tank as I can and refill it with new stuff.  Anyway on with the pictures (cell phone quality)

The much anticipated spacer  (didn't need it quite this thick because it barely left me any threads for the nuts to grab.





WOOO TURBO!!





Ceramic coated downpipe  (one made by Dave at PP long ago)





And a bit of intercooler mock up with pieces from my old setup  (should work nicely, only need a few modifications )