DD'ing a Diesel for winter!?!?

[8v-of-fury]

Yo guys what up!?

Got a lot done this weekend.

Took the old pump off and checked the timing before I did so. Got a weird reading of 0.041".. which was weird for how it was running. I later found out the cold start was pulled out.. IDIOT!

While i had the old pump off i took the time to remove the old and burnt out looking Gp's and installed my nice new Bosch Duraterm's I wired them "Vince" style and it looks super clean, and works super well. Terminated the fuse bus on the driver side shock tower and have the solenoid located on the driver side frame rail. nice and discrete .

Speaking of the old pump.. I don't exactly know what is considered a lot of pump shaft play lol. I mean you can move the shaft back and forth.. but whats a lot? Some have suggested using it as a practice pump.. I mean i could do that.. but maybe there is a way to get some money out of it? what would it sell for?

Got the '91 pump on and timed to 0.040" Runs great! and nearly completely got rid of the smoke while running! I think I am now pro at putting on a t-belt and timing the engine now.. as i had to do it three times on the last engine before i got it right.. got it first try with this engine! I was sooo proud of myself . THIS THING RUNS LIKE A TOP!

The loud audible "CLUNK" of the solenoid can easily be heard from inside the cabin, which makes it good for knowing if the gp's are actually firing. Wired it up to a nice red toggle switch on the dash for some awesome after glow.. it really does help with cold running. started amazingly!

Started on the brakes today.. and the one thing i forgot to order, I NEED. Wheel cylinders.. I figured i could get away with the old ones... seals are toast and the bleeder screw broke off! DARNNIT. SO i will get them and some smaller tubing for the injector return lines (as the ones i have leak a little bit) and it will be good to go hopefully lol. Also need to do the pump head seal.. but at least it runs, and the pump only drips every 5 seconds.. lol And oddly enough it doesn't drip on the hoses lol it drips on the back pump bracket and drains down the block.. but that causes the engine to steam/smoke with the burning diesel lol .

I guess I will experiment with the old pump, maybe try out the Governor Mod. Try out replacing some seals so I can do it on the pump in the car later !

I HATE DOING BRAKE JOBS.

I need some good techniques for loosening the bleeder screws on the calipers..the brake fluid is black so i want to swap it out with some fresh Dot 4 stuff.

Ughh.. I also broke the rear brake line.. right at the connector for the wheel cylinder.. like WTH I think I will stick to engine work.. it ALWAYS works out for me! anything else never does.. lol What do i do? Can i just get new fittings and re-flare the old lines? I think that should work.. anyone know the size of the brake line fittings?

sorry FOR BLABBING. thanks guys lol.

Before:


After:

notice my pretty GP wiring SCORE!

Have a nice night fella's lol

[maxfax]

Had I been thinking I should have shipped you one of my junk IP's when I sent the goodie box up that way.. I have several that have been sitting dry in the back of a parts car with no plugs in them... I'm pretty sure they are crap by now... Take your time, read up, they actually aren;t hideously bad to reseal..  I managed with only the diagram that you posted on vortex..  I didn;t properly mark the smoke screw, but with a bit of drive and tweek it was good...

I've pretty much gotten to the point that when I buy another VW it gets wheel cylinders right off.. Those tiny little bleeders take nothing to break off..


You may be better off getting a section of pre made brake line.. Carquest and Napa carries the stuff..  VW uses a "bubble flare" which takes either a special tool, or some finesse with a double flaring tool..  A fitting that fits the wheel cyl and 3/16" brake line will work..  Brokevw has a writeup on the flares here http://www.brokevw.com/flare.html

Bleeder screws..   

Soak the living crap outta them with PB Blaster or equivelant.. Find a six point socket that fits them well (I forget the size, 7mm??)  If they round off, or are already rounded, get the vice grips.. Slightly turn the bleeder as if you were tightening it.. Don't go He-Man on the wrench, just slightly and gently..  This'll sometimes break the rust loose. Then give it a try, gently!  If it feels like it's gonna twist off repeat above steps...    Heat is an option, but a last resort..  Don't wanna nuke the piston seals.. And the bleeders are rather tiny..   Too much heat and they twist off rather quick..

  Once you get them loose, screw them the whole way out and clean the threads on the bleeder screw..  If you have some never-seize go ahead and use it, just make sure you install the never-siezed bleeder before you do your final brake bleeding so as to make sure there is non of that stuff floating in the brake system...

Worse case scenario, drill and easy out.. But remember, drill bits and easy outs are brass....

[maxfax]

One other thing..  IF you have some means, suck the old fluid out of the master cyl.. Well, at least what you can..   That way you won;t be flushing all the crap in there though the system..   

[8v-of-fury]

So I opted against bleeding all the fluid out because it was a waste of time at the moment, and sure to raise things that would hinder my progress.

The brakes work and they work good.. but you gotta press like you got 4 wheel manual drums lol! I was bombing it around some logging roads for about three hours today.. fuel gauge barely moved.. I LOVE IT that woulda sucked alotta fuel in my gasser. I was doing quite a few Italian tune-ups lol

I think I will practice the governor mod on the old pump.. and try re-sealing some stuff see how that all goes. then try it on the other pump when i know what the hell im doin right lol

Sadly however the car is parked till spring. i didnt get it all done in time.. I mean I could very well be driving it.. but im not ready to give up my luxuries that are in my other mk1.. lol

mk2 seats, mk3 wiper motor, in trunk lights (super idea), stereo, subs, fog lights, rad fan switch... i mean i could switch it all over.. but then what happens when it doesnt start right.. ? I mean the gasser has never given me one problem.. so i guess ill go diesel in the spring lol.