Author Topic: The old blue rebuild (1983 1.6 TD)  (Read 43302 times)

July 23, 2010, 12:13:53 am

dankcorey22

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The old blue rebuild (1983 1.6 TD)
« on: July 23, 2010, 12:13:53 am »
Hello guys my name is Corey i am 20 and this is going to be my first full size rebuild. I might have a lot of questions and thats why im here and to show yall another build project, I know yall like these. I bought this car about 2 months ago with 268,000 Miles on it. I bought it for $275 and then drove it home and even then added 2,000 more miles on the odometer! This is going to be a really really budget build with all the cheapest stuff i can find! ;)

Spec. 1.6L Turbo diesel  broken 5 speed trans. engine code CY Mileage start rebuild 270,012
My plans- 1MM over sized pistons :o, rebuild trans, new valves lifters, new seals and bearings, new timing belt kit, homemade 2.5 inch down pipe.

Well heres both of my cars togather








That down pipe and CV axels are a pain to get apart!


Heres how i got the exgust spring clips off








« Last Edit: September 15, 2011, 10:26:42 am by dankcorey22 »


MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods

Reply #1July 23, 2010, 12:18:30 am

dankcorey22

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #1 on: July 23, 2010, 12:18:30 am »
Heres my new pistons
 



Hehe thats me doing something






MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods

Reply #2July 23, 2010, 12:22:07 am

Smokey Eddy

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #2 on: July 23, 2010, 12:22:07 am »
I wanna see pics of your tdi! :D
but seriously, nice work. Have you seen anything about my catastrophe that is unfortunately a VW?
that fram filter may or may not give you issues. I got a puralator one once and it restricted the flow so badly it set off my oil pressure buzzer. Shoot for Mann or Bosch.
Ed
Blacked out mk2 AAZ Jetta RIP. You will be are missed.
White 1999.5 ALH Golf 2dr. 2" wider. 2.5" lower.

Reply #3July 23, 2010, 12:22:35 am

dankcorey22

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #3 on: July 23, 2010, 12:22:35 am »
Clutch and Flywheel



That little spring that holds the pressure plate on it a pain to get off. i cant imagine how im going to get it back on






MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods

Reply #4July 23, 2010, 12:24:20 am

Smokey Eddy

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #4 on: July 23, 2010, 12:24:20 am »
Your post tells me that my spring thing is too small for my 210mm clutch... mine from my 200mm clutch went in fairly easy.
well, yours a 210mm that's a bonus! that plus manual steering rack AND AC! you have it all! that engine looks to be in incredible shape.
Ed
Blacked out mk2 AAZ Jetta RIP. You will be are missed.
White 1999.5 ALH Golf 2dr. 2" wider. 2.5" lower.

Reply #5July 23, 2010, 12:26:50 am

dankcorey22

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #5 on: July 23, 2010, 12:26:50 am »
I wanna see pics of your tdi! :D
but seriously, nice work. Have you seen anything about my catastrophe that is unfortunately a VW?
that fram filter may or may not give you issues. I got a puralator one once and it restricted the flow so badly it set off my oil pressure buzzer. Shoot for Mann or Bosch.

Hey man! heres a video of my TDI in the engine bay check it out Overlook of the TDI.3g2  post a link to your failed VW haha
I liked the Fram so far it has not given me any problems
MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods

Reply #6July 23, 2010, 02:58:35 am

arsenicpants

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #6 on: July 23, 2010, 02:58:35 am »
nice progress :)
looks just like mine ;)

Reply #7July 23, 2010, 04:54:18 pm

dankcorey22

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #7 on: July 23, 2010, 04:54:18 pm »
Got it in the basement on the engine stand






Look the camshaft on the first lobe there is chunks missing


MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods

Reply #8July 23, 2010, 06:23:30 pm

dankcorey22

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #8 on: July 23, 2010, 06:23:30 pm »
I have a few questions about the advance pump spring timing. what spring do you supposed to have and when your timing the whole engine do i time it the same as if i had the stock spring in the pump? Thanks alot

Heres my spring out of my pump
MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods

Reply #9July 24, 2010, 02:10:59 pm

Rabbit on Roids

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #9 on: July 24, 2010, 02:10:59 pm »
Your post tells me that my spring thing is too small for my 210mm clutch... mine from my 200mm clutch went in fairly easy.
well, yours a 210mm that's a bonus! that plus manual steering rack AND AC! you have it all! that engine looks to be in incredible shape.

most mk1 cars had manual steering.

most mk2 cars had power steering.

Reply #10July 25, 2010, 12:15:26 am

dankcorey22

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #10 on: July 25, 2010, 12:15:26 am »
I have a oil pressure gauge and i need to know the best place to drill and tap a hold for the sending unit.
MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods

Reply #11July 25, 2010, 12:34:11 am

Baron VonZeppelin

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #11 on: July 25, 2010, 12:34:11 am »
Hey Corey, that 83 looks to be in pretty well kept shape.
Its the only 83 TD that i know about in our state.
Probly at least a couple few others somewhere out here, but they are scarce. Only know of one 84 TD.

Try to TEE off the oil port on the driver side of the cylinder head where the low oil sensor is. A tee will retain the sender too.
That is the lowest pressure/best spot to get reading from.

If it is an electrical gauge - you might can just splice into the wire for the low pressure sender.

Reply #12July 25, 2010, 02:50:35 pm

wolf_walker

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #12 on: July 25, 2010, 02:50:35 pm »
Good looking project, are you on ncdubs?
Many things we do naturally become difficult only when we try to make them intellectual subjects. It is possible to know so much about a subject that you become ignorant.
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Reply #13July 25, 2010, 05:27:07 pm

dankcorey22

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #13 on: July 25, 2010, 05:27:07 pm »
No im not on that but several people has asked me about it. I like to keep it all diesel tho   ;)
MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods

Reply #14July 25, 2010, 05:33:13 pm

dankcorey22

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Re: The old blue rebuild (1983 1.6 TD)
« Reply #14 on: July 25, 2010, 05:33:13 pm »
Hey Corey, that 83 looks to be in pretty well kept shape.
Its the only 83 TD that i know about in our state.
Probly at least a couple few others somewhere out here, but they are scarce. Only know of one 84 TD.

Try to TEE off the oil port on the driver side of the cylinder head where the low oil sensor is. A tee will retain the sender too.
That is the lowest pressure/best spot to get reading from.

If it is an electrical gauge - you might can just splice into the wire for the low pressure sender.


Hey man! thats awesome that its one of few in our state! It is in excellent condition for the year.

Im thinking of a way to TEE off the oil port, i know what your talking about but i dont know how i would tee off of it.
MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods