The old blue rebuild (1983 1.6 TD)

[wolfsburged]

I'm in Raleigh and have a close relative to your car, but mine's an '84 Jetta GL TD vs your 83. Pretty rare in this setup, and looks like you have a real nice example to start with. I'll be starting the same project this coming weekend for a rebuild. Will be keeping a close eye on this thread. I'm on NC Dubs as well.

We need to have an NC IDI diesel meet at some point.

[dankcorey22]

I'm in Raleigh and have a close relative to your car, but mine's an '84 Jetta GL TD vs your 83. Pretty rare in this setup, and looks like you have a real nice example to start with. I'll be starting the same project this coming weekend for a rebuild. Will be keeping a close eye on this thread. I'm on NC Dubs as well.

We need to have an NC IDI diesel meet at some point.

Are you gonna post pics of your build? Your car has a moon roof right? I know we need to have a meet some where i would like to see some other diesel mkI and MKIIs around NC

[dankcorey22]

Drilled and Taped a place for my EGT probe






Heres the oil pressure gauge sending unit. im still thing about how im going to tap off the low pressure switch. that sending unit is pretty big

[Baron VonZeppelin]

We need to have an NC IDI diesel meet at some point.

We could all gang up and go crash the VW Gasaholics get-together at Tom's shop in Winston sometime.

Corey, try these:

1. hooking up your gauge by a wire going to the low press sender and see what happens.

2. see if the new sender will screw into the head without leaking. Some of the senders are not metric threaded. But sometimes you can run a metric die on them an convert them.

I'd rather have the gauge than the low press warning.

3. Most hardware brass TEE's will be standard thread sizes - but hopefully you can find or improvise something eventually. I'm not sure how the Mk1 GTI and cabby's have the senders arranged, but they have gauge sender and warning senders, both. Maybe you need some hardware from a gasser.

[theman53]

I bought an air manifold with 1/4npt inlets. Then you can either tap the spot you want from the factory m10-1.0 to 1/8npt and get an adaptor from 1/8 to 1/4 OR Buy a special M10-1.0 to 1/4npt fitting. I did this so I could run the turbo feed, oil temp, and oil pressure.

[dankcorey22]

I think im going to eliminate the low oil pressure switch and just tap the gauge into the head instaed

[theman53]

http://cgi.ebay.com/3-Way-Air-Connector-Manifold-Solid-Brass-/170510404813?cmd=ViewItem&pt=LH_DefaultDomain_0&hash=item27b3364ccd

That is what I was talking about. Then you can run both

[dankcorey22]

Thats really neat ive never seen anything like that, but i doubt my oil pressure sending unit will work. Its too big

[Smokey Eddy]

your egt sender looks eeeeerily similar to mine
in location and product

ps. I THINK (someone please correct this if im wrong) but the low pressure switch, blue[on the right side of the head], triggers no matter what where as there is a higher pressure switch, grey[above the filter], that triggers over a certain RPM read from the W terminal (blue wire) on your alternator.

You want to keep the blue one and can scrap the grey one if you're improoving the monitoring with a gauge. That way if you have catastrophic oil loss the low pressure switch will still set off the light & buzzer in your dash incase your gauge fails to raise your awareness.

[dankcorey22]

your egt sender looks eeeeerily similar to mine
in location and product

ps. I THINK (someone please correct this if im wrong) but the low pressure switch, blue[on the right side of the head], triggers no matter what where as there is a higher pressure switch, grey[above the filter], that triggers over a certain RPM read from the W terminal (blue wire) on your alternator.

You want to keep the blue one and can scrap the grey one if you're improoving the monitoring with a gauge. That way if you have catastrophic oil loss the low pressure switch will still set off the light & buzzer in your dash incase your gauge fails to raise your awareness.

That egt probe was dirt cheap all this stuff im getting is! i like my gauges tho!

I think i might just use the oil pressure gauge and scrap the one on the head i dont think its that big of a deal.

But i do have one question i was pressure washing my block the other day and a oring type thing got blown out of the block i have no idea what it was or where it goes. It was a really baby round oring, Im afraid if i get the engine back together i wont have any oil pressure because i dont know what it goes to or the location.

[jseeley]

.... one question i was pressure washing my block the other day and a oring type thing got blown out of the block i have no idea what it was or where it goes. It was a really baby round oring, Im afraid if i get the engine back together i wont have any oil pressure because i dont know what it goes to or the location.

how small? dipstick o-ring?

[wolfsburged]

Heres the oil pressure gauge sending unit. im still thing about how im going to tap off the low pressure switch. that sending unit is pretty big

I have a similar sized dual sender from a Cabriolet - came with the triple gauge setup I got. It is too big to fit in the stock warning sender spot, the oil return line is in the way.

I was thinking of either getting a T fitting or using some sort of relocating kit. Other option I would like to try is getting a seperate, smaller pressure transducer and tapping another hole in the head for it. Interested to see what you do.

What EGT setup are you going with? I've been eying up the Isspro gauges. I like the green/yellow/red markings on the gauges.

We should organize and NC diesel meet sometime. Todd - I still need to see these trucks of yours!

I'll post a build thread here once I start pulling the motor. For now, you can check out the past 2 years worth of progress on NC Dubs. It's been a joint project of my now-wife and I. http://forums.ncdubs.org/showthread.php?t=11115

Another NC Dubber just picked up a 2 door silver Jetta diesel.

[JessaBug]

Definitely awesome to see another Mk1 TD around the state! I'm Wolfsburged's wife

Definitely should check out NC Dubs. There is an '82 diesel Jetta that just got picked up in Havelock, I think. Got another Mk1 Jetta in Raleigh too getting worked on, but its a gasser. Seems as though the Mk1s are gaining in popularity lately.

Good luck on the rebuild! We'll definitely be watching the progress, especially once we get started on ours, which will hopefully be this weekend.

[dankcorey22]

.... one question i was pressure washing my block the other day and a oring type thing got blown out of the block i have no idea what it was or where it goes. It was a really baby round oring, Im afraid if i get the engine back together i wont have any oil pressure because i dont know what it goes to or the location.

how small? dipstick o-ring?

Like dime size. But the block is at the machine shop so i cant look at it at the moment

[dankcorey22]

wolfsburged Thats going to be a awesome build! I am going to keep tab on your build

With the oil pressure gauge im just going to wait and see what happends cause thats going to be hard to rig something to work

I went with a Ebay EGT gauge. http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItemVersion&item=300431217753&view=all&tid=446814401020

Tell me when you want to do a meet and we can work it out( but ofcorse after we get our builds finished)