Klaus, the 84 Jetta TD, gets a rebuild

[arnold]

How exactly did you set the timing on the engine stand without flywheel and trans installed ?

[wolfsburged]

I had marked a spot on the timing sprocket against the block. Going to reset the timing now to 0.9mm anyway though.

[wolfsburged]

More progress!

Got a new steering column bearing and got my dad to press it in. Steering column all tightened up and reinstalled!

Also he came up with a good fix for the air box which had worn down the latch area:


Spent some time today fixing up wiring that was broken or about to break. Replaced the fan plug with new style to match the new fan.

Then got the turbo back on (had to get it sent out to get the broken stud out), got the downpipe on, and reset timing to 0.9mm.

Replaced passenger side axle with reman unit.

With the help of everybody up at the shop this weekend, got the engine back in! Resting on the side and front mount. Still need to get the rear mount on. Obviously still need to hook everything up!




More coming tomorrow!

[arsenicpants]

your injectors should not be connected to your LDA

otherwise motor looks great!

[Thezorn]

your injectors should not be connected to your LDA

Yeah, that won't work well that way.

In case your not sure, the injector overflow line that you have connected to the LDA should go to a barbed fitting on the back side of the injection pump.

The LDA line should be connected to your intake manifold (there should be another barbed fitting on the inlet elbow of the intake). It needs to be here because the LDA is controlled by "boost pressure" which adjust fueling accordingly.

-Will

[wolfsburged]

Just checking to make sure people were actually looking at my pretty pictures 

[R.O.R-2.0]

Just checking to make sure people were actually looking at my pretty pictures 

this is like diesel porn.. of course were looking!

great work BTW.. you are gonna have a BRAND NEW mk1 TD Jetta in the end..

[wolfsburged]

Got more done today. So close to being able to start!

Got the car up on the lift and connected the driveshafts, downpipe to exhaust (curse you toilet bowl clips!), front and rear motor mounts, and shift linkage.



Got a lot of the hoses connected, fuel lines connected, radiator and fan back in. Reconnected about 80% of the engine bay stuff. Need to do some more research on the wiring. Got stuck on a few connectors which I didn't label and can't remember where they go. I'll probably start another thread on matching those up.



Got stuck on the ignition switch housing on the steering column. Can't get it on far enough to get the bolt in that holds it to the outer column sleeve, seems stuck.. Also need to install the EGT gauge.

I'd say we are about one good day's worth of work away from a start attempt!

[mtnbob]

Beautiful work. I am taking notes and will reference some of your pictures as I try to get mine back together!!

[JessaBug]

Glad we can be of assistance! Its certainly been one heck of a fun project. I know I've learned a ton (its so much easier to learn how an engine works when its apart!). Not to mention, I've learned just how much I like wrenching on cars

Can't wait to get the car started again. We're so close! Hopefully just another day of working on it will lead to a starting attempt...

[wolfsburged]

I've posted a separate thread in the troubleshooting section for my wiring identification issues. Please take a look!

http://www.vwdiesel.net/forum/index.php?topic=27687.0

[wolfsburged]

Well after a few mis-steps, the engine is running!

Had to clean the grounding points of paint and run an additional ground cable to one of the starter bolts before it cranked.

Making good oil pressure. Drove it only about 3 miles total this weekend. Looks like the fan switch crapped out, and is leaking around the seal to boot. Tested the new fan by jumping the wiring at the switch and it works, so a new one is on order. In the short driving, only saw EGTs to about 5-600 *F.

Shift linkage is not quite right. Looks like the main shift selector rod got bent at the paint shop. Luckily found a replacement locally along with a full bushing kit and the other transfer rods.

Hopefully next weekend will rectify the shifting issues and radiator fan. Need to clean up some wiring and mount the EGT gauge more permanently. A few other misc. small things. Also need to get the coilovers installed and the rear bumper tucked.

But overall, running quite well! Very quick and easy starting, and sounding good!

[xxkoadyxx]

This is very sweet! im hoping to rebuild my spare 1.9td for my mk3 while its chillin in the garage.

[GEE-BEE]

If you want to fill in the gap between the radiator and core support let me know I will mail you the correct seal for that ?

Did you go to the MKII 250 watt scirocco fan  ( two speed) ?

GB

[madmedix]

Oh, I've got a soft spot for those Jettas. Beautiful job. I also have a soft spot for a lift and garage like you've got 
Good work.

Andy