Klaus, the 84 Jetta TD, gets a rebuild

[wolfsburged]

Small update...

Parts are at the machinist. He got the head bolt out. Some possibility that the head is salvageable. We will see after the final report.

Also sent the turbo off to G Pop Shop today.

Hoping to hear soon that Giles has received the pump.

Now mostly will be concerned with cleaning what I have left until parts start rolling back in. Compiling my list of replacement parts I need. 

[wolfsburged]

Update from the machinist. Head is reusable! Pistons are not. Looking at 0.020" overbore.

Best source for good new pistons for the TD?

Power washed the bay last weekend to good results. Looking to have someone paint the bay possibly before the motor goes back in.

[Baron VonZeppelin]

I knew that head was gonna make it !
(well - fingers and toes crossed anyway)

Don't toss the old pistons, i'll take em before they go to the garbage.

You know who has the best price on pistons, down south of us.
Can't get close to his piston price, many have used them.
Rings, nope.

4pack of Kolbenschmidts pistons is supposed to be the ticket.
Myke_W deals in them, AutohausAZ, and vwdieselparts.com (< NOT a Prothe website) its the guy named Jack in Ohio - pretty sure - and he has a VW Diesel forum also.

Have guns - can travel.
BaseCoat/ClearCoat silver metallic in the bay ?
Let me know if you need me on that.

[wolfsburged]

Working on my rebuild parts list. Trying to cross-shop this to get prices down.

A few questions:
Valve guides - I see 42.5 and 36.5mm listed. Machinist just said I need new, is there a hard/fast rule on what size the TD would be, or do I need to do more research on which I have?

Bearings - I was leaning towards Kolbenschmidt along with the pistons, but any brand preference between these vs Mahle or Glyco? Are the integrated thrust bearings better or worse, as long as they are fitted properly?

Clutches - I am assuming 210mm, but need to check on this.

Bolts & Hardware:
I'm not 100% on these, as I'm not 100% sure what can be reused vs stretch type.
Obviously new head bolts. Looking at ARP, but $175 a set!
Con rod bolts & nuts - do these need to be replaced? Nearly $100 for everything here.
Main/crank bolts?
Crankshaft sprocket bolt - needs to be replaced, correct?
Flywheel and pressure plate bolts - need to be replaced, correct?

I've worked up a spreadsheet of parts, with #s and pricing from vendors. Maybe someone can look through quickly and see if anything looks amiss on brands, pricing, etc? I went mostly with Autohaus AZ and Bus Depot for pricing. Can't get it to post inline, so you'll have to link in to it:
http://www.knightcreations.com/jetta_parts.htm

[rallydiesel]

I use Glyco main bearings and haven't had any trouble. Integrated thrust bearings suck because they provide 50% less surface than the separate thrust bearings. If you do decide to use integrated bearings, make sure that when you start the car, DO NOT PRESS IN THE CLUTCH PEDAL! Disengaging the clutch puts pressure on the thrust bearings and will accelerate wear to these bearings and the crank thrust surface at low oil flow conditions.

[wolf_walker]

I'm glad I'm not the only one that does spreadsheets of parts.  And not just at work.

[theman53]

If you go to summit racing they used to have the head studs for 130
I have a TD coolant pipe for cheap
Myke W on here has the 6 piece main bearing set like factory had and they are cheap here is his site
http://www.thedubdoctor.com/parts_site/

[jack's lack]

I used the Glyco's on mine. I got them from Myke W. a lot of folks have had trouble with the integrated thrust washers. I would avoid them. I went ahead and had all my bearings low-friction coated by swaintech as they were doing my pistons it seemed like a drop in the bucket, but I understand this is a budget build. Oh and I don't know if the 1.6 engines have it, but on the 1.9TD the no. 4 main bearing has a 360º oil channel so you end up with 4 flat and 6 grooved main bearings in the set. This apparently feeds oil to the aux. shaft. My MKI Bentley does not mention it.

I think you will find that for the price of stock stretch bolts it will only be a few more $'s to go up to the ARP, and if you are going to run a lot of boost I would definitely at least do the headstuds. They will pay for themselves. Especially if you ever need to remove your head because you maybe messed up and inadvertently ordered a TDI head gasket by mistake and ended up spending 6 hours swapping it out like someone I know  

updates? and lets see pictures of those coils we all helped you win  

[wolfsburged]

Well sent of the order for my parts tonight.

Ended up going with the Glyco bearings w/ seperate thrust bearings. Also went ARP for headbolts and also rod bolts.

Hopefully will start seeing parts come in before too long.

ISSPRO EGT gauge and Aircraft spruce probe showed up a few days ago.

Finished moving stuff out of the engine bay and rolled the car down to a nearby paint shop that is going to be painting the bay while the engine is out.

Dropped off a box of brackets and bits, including the radiator fan shroud, at Top Coat who is doing some powder coating for me.

Also thanks to everybody's vote, we ended up winning the BFI coilover contest!


Probably will be a bit before more updates. I've been out in California visiting my ailing grandmother and just found out that she has passed away. Next week Jess and I will be traveling out there again for the memorial, so slow progress/ less budget for now.

[wolfsburged]

So now that the forums are back up, a bit of a backlog of an update!

So some photos of recent developments...

First of all, had the engine bay painted! Pretty happy with how it came out.


So fresh and so clean, clean

Also took all of the parts we scrubbed on over to Top Coat for powder coating. First batch is back, waiting on a second... Very happy with the results, and the price.


Misc. brackets


Intake manifold.

Got my Aircraft Spruce EGT probe, and drilled and tapped the exhaust manifold. Also got ARP Head Bolts, Rod Bolts, and Main Bolts (Not pictured).



R134a AC retrofit parts also have started arriving. New parallel flow condenser and new compressor have arrived. Will need to make up some new custom barrier hoses as well.


AC compressor. Slightly longer. Don't think it will be an issue. SD-508 style made by Behr.


Condenser

Painted the transmission and some misc. bits as well.


Hi-temp silver paint

And then most excitedly, some performance goodies!!

First, rebuilt "SuperPump" courtesy of Giles at Performance Diesel Injection!


That is a sexy pump!

Aaanndd a freshly "performance" rebuilt Garrett T3 courtesy of Gpopshop!



Hopefully block and head will be back tomorrow! Going to get some paint on and then go off to H2O! Then hopefully moving ahead with some steam again soon!

[Baron VonZeppelin]

Great STUFF and nice work !!

D
E
L
U
X
E

Pretty soon its going to be 1984 all over again 

[catlin_cava]

the picture of the pump made me weak in the knees  , Your looks mint, Good Luck with the build

[wolfsburged]

What is the board's general opinion on replacing oil pumps during rebuild? I can see nothing wrong with the pump I have, I checked the gear backlash and according to Bentley specs it is fine.

[catlin_cava]

Did you have any previous oiling problems? If not I would leave it, but it is taking a chance at the same time.

[arb]

with all your time and money invested so far, I'd pop a new one in. I think there's an option for a higher volume pump - can't hurt with your turbo...