Just bought a GTD engine n' box... advice for refurbin'

[YoSono]

Hey guys... Firstly, i'm new to this forum, and indeed diesels so excuse me if i sound like a novice

Anyways, i currently drive a 1.6D caddy, and recently spotted a GTD in our local scrapyard. It had just come in, so it hadn't been touched. It took a bit of bump starting (the glow plug light didn't come on, and the engine turned but didn't start off the ignition) but once it got going it ran pretty smooth, so i took it for a drive around the yard, lol.

I decided to buy the engine and 5 speed box for a conversion on the caddy. It's done 150,000 miles, and the whole car looked stock with no mod's or messing about with. I know i have to have a custom downpipe made, but as the engine will be out of the car over the winter period (looking at getting it into my caddy in march '06) then i though i better attempt a strip down, and rebuild, so that i get the best out of it once it goes in.

So guys, what sort of things should i replace or upgrade? and is there anything i could do to the engine that would give it more power?

Cheers for listening guys... heres my caddy, and the engine before i took it out of the donor car:





you can take a look at our website here too: http://wearecentralpark.com

[jwspin]

are you from the states? i assume since ur website is central park you are from new york?
if so how did u score a gtd in a junkyard?
im jelous

-jared

[mpg]

i'm jealous, too!! :shock:  I'm sure this link will help with power. http://vwdiesel.net/phpBB/viewtopic.php?t=645

[RAMMSTEIN]

Where do they put the battery on a GTD???

I don't see it, or it was removed prior the picture was taken. :arrow:  :?:

[RAMMSTEIN]

are you from the states? i assume since ur website is central park you are from new york?
if so how did u score a gtd in a junkyard?
im jelous

-jared

Look at the wipers. Notice they are on the wrong (right) side?

Not on the caddy, but on the GTD...

He's (maybe she's, it says Rachel on the website provided) from Great Brittain, south Africa or Australia/New Zealand.

[YoSono]

LOL, my name is Lee, and my girlfriend is Rachel and i'm from Nottingham/England  :lol: We named our site Central Park, because of us being centrally located in the UK, and we hold VW meets in Parks rather than in pub car parks - simple really.

Will check out that link  :arrow:

cheers,
lee

[DieselsRcool]

I'd give anything  for that intercooler and tubing. Anyone need a left nut? :shock:

[mk1vdub]

Hey Lee
I'm in the UK too, down in surrey
I've got a GTD engine in my mk1, I completed the swap a little while ago, replacing the tired old 1.6 n/a diesel. Its an awesome conversion and makes a really neat package, I haven't calculated anything but I'm sure I could get 60mpg drving sensibly, but it also has a suprising turn of speed, especially since I've done a few mods .

for things to replace and upgrade it kind of depends on how far you want to go - I completely stripped mine down a rebuilt it with new rings and bearings but I bought it knowing it had been overheated so needed to strip it and check the head and have it skimmed anyway so it made sense to rebuild it.

at 150k it its getting on but it depends on how well its been looked after on its condition - you could strip it down and give it a good check to determine what might need doing?

a few things you could do are: pop test the injectors, renew glow plugs, renew oil pump, check the turbo for play in the shaft.

for more power there are quite a few things that can be done - a search around the forum should reveal plenty of results to have a read through, so you can decide what you might want to do.
there are a few things that it would be worth doing if you end up striping it down like, porting and flowing the head, and modifying the injection pump internally as these are obviously much easier done with the engine in bits and off the car.

as you mentioned you'll need to fabricate a downpipe, you'll also need to swap the drivers side engine mount for the one on the original engine  but with your caddy already being a diesel theres not all that much that needs messing around with.

anyway I think I'll stop there but feel free to ask me questions, and obvously you can ask more on the forum when you get more specific querys, when you decide exactly what you want to do

cheers
Paul

[tylernt]

check the head and have it skimmed anyway

What the... I thought you couldn't do that to VW diesel heads because of the prechamber inserts? Do you take them out and shave them separately or leave them in the head during milling?

Can this also restore a head warped from overheating?

[mk1vdub]

yeah my head was warped can't remember by how much? - the machine shop did take the prechambers out and therefore I presumme did them spearately, I did get a quote from a different machine shop who said they just skim the head as one with the prechambers in and haven't had any problems.....?

it would obviously depend on how badly warped the head is but if its within the right tolerances then yes you should be able to restore a head warped from overheating.

[YoSono]

Ahhhh cheers mk1vdub

I'm actually gonna build one of those aluminium sheds within the next month, which will give me ideal space to work on the engine. Gonna give it a strip down, and see whats what - it does kind alook like it's been looked after, with it also having new glow plugs oil and air filter, so who knows  - the car did look absolutely stock too.

oooo, actually, how do you poptest the injectors?

will get some pics of it once it's on the go - is there any posts on how to strip down a diesel lump that you know of?

cheers,
lee.

[tylernt]

it would obviously depend on how badly warped the head is but if its within the right tolerances then yes you should be able to restore a head warped from overheating.

Dang, thanks for the info. I guess I shouldn't have thrown away all the heads I've warped!!

Ok, so "all the" is really only two, but still...

[mk1vdub]

I don't remember a how to strip an engine down post off the top of my head but its fairly likely theres one here, and if not its definately having a good read around the site anyway - it truly is a wealth of information and makes for great interesting reading

unfortunately there is no manual which covers our exact engine as the bentley for the mk2 turbo diesel isn't the exact GTD engine as america never got it,though I think the only big difference is the intercooler, I would recommend getting the bentley manual: for Golf (Rabbit), Jetta Service Manual: 1977 - 1984 Diesel, which covers the mk1 turbo diesel which is basically close enough
which is available from here http://www.vwbooks.co.uk/
or here http://www.motorbooks.co.uk/

I had never rebuilt an engine before I did mine, but its not particularly hard, take lots of photos, label stuff, and if possible lay stuff out in order when it gets taken apart and you wont go far wrong

as for the injectors try some local diesel places and if they can't help they'll probably know someone who can
I just did a quick google and found this:

Gee Diesel Services Ltd
Unit 5
Daniels Way, Watnall Road
Hucknall
Nottingham
NG15 7LL
United Kingdom
Tel: 0115-963 7300
Fax: 0115-968 1233

give 'em a ring and ask?

heres my thread I posted about my mk1, its by no means detailed but it might give you an idea of whats to come
anyway good luck with it all and as I said - I've done this exact conversion already so feel free to ask me questions and I'll do my best to help

cheers
paul

[mk1vdub]

it would obviously depend on how badly warped the head is but if its within the right tolerances then yes you should be able to restore a head warped from overheating.

Dang, thanks for the info. I guess I shouldn't have thrown away all the heads I've warped!!

Ok, so "all the" is really only two, but still...

bugger thats a shame mate, well at least you know for the future - not that you want to warp anymore heads! :lol:

[regcheeseman]

I'm in exactly the same boat as Lee only a few weeks behind....

1.6 GTD motor into MK1 Caddy

I'm stripping the motor at the moment...

Noticed the turbo has very small amount of play in it - how do I know how much is too much? I've searched a lot but not found anything (found lots of other useful stuff though.

Shame that the Bentley manual isn't too good for GTD owners because I ordered one about 10 minutes ago on the strenght of an Amazon reviewer saying "this manual was excellent for working on my GTD" or words to that effect.  :roll:

Anyway another few questions for you GTD'ers out there....

my turbo is watercooled   it has what looks like the remains of a temperature sensor on the top banjo of the water feed to the turbo - should it be a sensor/switch and what's it wired to?

what is the big lumpy thing called on top of my IP?

On my IP there is what looks like a vacuum connection, strage rubber hood affair with a 1/8" pipe coming of - it has been chopped by the scrappy, where does it go and what does it do?


Lee! Hows the conversion going? how about an update on the caddy or are you not talking to me because I kept my chrome grille  :wink:  :lol: