Author Topic: GREEN MACHINE  (Read 3279 times)

August 02, 2016, 11:39:10 pm

srgtlord

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GREEN MACHINE
« on: August 02, 2016, 11:39:10 pm »
Sometime around 2009 I purchased a 1992 4 door Golf with a 1.8 digifant powered motor. It was a very reliable car for the 5 years that I drove it but decided to have engine management electrical issues the moment I gave the car to my Dad..... Fast forward to May 2016



The car has been sitting for 3 years. The 1.8 gas motor was pulled out for my Cabriolet carb project.



I knew that from sitting so long that the floor had rotted out and a small rust patch had formed above the rear axle. I pulled off the rear beam to see how bad the rot was...




Yep , so I spent the next week cutting , gringing and welding new metal  in.






Also had to weld up the driver's side floor too





After the welding was completed the time had come to find a donor vehicle for an engine. In this case it was a 1981 vw caddy pickup truck that the body had rotted away on.

It was quite a process to yank the motor out in the middle of a farmer's field



Once the motor was out it was time to prep it to go from an mk1 motor mount setup to an mk2. It was convenient that all of the bolt holes were already drilled and tapped from the factory. The mk1 tranny did not however have the proper bolt holes so I reused the transmissionn that was bolted up to the gas motor.


 Ran into a bit of an issue with the stamped steel non/ac bracket not having anything to bolt to. So I made my own 3rd mounting point :)


After installing a TDI starter for a 2000 automatic jetta, a new timing belt , and upgrading to the one piece rubber valve cover gasket I bolted the engine in and attempted to start it.





Well it turns out injection pumps do not like to sit for over 12 years at a time. It started alright and went to full throttle...

Turns out the governer was stuck.


Fixed that and the pump just would not keep the car running even though I had fuel to all 4 injectors. Swapped the injectors out and still had the same problem. Swapped a different pump in and voila! Purrs like a diesel kitten should :) I want to give a Big thank you to all you diesel folk on this forum for helping me on this project

Anywho enjoy this video of this thing running
https://youtu.be/DrDt1SNQPWo



Reply #1August 03, 2016, 12:45:56 pm

RabbitJockey

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Re: GREEN MACHINE
« Reply #1 on: August 03, 2016, 12:45:56 pm »
digifant is great when it works, and its fun to fix if you like to tinker... but its not fun if you just want the car to run haha.  now its time for a turbo
98 Pontiac Grand Prix GT:stock daily
 81 Jetta: in progress 1.6td, ported head, holset turbo.
81 Rabbit:AAZ, hybrid T3 turbo, Giles pump, lightened fw, and yellow clutchnet clutch.

Reply #2August 03, 2016, 03:37:03 pm

ORCoaster

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    Restoring a Caddy as time and weather allows
Re: GREEN MACHINE
« Reply #2 on: August 03, 2016, 03:37:03 pm »
Nice use of the excavator engine hoist.  Not everyone has that at hand. 
Rabbit repairs to body damage need attention before trying to sell it in the spring

Reply #3August 03, 2016, 09:43:55 pm

vmb

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Re: GREEN MACHINE
« Reply #3 on: August 03, 2016, 09:43:55 pm »
Oh, that's pretty awesome. Nice work.
1986 Jetta 1.6l TD
2003 Golf TDI, ALH with Malone stage 1, EGR delete & 2.5in straight pipe exhaust

Reply #4July 03, 2017, 06:54:38 pm

srgtlord

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Re: GREEN MACHINE
« Reply #4 on: July 03, 2017, 06:54:38 pm »
Fast forward to 2017 lol I put the original pump back on and BLAM it runs with no leaks

Reply #5November 22, 2017, 03:30:39 am

VWee

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Re: GREEN MACHINE
« Reply #5 on: November 22, 2017, 03:30:39 am »
too bad the photos aren't loading. Anyway, good job because it has no leaks

Reply #6August 09, 2019, 05:56:54 am

seamaster301

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Re: GREEN MACHINE
« Reply #6 on: August 09, 2019, 05:56:54 am »
How is it now?

Reply #7November 15, 2019, 12:57:33 am

bedgyalf

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Re: GREEN MACHINE
« Reply #7 on: November 15, 2019, 12:57:33 am »
Can't see clear photos of the car. Too bad.

Reply #8August 01, 2020, 09:39:09 am

srgtlord

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Re: GREEN MACHINE
« Reply #8 on: August 01, 2020, 09:39:09 am »
Project came to an abrubt end when massive amounts of rust were found in the front frame rails,  rear shock towers, front shock towers, the support structure of the roof and the firewall. Wasnt much metal left on the whole car.... The transmission went to my 85 golf and the engine sits awaiting a rebuild