Author Topic: Sharing my 1.6td project  (Read 1165 times)

September 27, 2023, 09:43:41 pm

as4k

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Sharing my 1.6td project
« on: September 27, 2023, 09:43:41 pm »
Long time Audi/VW owner but new to diesels.  I found this site and have been combing through a lot of topics.  Seems like a great place to learn!
Wanted to share an interesting project that is applicable here but is an Audi.

Back in 2010 an Audi 4000 showed up at a show in Pennsylvania.  It was on a dolly and parked with our club.  I knew the guy who brought it and the car he had was really interesting.  It was a 1981 Audi 4000 turbo diesel 5spd.  I had never seen one of these as Audi didnt make or bring many of the td models here, and if so, most were automatics.  You see more 4000 diesels than these things.  So a lot of us poked around and I took some photos (which become important later), then that was it.  The reason the car was on a dolly was due to a hole in the block but I was never told why.





So years go by.  One of my car friends in Georgia ended up with the car and was going to resurrect it.  He sourced a nice proper CY engine code block and had the original head rebuilt.  He also sent the injection pump to Giles for a rebuild.  The car sat for years inside but not a whole lot of progress was made.  Fast forward to summer of 2022.  My friend asks if I would be interested in it.  I say of course and have it shipped from GA to IN.  Upon receipt of the car, the longblock was in the engine bay but everything else (nuts bolts, brackets, etc) were in crates in the car.  So this was going to be fun.





A few things about this particular car.  Its Helios Blue, has power windows, no sunroof, and has dual radiators (which was an option).  There was also a hand written story from the previous owner on the car but that appears to have gone missing.  I've been told this was a demo car for Audi/VW but I also believe it was some sort of emissions test car based upon the odd EGR set up AND the factory stamps in the maintenance book, along with it doing some 6000 miles in a month. 

Work started on the car immediately but I'll jump ahead and leave the better stuff for later.  Since GA didnt require titles for cars before 1985 it made getting one for this car a bit challenging.  A court order later I was able to title, register, and plate this thing.  Interesting fact is that since GA never required a title the original NJ title is still around.  Neat relic to have along with some paperwork from when it was bought from the auction after VW/Audi got rid of it.

Needless to say this thing was going to be a project.  I'm more of a 5cyl Audi guy but have owned 3 other 4cyl gas models.  The only other diesel I have owned (and still do) is a 2012 dieselgate Jetta.  Thankfully a good friend in our local car club is a VW guy and has an awesome VW caddy diesel truck, so he has been helpful over the course of a year.

I unpacked the car and tried to sort through everything.  Some parts diagrams were tough to find or not available.  A few of the EGR parts are nowhere to be found in any parts catalog.  Pretty much 90% of everything was there, but a lot of stuff needed cleaned or just plain replaced.  Thankfully the engine itself and injection pump had zero miles on them, albeit sat around for a while (pump had all the caps on the open ports).







Lots of cleaning and scrubbing, also seeing where things fit.





Time goes by and so many parts are ordered, installed, rinse wash repeat.  Got everything in terms of gauges, lights, all power windows, and locks working.  My goal was to get the car ready for the show in PA where I first saw the car, but that was May and it wasnt looking good.  I actually had the car running by then but the main radiator needed fixed (that unfortunately took ALL summer). 

So fast forward to a month or so ago.  The car starts ok, gets up to temp great, so I wanted to see if it moved and stopped.  I replaced the front calipers, pads, and rotors.  Rear drums were cleaned but the shoes and wheel cylinders were perfect.  A brake bleed and everything seemed good.
I had an issue after I got the car on the street.  The clutch pedal engaged VERY high, which made the car undrivable.  Add to that the brake pedal was hard.  Car would stop but it took effort.  This is where I'm at.  I ordered a seal kit for the vacuum pump and will install that tomorrow.  The clutch is another story.  I didnt realize there is a measurement for the release level in relation to the clutch cable bracket.  There is zero free play in the pedal so I need to get the cable off and adjust that lever, then start over. 

I'm dying to drive this thing.  Its got such an interesting story.  I reached out to Audi and every damn contact I have but cannot find production/sales numbers for 1981 models only.  I've heard of 1982 and 1983 turbo diesel models but never an 81.  With a 1/81 build date AND the factory build sticker in the trunk it all checks out. 

Appreciate you guys taking time to read this.  Here are more random photos.  I've got a youtube channel (Mike's Virtual Garage) and IG (mikesvirtualgarage) for lots of Audi content, and even a video on this thing.  Looking forward to learning here!

























1986 4kq
1981 4ktd
2012 Jetta TDI

Reply #1September 28, 2023, 10:35:42 am

Dennis Froelich

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Re: Sharing my 1.6td project
« Reply #1 on: September 28, 2023, 10:35:42 am »
81 is the earliest VAG car with a TD I believe...
79 Golf GTD
96 Golf GTD(TDI)

Reply #2September 28, 2023, 02:42:20 pm

as4k

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Re: Sharing my 1.6td project
« Reply #2 on: September 28, 2023, 02:42:20 pm »
81 is the earliest VAG car with a TD I believe...

Oh hey Dennis.  Nice seeing a familiar name.  Come on down to Fort Wayne sometime to hang!!

1986 4kq
1981 4ktd
2012 Jetta TDI

Reply #3September 29, 2023, 08:45:07 am

Dennis Froelich

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Re: Sharing my 1.6td project
« Reply #3 on: September 29, 2023, 08:45:07 am »
Will do. Nice to see faces I personally know.
79 Golf GTD
96 Golf GTD(TDI)

Reply #4October 19, 2023, 04:10:22 am

morgoon

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Re: Sharing my 1.6td project
« Reply #4 on: October 19, 2023, 04:10:22 am »
Great story,

Thanks for sharing with a great write up and pics..

Hope to see more!

Reply #5October 22, 2023, 12:02:49 pm

RabbitJockey

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Re: Sharing my 1.6td project
« Reply #5 on: October 22, 2023, 12:02:49 pm »
very interesting car.

especially because it's an 81, the turbo diesel engine wasnt released until 1983
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.