Franken Build, Need Parts Help 1y and 1.6TD Mixup

[vwpieces]

You going to put a turbo on it?

Absolutely.
I was prepping TD exh manifold and a 171 TD down pipe last night.

[vwpieces]

Mocking up parts to block to get an idea of whats Not going to work

No harmonic balance damper pulley. I have a V belt damper from 1.6 TD but pass. The 1.6 I'm running now I did not use one either.
VW logo INA T-belt tensioner pulley found in the hoard. Think the WP pulley is NOS too, 068***K I believe is the number on it.


No non AC alternator bracket to mock alternator but have crank and WP pulley alignment sorted. Hard to get the cast iron ones anymore. May need to just use the one on car currently that I fitted a 90A alternator on.
Think the 30mm WP is Graf, says Hecho in Germany on it... seriously, it does. Metal rubber later gasket to housing and stainless bolts.


Dug up a really nice set of 1.6 TD injector lines. And as predicted, they don't fit. But if one needs to mod earlier lines, these would be it because they have places where some length could be made. More squiggly's or service loop length than NA 1.6 lines.



Ordered a few N90577101 crank bolts (47mm), 12 point  with the Nub on end. About $3ea from AutohausAZ, Only to realize they used the older 1.6 TD crank bolt previously and it is 56mm long. Head is hammered from impacting, on/off a few times in it's life. But I think I am going to use the Earlier bolt again, saw a new one on ebay for $15. The couple I have in the stash are just as hammered as this one. This one also took the Big Boy M18 Milwaukee to get it off.
Even with the early HD bolt and being stoopid tight, I can still see signs of movement. Also looks like the mating surface on crank gear is Not flat. MIM or metal injection molding flaws, mold flaws, just wear? I dunno.


Found this 068105263C crank gear in the hoard. It is identical in every measure to the 028105263 I took off. Got it... Use It.


Did some deep digging and I came up with a new set of pistons, here in USA! Correct 24mm pins. NPR Europe brand. I have used the brand before and Shouldn't be made in China. Beat PPI price by around $100 to my doorstep.

[fatmobile]

I think you should use the later TDI crank sprocket.
With the flat spot.
 Those crank sprockets were a known failure point for the AAZ and 1.6D.
You'd have to make a flat spot on the crank but I can send you my special tool for doing that.

  The AHU came with a serpentine belt setup. I'm not sure how it works with a non-AC setup.
Otherwise I would use the MK2 alternator setup because the alternator is a 90 amp one.

The weekend is over so I'm going to start pulling the 1.9 apart and swapping it over to the 1.6.
I'll start a thread on the topic take some videos and pictures.

Also need to get the rest of the garden in.

[vwpieces]

I'm going to keep the notched crank timing pulley as is. Not going to have any substantial weight on crank snout and also only going to have one V-belt to drive. I DO have a New 6 point longer 10.9 grade bolt ordered.

Crank bolt differences


A Few parts cleaned up.

[vwpieces]

Couple sets of AAZ injector hard lines in the parts score. One set really rusty and did some chemistry test on them first.




UGLY


Did use the ultrasonic cleaner


Heated and did make some black phosphate on surface. But no rust anymore.

[vwpieces]

This is the nicer set I am going to use. After about 15min in ultrasonic solution.



I went a bit further to blacken or cold blue this set. Also dug up an IP with longer delivery valves and these lines fit perfect.


More Mock-Up and seeing what fits. 028 IM pulley and 068 IP pulley work.




But now to take it all apart and try to get timing covers to fit. I have a funny feeling I will need to use the AAZ IP bracket and Cut off the MK1 IP/engine mount. Todays adventure.

New pistons Will be here tomorrow.

[vwpieces]

Tried searching...
But I did notice the longer delivery valves I stole off an ECO IP have some really small holes. Anyone know if this is ultimately gong to be a restriction point?

Eco DV


And the one off the 1.6TD IP

[ORCoaster]

Any hole that size will have two effects.  Less delivery at the same pressure or equal delivery at a higher pressure.  Given the IP has plenty of push that really can't be increased by much, I would say you are going to get less fuel to the injectors compared to the stock 1.6 ones. 

[fatmobile]

 Is that the only injection pump bracket you are using?
 I think there is supposed to be one bolted to the front of the block too.

 I'm not sure the bolt pattern on the front of the block allows the 1.6 bracket.
 I believe if that bracket isn't on the front of the block, the belt will probably track off the sprocket.
 The difference between the AAZ and AHU pump brackets is
the one on the AHU has a place to bolt the extra idler pulley that goes between the cam and injection pump sprockets.

 I took some video of the different setups but haven't edited it yet.
 Should have taken pictures.
I have a 1.6, a broken AAZ, an AHU (that's going in a certain grey GTI, yes I still have it) and an ALH block all in the same area.
I might as well do a video on the differences and similarities.

[vwpieces]

Yes there is another bracket, hiding behind the IP. It does the rear supporting of the IP. And Yes it fits my 1Y block. However that all quickly got scrapped when I decided to try to install the timing cover inner metal.

Last Mockup with inner timing cover revealed I can not use the MK1 1.6 Diesel IP/engine mounting brackets. Now going with a gasser passenger side engine mount and a small diameter hole, cast iron AAZ IP mount. Smaller hole is same as the 1.6 injection pumps. I also flattened the front end of the gasser side engine mount in the press. I was looking for an alternator bracket to hack off the side that goes under the gasser engine mount but didn't find one in the hoard. Considered washers but then just flattened it in the shop press. But I did score a Non-AC Diesel alternator bracket I did Not know I had. I have one on the 1.6TD in the Jabbit but remember needing to source it on that build. Those AIN'T easy to find anymore.
Quickie mock-up, only pic I took with inner timing cover fit and the AAZ small hole IP mount that fits the 1.6L IP.


Blasted and most painted, another mount pressed in that gasser bracket too
Mount press tool and air over hyrdaulic press... like cheating. VW tool number US745




Flattened gasser mount


All blasted and now painted, just need to paint the opposite side of the inner timing cover yet.


And I was real happy to find this mount in the hoard. Didn't know I had it.


New pistons should be here Today! 3:30AM, off to get "some" Sleep.

[fatmobile]

Those non-AC alternator brackets are hard to find, glad you found one.
I have one with a place a for power steering on the bottom, even more rare.
I'll probably never put power steering in a Rabbit but I can, ha.
 
 I'm going to try to use the AAZ alternator bracket so it has a serpentine belt setup,.. but it will only have 3 holes mounting it because the top right threaded hole is missing on the 1.6 block.
 I just cut the MK1 injection pump bracket short to make the MK1 motor mount:


The AHU alternator bracket has an ear to bolt the extra idler to:
AHUinjectionpumpbracket by vwfatmobile, on Flickr

Good to hear the 1.6 pump will fit that mounting bracket.

[vwpieces]

Moving along... Last couple days work.

New pistons installed. New rod bolts etc.
Head is on and torqued. One notch MLS head gasket...


Intake installed, upper elbow in an NOS 068 from the hoard, rubber hose too.
Exhaust manifold on and torqued.
Didn't fully torque that turbo down, yet. Also need to dig out the correct support bracket for the 171 down pipe.




Moved on to fitting some 1.6TD oil return lines to the NOS oil pan. There were 2 pans, different angle on the fitting on pan and each used a different oil return tube.
Uncrimped the SS braided hose from the required return line to fit this pan. Taller block so it needs lengthening. New hose should be here tomorrow. 3 Otiker clamps at each end will be adequate.
Had to align the tubes.



Decided to use a -4 AN line for the oil feed to turbo. Line and all Stainless steel fittings arrived today. Still waiting for the SS banjo to -4 for top of oil filter housing, Stainless bajjo bolt too. Fitting for top of turbo to AN is steel. SS for that was elusive in my search. Well, did find one in Taiwan for a few bux but wasn't going to pay $20 shipping plus fees.

[vwpieces]

Did all the coolant hoses I can. Local parts store had all the hoses and even an NOS water pipe In Stock. 
OK, Parts store is in the second floor of MY shop.
Coolant necks and temp senders too.



And a Few more little things.
Injector line clamps, injector return hoses and NOS German Hella oil presure sender.