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

[vwpieces]

Looks like you remembered to put the T-bolt in the waterpump before putting the alternator bracket on.
Ha. Hate it when I forget that after all these times.
Moving right along quickly.
 It looks great.
Took me hours to find the little standoff for the MK2 upper timing belt cover.
 But I got a chance to organize fasteners, inventory the hoard and did actually find one.


Is you lower timing belt cover from an AAZ or AHU?
 I'm thinking AHU.

Of course I remembered the "T" bolt.
After the alternator mount was on.

But you missed the upsidedown motor mount.

This thing has been apart and back together so may times now. Just wait till the next time it's apart to address that too. And that, and that ..

[vwpieces]

i sold him some of these bits, the lower cover is off of the ahu that's currently in my car. I think the aaz and ahu lower covers are the same or close enough, i used the aaz one on my ahu because it was already trimmed for running a v belt. 1.6 lower cover is different, the split where it meets the upper cover is more of a straight line where the aaz/ahu has kind of a z pattern

Only remember ya saying TDI, don't know engine code. Had to open center hole for the cast 068 pulley. Might need to remove the metal ring to clear the V belt too. Need to dig out an alternator. 90A on Jabbit, same bracket, and had to custom make an adjustment arm. Going same route here.

And had to post this one.

[fatmobile]

I have both covers (and a few 1.6 lower covers) here and I like the AHU one better.
 It looks stronger around the pully. Sounds like that makes it hard to use with the V-belt crank pully.
Makes sense, it's opened up a lot on the AAZ lower cover.
Glad he has someone local helping him with parts.
 These 1.9s are rare and can be hard to find parts for in the US, especially plastic parts.

Oh that motor mount is upside down, dang it.
 I fill the gaps in mine with urethane. Almost impossible to find the V-shaped heavy duty motor mount.
Parts geek said they had them for $35, then sent me the weak one they had for $10.
Refused to make it right so last time I bought from them.

 The head on the broken AAZ I'm playing with has a KS head on it.
 I really hope it survived,.. but a thrown rod can cause a lot of damage.

[vwpieces]

Managed to get the engine mount out with minimal paint damage. Hacked up a rusty mk1 diesel mount and sliced to be the receiver. Also used a chopped old mount to press with.

[vwpieces]

New main bolts arrived today. Had the old ones torqued to 48ft/lbs just temporarily.
Bolts in, NOS VW 026 oil pump, windage tray and NOS TD oil pan all buttoned up. No pics before pan went on.




Running out of SHtuff to do 
Today was more fixing things already done... Mount re-do and then found out the oil filter no fitty. Hits that curly hose from the water pipe.


MK2 pipe needed some re-bending, hose from WP to pipe shortened. Febi part, don't remember needing that on the Jabbit.
But it fits now.


Turbo clamped down, and the mk1 special support bracket to the cast iron DP installed.


Waiting on hose for drain pipe and oil feed fitting to AN for feed. 2 more glow plugs and the buss bar to install.
Oh, yeah, that bushing barely hanging on the alternator mount reminds me.... Alternator!





Need to clean/straighten the tin between engine and bell housing. Sort and dig up some flywheels, clutch parts etc.
And clean up the damn mess in the big shop from digging up parts. Take back and put away all the SHTuff I brought into basement and didn't use. That'll be a Few days work. Maybe the fittings will be here by then.

[vwpieces]

Anyone ever see one of the On a Bentley.
Not in the Bentley. 

[Dennis Froelich]

Cool tool!!

[fatmobile]

 Dang, chop,chopchop.
To press in MK1 motor mounts; I use flat plates with a hole to clearance the bushing center bump.

I have one of those belt tension checking tools.
 Don't really use it anymore.
 I adjust the belt so it doesn't vibrate a bunch between the crank and tensioner when running.

Using the MK2 metal waterpipe? How's that going to work with the starter/ front motor mount?

[vwpieces]

Using the MK2 metal waterpipe? How's that going to work with the starter/ front motor mount?

Craig, forgot to ask earlier. What Polyurethane do you use to fill the side engine mount?

It works, 6 years maybe? on the Jabbit.
I may have used the same on the 83 TD jetta too, that would have been 20 years.
need a reducer hose at the end to heater, think it's the 16V scirocco part. 533121623
I just cobble what I have and cut what fits for that one. Hose hoard is extensive. Big box of smaller ones up stairs.
V-belt collection is the other side of the stairs, wraps corner and 3X if counted by piece.
Local parts store usually has what I need in stock.
But that is where figuring out what I did or used 3, 5, 10 years later gets hard when you just use what you got and it fits. I would need to go back on vortex to see what serpentine pulleys I used on the 16V in the 2dr Jetta. Jabbit is right outside in this case...

Jabbit pipe and mount


Get hosed... Here

[vwpieces]

The Jabbit... not a typo. Guess I should have posted this earlier, for those not familiar.
Jetta hatchback. 
Quick story, I got a free rabbit. It needed fenders. Welp, I had Jetta fenders and was parting the rusty 83 TD Jetta I winter drove for 20yrs. Those fenders were junk but the front core support was salvageable.

[fatmobile]

 I see, the motor mount makes it past the coolant pipe.
I always thought there would be a problem with the MK2 pipe and MK1 starter/mount.
 There might be a different pipe/mount combo I was thinking of.

 Great selection of hoses.
 I have a bucket of them and a few hanging but not all the options like you have there.

 That front end looks fantastic on a Rabbit.