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81

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by fatmobile on March 03, 2024, 10:01:30 pm »

  Ahhh too bad some stuff didn't fly out and then it turns.

 No, I have had several friends who got burned by parts place.
 Try fcp euro or maybe autohaus AZ.
 Rock auto is a good place.

 Did you figure out what cylinder is stopping the piston?

 I wonder if the flywheel was put on wrong.
 Been a long time since I heard of someone changing the clutch and screwing that up.
 While the injectors are out see if you can confirm the TDC mark on the flywheel is at TDC.
 Maybe feel where the piston is as the valves are opening.

82

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by Mohatanous on March 03, 2024, 04:36:22 pm »

Also, when looking up parts for this, is this a reliable site?

https://www.partsplaceinc.com/amfinder/?find=1983-rabbit-1-6-d-153473991&p=2

I typically use Rock Auto for all my other things, but didn't know if this site would be decent for things Rock Auto may not have.

83

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by Mohatanous on March 03, 2024, 04:11:54 pm »

After pulling the intake manifold off I was able to see inside a bit with a camera I have for peeking into small places like that. I was able to see all the intake valves moving freely, and all of the exhaust valves also appear to move freely and without sticking from the top when I turn the camshaft by hand. I was able to see the pistons coming up to the top of their rotations on each cylinder, but it still does not turn a full rotation. Pulling the injectors and glow plugs out and a combination of blowing air with a vacuum on the intake valves has not helped the issue, (I made sure that the intake valve for each cylinder was open while I had the vacuum on it to make sure any small crap may have been sucked out). I did not see any debris in the cylinders from my viewpoints. At this point I suppose my next step would be removing the head, although now I wonder if it could be something in the bottom end?

The saga continues!

84

IDI Engine / Re: Booster full of brake fluid

« Last post by ORCoaster on March 02, 2024, 06:11:17 pm »

Yesterday I got to tearing into an MC and proportional valve I found on Craigslist.  MC looked pretty good and once I cleaned up the little bit of rust inside the bore I was able to bench bleed it and have it hold pressure with all ports sealed off.

The proportional valve was a different story.  If you have ever had the chance to pull one apart the bottom tow caps are under heavy spring pressure and will shoot off at you if you are not prepared for that.  I back them out a bit with the wrench then throw a rag over the end and slowly remove them all the while pushing down on the cap.  I did this with the first one and sure enough right at the end it kind of sprang at me.

The other side was not pushing at me at all.  Odd I thought and once I got it out of the valve body I saw that the spring was rusted up tight and I was just waiting for it to shoot the red valve stem across the room.  I was able to pop it apart and clean it up without damage to man or valve.  But that was the tightest I have ever seen a spring all rusted up like that. 

Today I went out in the sleet and rain and checked on the booster before I tore off the old MC.  I couldn't get it to hold a vacuum at all.  I was only using a small volume hand pump and the weather got so bad I had to quit, or rather decided enough of this.  I might try the old vacuum cleaner I use for the floors in the truck and see if I can get enough volume out and have it hold with that.  The weather is not supposed to be much better for a few days so maybe next weekend. 

85

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by ORCoaster on March 02, 2024, 05:59:40 pm »

If the mice left anything in the intake and it got pulled into or fell into the cylinders then You need to pull off the intake from the back of the engine and put a shop vac on each cylinder and rotate the crank back and forth to see if you can pull anything out of there.  You might pull the glow plugs or injectors off so you can get air in from the underside of the head and suck it off the valves.

Just my thought on it.  If you have one of those chip/sawdust collectors that go between the shop vac and the end of the hose use it.  That way you will be able to tell us what and how much crap you had in there messing with your start-up.

86

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by fatmobile on March 02, 2024, 11:09:56 am »

  It might be a piece of nut shell in there, from the mice in the air filter.
 Or a dead mouse.
 A bent valve might show itself with the valve cover off, looking from the top.
Can you tell what cylinder it is? So you kinda know what valves to look at.
 1 and 4 TDC, or 2 and 3 180 from TDC, then what valves are open.

 Great idea to turn the engine by hand first.
Might want to try turning the cam too.
 Maybe pull the intake first so more stuff the mice left in there doesn't go into the engine. That won't cost anything, the intake gasket probably won't fall apart.

87

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by Mohatanous on March 01, 2024, 10:34:30 pm »

Also, I'm not sure what this may mean, but when turning the camshaft it would not turn smoothly, but rather would move in sudden bursts, sort of like hitting compression. I'm not sure how to describe it, really. Thanks!

88

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by Mohatanous on March 01, 2024, 08:49:24 pm »

Update:

Upon digging a small amount more into the issue, I managed to get the camshaft to the position it is supposed to be in, but upon trying to turn the motor to the TDC mark on the flywheel view port, it will not go to the "0" mark, as that is where it is sticking. I'm suspecting there are bent valves and that the head now needs to come off, so that is my next step. What else should I check after pulling the head off? Does anybody have suggestions for what I should do if I get the head and valve train redone? Any recommendations would be great!

Thank in advance!

89

IDI Engine / Re: Booster full of brake fluid

« Last post by Rabbit79 on March 01, 2024, 10:36:14 am »

After I exorcised the brake demons from mine they were floating around searching for their next victim and apparently you were the closest. hehe

90

IDI Engine / Re: Booster full of brake fluid

« Last post by ORCoaster on February 23, 2024, 09:42:05 pm »

I am reading this and the old posts thinking.  While I was out tooling about the town I noticed a lack of brakes and the MC doesn't seem to hold when I push down and hold the pedal.  It slowly sinks to the floor.  So, maybe a bad seal in the MC. 

Odd that my brakes act up as you update us that yours are finally fine.  There must be some yin-yang thing going out there that some number of VWs must have bad brakes all the time to keep the planets in line or something.