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Engine Specific Info and Questions => IDI Engine => Topic started by: Ziptar on October 14, 2007, 12:45:06 pm
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Ok, after a year of talking about it.... it's Go Time!!!
(http://ziptar.com/eco_carat_project/eco_carat_project_1.jpg)
I spent yesterday degreasing the Eco and ripping out the soaking wet moldy interior, there was actually standing water and lots of rust under the moldy carpet.
(http://ziptar.com/eco_carat_project/eco_carat_project_3.jpg)
(http://ziptar.com/eco_carat_project/eco_carat_project_4.jpg)
Just as I was finishing up my buddy showed up with the 89 Carat in tow. Fresh out of almost 4 years storage in his garage.
(http://ziptar.com/eco_carat_project/eco_carat_project_6.jpg)
(http://ziptar.com/eco_carat_project/eco_carat_project_7.jpg)
(http://ziptar.com/eco_carat_project/eco_carat_project_8.jpg)
So today I have begun removing all the gasser junk from the engine compartment, and pull the wiring harness. Next weekend I'll most likely pull the motor give the engine compartment a good cleaning and maybe even get the Eco motor out.
After that I have to start swapping in the CE2 TD wiring harness and figure out hooking up to the CE1 power options. After that swap the fuel tank and lines and finally drop the Eco in after I fix the leaky IP and do stuff like the timing belt, gaskets, seals, and etc.
This is going to be a daily driver so my only mods really are a GTD intercooler, 1.6 LDA, gutted cat, and light pump tweaks.
Beyond that I need to find a sunroof head liner, and do the suspension and brakes. It has "new" eibach lowering springs and Boge turbo gas shocks but, I don't like the look or the ride of lowered cars. And finally a good detailing. With any luch I'll be done by Christmas, maybe sooner work owes me buckets of time,maybe I'll take a week off and focus on the swap.
I think I might use the ASF Code Carat Transmission, seems like for highway use it's the way to go.
Code 1st 2nd 3rd 4th 5th R&P
AVX 3.45 1.94 1.29 0.91 0.75 4.25 Ecodiesel
ASF 3.45 1.94 1.37 1.03 0.75 3.67 Carat
With the Stock tire size of 185-60-14 the ASF Tranny looks to be 2848 RPM at 70 MPH, the AVX would run 3298 RPM. I just worry around town it might be tough, or maybe I need to keep the AVX trans with the lower 3rd and 4th and put the AVX 3.67 Final on it. Not sure yet. I'd just like to get it going for now, maybe swap that later.
I'll post Updates (and probably allot of questions) as things progress, for now i am off to remove more engine copartment stuff from the Carat.
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Very nice, it's great to see this project taking another step forward :D
I think you should use the ASF box, I asked about it before on here and everyone seemed to like it.
That carat looks good, keep the pictures coming
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If you don't use the AVX trans, and it's good, I'll take it.
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Progress Report:
Taking a much needed week off of work this week after 2 months of 60-80 hour work weeks.
Got the gasser out of the Carat today. :D A freind of mine has a hoist he is letting me borrow but, the engine removal was going so quick I didn't want to stop to go get it. I dropped the motor and tranny with a jack. I'll pull the TD and install it with the hoist though.
Tomorrow I pull the interior and the wiring harness. Have to clean the engine compartment, and start swapping in the TD wiring harness and join it to the Carat power stuff.
Tthe battery tray is a bit rusty so while it's all apart I ordered the $18.00 POR15 Starter Kit (https://www.por15.com/prodinfo.asp?grp=SSK&dept=1) should be plenty for the tray and not bad for the price. At least I won't have to worry about it rusting anymore.
oh, yeah.. The hood isulation pad migrated it's way over to the Carat too.
and of course... PICS!!
(http://ziptar.com/eco_carat_project/eco_carat_project_9.jpg)
(http://ziptar.com/eco_carat_project/eco_carat_project_10.jpg)
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Not bad progress for the remainder of the week. I swapped the diesel fuel system, fuel tank, and exhaust in, degreased and pressure washed the engine compartment, pulled the interior and started swapping the CE2 diesel harness in place of the CE1 Digi harness. The Carat Power stuff is turning out to be easy to hook up. I'll work on the wiring nights this week and probably pull the TD engine this next weekend. Need to get the donor car out of the garage, it's getting really cluttered.
When swapping the fuel system over, I found that someone had completely removed the water separator, only the sensor was hanging and it was wrapped in electrical tape, I guess I know why my glow plug light always blinked now. I'll have to get another one.
Anyone have an opinion on which brake booster I should use?? Does it matter? I am leaning towards the diesel one at the moment, just seems like the right thing. I am swapping over the tilt column from the 1991 anyway so it'll be easy to do the booster too.
Also thinking while I have the interior apart, I should probably put a new heater core in just because I am there. I am also thinking about removing all the batting used for installation under the dash and replacing it with some sound deadning material? Good idea?
PICS!
(http://ziptar.com/eco_carat_project/eco_carat_project_11.jpg)
(http://ziptar.com/eco_carat_project/eco_carat_project_12.jpg)
(http://ziptar.com/eco_carat_project/eco_carat_project_13.jpg)
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My humble suggestions before you put that dash back together...
- sound-deadening material is always a good idea AFAIK; but I've discovered in the last couple of weeks that having all the fasteners (machine screws) present really help with the cold start rattles. I even put 1/8" foam tape around a instrument cluster I just got with a tach in it to prevent that really annoying plastic-on-plastic rubbing sound my last two high mileage diesels eventually get between the clear plastic and dash insert (I commute).
If you're going to put it on the firewall/footboard, might as well do the door interiors too. I got away with some surprisingly dense carpet underlayment given to me under the carpet to quiet down the noise coming from the road. Works way better than the stock fluff VW put under there. The commercial sound-deadener was frighteningly expensive to do the whole inside, let alone the doors/footboard area. (anybody know a good alternative? I've got a Golf that needs it)
- You might want to mount a wiring block (screw-type or spade connector style) within easy reach for the stuff you'll eventually install to be controlled by switches you're going to mount in the 6-pack area between the instruments and radio. That way you'll have 12v handy. I put in a combo of fused 12v always on & switched. I also ran a trailer 4-wire harness from the engine compartment through the radio antenna grommet to use for guage sending leads. Haven't put in the guages yet but when I do, I can just unplug 'em. Also mounted two on the inside of the center console: one for ground and one for power. Here I run the accessory plugs for the cell phone, PDA etc and don't need the ashtray open to get at the lighter socket....(used a MOLEX 9 pin connector for the days I want to remove the console for any reason).
Also, don't worry about putting in another water seperator under the passenger rear unless you really feel better with it in. I deleted mine this spring and no problems (FYI: VW never used them again in the MK3 or MK4). I just drain every few tankfulls from the bottom of the fuel filter, and there is very little water in there when I do. I just cut the wiring and plumbed the fuel line together with the anti-drainback valve and it's been good for just over 5700 miles.
Nice pictures!
Andy[/b]
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Thanks Andy,
I hadn't thought of adding electrical plumbing, good idea.
I had been doing some asking around on the Vortex last week about sound insulation and yesterday decided with everything out I should just do it. So out the column, pedal assembly, and HVAC box. Now the interior is truly bare.
I have been doing allot of reading about what to use. There is all kinds of stuff. Some of it is expensive. People have used everything from Dynamat which is $$$ to adhesive roofing material from Home Depot. I did a bunch of reading and being that I live in Florida where it hot, humid, and mold is a problem, I was more concerned about adhesion and water / mold resistance. I found a pretty good write up someone did about the different kinds and did some testing. http://www.sounddeadenershowdown.com/ Its a good read.
I also got a response from vwjettacoupe on the vortex in my Things to do while the interior is completely gutted?? (http://forums.vwvortex.com/zerothread?id=3527203) he was insulating his Jetta also.
He used the RAAMat BXT (http://www.raamaudio.com/cgi-bin/index.cgi?p=pr) that was found to be the "Best Value" in the showdown article.
He had good things to say about it and also pointed me to their Ensolite product that is a water / mildew resistant closed cell foam that can be used in place of Jute Padding, and is fairly inexpensive.
So, I think that's the route I am going to take, it means a short little detour $$$ and time wise to getting the Jetta on the road but, since I am also a commuter, it will be time and money well spent.
So for today, I'll finish POR15'ing the battery tray and a few small rust spots in the engine bay and start cleaning the left over jute and sticky stuff from the inside of the fire wall. If I have enough time, I'll prep the Eco for removal as well.
Next week, I borrow the engine hoist and I'll pull the Eco engine from the donor so I can get started on getting the pump out and resealing it and do the water pump oring, check the turbo, look for other deals to do etc.
I also really need to get the donor car out of the garage as I am really out of room.
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2X on running lots of wires between the engine compartment and the dash area... much easier to loom 'em and seal 'em while the engine is out.
You could also add some oil pressure gauge tubing (like from the cheap kits NAPA sells) for an eventual boost gauge if you're feeling naughty.... or even thermocouple wire ?? Perfect time to tap the exhaust manifold pre-turbo ??!
My A3 looks like yours at the moment and because everything is so easy to get to and parts are so darn cheap from WorldPac I'm also:
- rebuilding the entire shift linkage
- replacing both flange seals, the main seal, throwout bearing, and the pushrod bushing and seal on the tranny.. then she gets a fresh fill of MTL.
- redoing all the big grounds
- replacing ball joints, worn suspension bushings, and repacking the CV joints
- spot-repairing and then painting rust... particularly due to battery acid
- relayed harness for the headlights... so easy to run with the rad out
The engine is getting a new clutch and pressure plate and the starter a new bushing,... again, trivial since the thing is in pieces.
Just some thoughts of stuff you can do while it's so so easy, in case you have time on your hands ;-)
Vince
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Looks to be coming along nicely. I'm envious of your garage :shock:
Care to sell me your K14 if it's not in good shape or if you want to trade a T3 for big boost? :D
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I'm also:
- rebuilding the entire shift linkage
- replacing both flange seals, the main seal, throwout bearing, and the pushrod bushing and seal on the tranny.. then she gets a fresh fill of MTL.
- redoing all the big grounds
- replacing ball joints, worn suspension bushings, and repacking the CV joints
- spot-repairing and then painting rust... particularly due to battery acid
- relayed harness for the headlights... so easy to run with the rad out
The engine is getting a new clutch and pressure plate and the starter a new bushing,... again, trivial since the thing is in pieces.
Vince
Heh, Plan is to do alot of that too if I have the time and funds, clutch and linkage at the very least. The tranny seals and all seem good, probably just put in fresh Red Line and see how it goes. Suspension I may do later, the green car has a fairly new set of Boge Turbo gas shocks/struts but has Eibach lowering springs :( mean while the white car has stock springs and the original struts, probably swap the springs onto the turbo gas struts at the very least, redo everything with new stuff once I get the TD swap and interior all squared away.
I did some spot rust treating in the engine compartment today, the battery tray in particular, it wasn't bad but, it had some acid induced rust on it. There were a few other small spots that got done as well. Actually those little cans of POR go a long way. I did spot treatment, battery tray and the engine cross member and still have just under a 1/2 a can left. I think I'll use it on the Fuse box bracket, VW just primed them all it looks like, or was that so they grounded?? I'd hate to POR15 it and find I have lost the grounds for most of the whole car. :shock:
Before....
(http://ziptar.com/eco_carat_project/por15.jpg)
After a wire brushing, some sanding, and the POR15 Treatment.
(http://ziptar.com/eco_carat_project/por15_tray.jpg)
Thanks Tyler, it's coming along bit by bit. The K14 seemed fine when I ran the donor and drove it, I'll give it a good once over once the engine is out, if it's Iffy I'll probably rebuild it. I don't have a big turbo and lots of boost in mind.
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Shucks
That POR15 seems to have done a good job. I can't wait to get going on my car. I think paint is first on the list once it's on the road
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It did a really nice job actually, I am impressed. It feels like its pretty durable, if it wears like they claim, I'll be happy.
Forgot.. the fully gutted interior.... :shock:
(http://ziptar.com/eco_carat_project/int_gutted.jpg)
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I pulled the TD out of the Eco and swapped the ASF transmission onto it and got it all dropped into the Carat this weekend. It's just setting on the mounts at this point I haven't started bolting everything up.
(http://ziptar.com/eco_carat_project/eco_carat_project_14.jpg)
I rolled whats left of the Eco body out into the driveway for my neighbors to enjoy, junk yard isn't picking it up until after Thanksgiving.
QUESTIONS:
The Eco's front engine cross member is slightly different, it has two small indentations for tabs that hold a plastic cowl that directs air to the radiator. Is that a diesel thing and really needed or just a big bumper thing?
The toilet bowl and Cat. When I removed it from the Eco I did from underneath with the engine still in it and it took allot of wiggling and finagling to get the flange past the firewall and the rack. I tried it put it in from the engine compartment before I dropped the engine in yesterday and there is no way the Cat will get past the rack and firewall.
Whats the trick to get the toilet bowl in?
The Clutch, Pressure plate, and flywheel looks almost new out of the box so I figured I'd just go with it. The turbo looks to be great shape with 0 wiggle on the shaft.
I am ordering a pump seal kit, timing belt, tensioner, belts, and all the hoses that could have had diesel fuel puked on them by the leaking pump.
I was going to leave the engine out until I swapped all that because I thought it would be easier but, I think it'll be better to do it in the car and I didn't want the weight of the engine and tranny pulling in the head bolts all that time (hanging from hoist).
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Sorry no updates in a while been busy! I pretty much have been spending every available moment on the Jetta for the last week because I really wanted to get it going. New battery,I resealed the pump, started buttoning up every last detail, nut, bolt, etc. Lots of updates.
Yesterday at about 7:30pm she left the garage under her own power for the first time!
She's a Driver!!! :D
It drives great!, noisy as heck because I didn't put the interior in yet., but it goes and goes well. I ran half a can of SeaFoam through the crank case for about an hour as it seems like it has a ticky lifter to me. I'll try and post a video later and you guys can tell me, maybe I am just too used to the TDI. Engine was noticeably quieter after I drained the cheap "Supratech" oil and SeaFoam and pt in some Mobil1 TD Truck 5-40 (after an hour of wrestling with the cheapie Fram Filter, I'll never do that again, OEM Only.). The Carat power stuff turned out to be a snap to hook up, the power windows, locks, mirrors all work great.
(http://www.ziptar.com/eco_carat_project/complete.jpg)
The trouble light in the picture was there to bake some JB Weld all night to cure. The 89 used the old style coolant reservoir and the bracket was welded to the strut tower, it is much wider and sits higher. It had a CE1 electrical connector, since I wanted to not cut the CE2 harness I am attempting to JB weld the studs for the late style reservoir and bracket in it's place.
(http://www.ziptar.com/eco_carat_project/coolant_tank_bracket.jpg)
It should work, the studs are surface welded on at the factory and twisted off pretty easily with vice grips. If it doesn't I guess I am drilling holes
I did some checking around about batteries before I bought one. I didn't want a generic Walmart or Autozone cheapie. It turns out a Company called Douglas Battery a division of Exide has the contract with Varta to produce new OEM replacement batteries here in the U.S. for BMW, Mercedes, Audi and VW. They are also sold under the brand name "Werker" through Batteries Plus (http://www.batteriesplus.com/pc-36492-61-Luxury%20and%20Import%20Car%20and%20Truck%20Battery%20-%20Werker%20SLI41-LI.aspx). The Group 41 Battery for the Jetta is a perfect fit and has the proper venting so hopefully battery acid won't slop all over my newly POR-15'd battery tray. At $89.99 the price is decent too only $10-$20 more that Generics.
Oh and last week a care package arrived for me from a distant land courtesy MontanaGTD. :D
(http://www.ziptar.com/eco_carat_project/ic.jpg)
I'll need to dig up a 1.6LDA or a pump soon and get it installed along with the Intercooler. Swapping the ASF code transmission in was a good call, at 60 MPH I am pulling around 2250 RPM and at 70 it's about 2500 RPM. 1st and 2nd gear though are slow, I definitely need more oomph, not allot, I think the Eco pump with an LDA should be fine, maybe if I save my pennies and can pay Giles to give it his special lovin' that would be enough. I am also going to look and see if I can bend or fab up the A/C line so I can use all of the GTD IC Shrouding.
I also changed my insulation / sound deadening strategy. I have been doing a bunch more reading about it on car audio forums. I read a really lengthy thread about sound deadening vs. sound quality. Basically the acoustic mat adds mass and improves sound quality but, the padding is what adds sound deadening. I also came across a couple of threads about a $6.47 closed cell camping mat that Walmart sells and, apparently it's made of the same stuff the audio places sell for allot more. I picked up 4 rolls and am doing a $27 insulation and padding experiment.
(http://www.ziptar.com/eco_carat_project/insulation.jpg)
I have used one roll already under the dash and in front of the A/C box. The thickness is about right and didn't notice much rattling and squeaking from the dash last night but it's hard to tell at this point. Without the interior or so much as door seals in it at this point, it's really hard to tell.
I'll post more when it's done. Today's plan is to get the interior in give her a wash and a good cleaning.
I have a slow drip from the throttle shaft to still to deal with and also I need to order up belts, timing parts, valve cover gasket, etc and do those. There will be some detail stuff for the body and interior as well (headliner) so I'll be doing stuff for a while but, the major stuff is done and I can drive it
I had also planned on replacing struts, I was worried the the lowered Eibach springs and turbo gas struts would ride to harshly but, so far it seems ok. I need to drive it more I guess.
I'll see if I can get some driving videos up later.
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:D Very exciting news
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Spent yesterday putting the interior back in and adding the blue padding. Seems like decent stuff, cuts and forms easy. Seems to do the job and does make it quiet, every bit as good as the factory jute padding. I ut it everywhere though so it made fitting the carpet a bit tight.
I only had time to do one short video yesterday. It was the first cold start of the day. http://www.youtube.com/watch?v=EqK4hHNXdMc
Am I being overly sensitive or do you here a ticky lifter or two?
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sounds fine to me, give it a while, when it warms up it will probably be gone..
btw, does montana gtd get the gtd intercooler setups on a regular basis? I really want one.. if you ever switch to a fmic, let me know...
Nice work tho! :D
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myke_w, Thanks for the input, hard for me to tell after 10 years of TDI ownership.
MontanaGTD and I had been PM'ing back and forth for pretty much a year about maybe being able to get me one. He finally went through a bit of time and trouble to hook me up.
He has two for sale right now, shoot him a PM. http://vwdiesel.net/phpBB/viewtopic.php?t=11372 they aren't complete but it's the IC itself and the shroud. The boost pipes and brackets would be pretty easy to fab up. I just had my mind set on a complete factory setup.
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:D
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Yesterday I finished putting the interior in and gave her a wash and a lite detail.
Lots of stuff to do yet, get an LDA, put in the IC, find a headliner, new carpet, and other interior details, decide on wheels, etc. I may just get a set of black Corrado steel wheel centers and run the 14" wheels for a bit. If the financial gods allow, my pump will take a trip to see Giles too.
I also waiting on belts, hoses, etc. Also have an oil leak to chase down, seems like the back of the engine, turbo line or valve cover maybe.
I filled it yesterday and added twice the recommended Power Service. Did a 60 mile test run on the interstate, too early to say for sure but, looks like my slow IP drip is gone. Is it ossible that the Power Service caused the seal to swell and seal again?
Nice thing is I have driven 70 miles since the fill up and the fuel gauge has yet to move. :lol: I am sure it's because I filled it way up but, interesting non the less. At 70 MPH RPM was just under 2750. The ASF trans is nice!
Now more pics: Don't mind the steering wheel, I have a really nice leather wrapped Corrado Steering wheel on the way.
(http://www.ziptar.com/eco_carat_project/eco_carat_project_22.jpg)
(http://www.ziptar.com/eco_carat_project/eco_carat_project_21.jpg)
(http://www.ziptar.com/eco_carat_project/eco_carat_project_20.jpg)
(http://www.ziptar.com/eco_carat_project/eco_carat_project_15.jpg)
(http://www.ziptar.com/eco_carat_project/eco_carat_project_16.jpg)
(http://www.ziptar.com/eco_carat_project/eco_carat_project_18.jpg)
(http://www.ziptar.com/eco_carat_project/eco_carat_project_19.jpg)
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Wow does that car ever look nice.
Good work
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Yeah it does. :lol: Thanks!
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Aye, that is. I am anxious to hear how the Wally-World bedding material works out :)
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Aye, that is. I am anxious to hear how the Wally-World bedding material works out :)
Me too.
That cleaned up really nice. Looks great.
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Hi, Excellent job your doing
i just have one question. I read that you want to get hold of an LDA to put onto you ECO Pump and just wondered how easy it was to fit, as i would like to do the same. Is it just a case of unbolt one bit put the LDA housing on? or is there more to it?
Thanks
Chris
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Thanks all!
Wow, what a difference a coolant flush makes!! Up until now my gauge ran just about 3/4 of the way up all the time. I ran some Zerex Super Cleaner (http://www.valvoline.com/pages/products/product_detail.asp?product=15) through it for about a week then flushed it and added a a 50-50 mix of distilled water and Zerex G-05 (http://www.valvoline.com/pages/products/product_detail.asp?product=10), (G11 equivalent). Now the gauge barley hits the halfway mark in fact it is mostly below it. It did seem that there was no thermostat, or it was stuck open when I flushed it. I have a new 87c one on the way but still impressive to see a flush really did something. Considering the high yesterday was 81F, I'd say it worked good.
madmedix: Wally World Sleep mats seem to be doing the job thus far, Hard to tell at the moment I haven't charged the A/C yet so I am driving around with windows and sun roof 0pen most of the time. I also don't have a headliner yet, that doesn't help.
I drove it on my 200 mile daily commute yesterday, going to again today so maybe I'll grab a video at highway speed with the windows and sunroof closed to give you guys an idea of noise. "ill grab some pics of the catpet too so you can see the fitment.
DooeyTrials: No idea really, I have read that it can be done with the pump on the engine, or if things work out, I'll just send it with my pump to Giles. I am probably going to have to buy a whole pump to get one. I want to keep the ECO plunger and head though. I think with the LDA, Intercooler, and some tweaking it'll give plenty of power and acceleration with giving up too much mileage wise.
Speaking of which, when I got home last night, I was just barely cresting the hump of a half tank and have gone 327 miles thus far :D. I think once I get the IC in, and LDA, and a some 195/60-14 tires on it, I'll be in the sweet spot of great MPG and nice Highway Cruising.
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Been following this project and must say Well Done Ziptar! :D
Nice clean looking car....great job.
Enjoy!
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Ok thanks. i dont really want to have to buy a new pump as they are expensive and as im only 17 and my insurance is madly high i dont have much money atm but really want to get more from my engine.
ill have to do the other mods first i spose, governor mod etc.
Chris
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Ok, here you go. Not sure how much you'll be able to tell but, made a vid on the interstate this morning with windows and sunroof closed. You can hear road noise and trans whine for sure.
I did some hard listening too this morning and the tires aren't all that great. I think the right front is a bit out of balance or has a small bend. It is particularly noisy and seems to be causing some vibration.
http://www.youtube.com/watch?v=4KH_1bBOtD0
I almost forgot, on the subject of noise reduction, I found another handy Walmart item. In the craft section they sell sheets of "Fun Foam" for kids crafts projects.
(http://www.demco.com/webprd_demco/product_block/D67/174067800.jpg)
They are closed cell foam sheets about the size of an 8"x11" piece of paper and a few millimeters thick. They are $0.44 a sheet and so far I have found them handy for wrapping wiring harness and dealing with odd squeaks and rattles. There was a bit of a rubbing sound between the center console and dash at idle. I trimmed a piece to fit and squeezed it between them, no more sound. Heck of allot cheaper than wiring loom and a good replacement for the original VW foam on the wiring harness that long ago turned to dust.
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Good call on the craft foam: As I sit here looking at the ornaments on the Christmas tree my kids made with the stuff wondering why it never occured to me too. More egg nog :D
Your car seems much quieter than mine, I think that's the way to go when spring comes. I'm running the quietest tires I can find (175/70/13) on older 7-spoke aluminums averaging 1084km per tank (~648 miles) @ 115km/h (~70mph) the non-vibration sweet-spot :) I'm looking for 14" wheels in the spring.
Cheers,
Andy
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wow great work and great final product haha even though ur not done.
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Nah, not done but, big job is done, and at least I can drive it now.
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I basically bought 3 intercooler kits off ebay to get the parts together to make up 1 complete kit for Ziptar. I have a GTd with the intercooler setup myself and I know what bits make it up!
It took me almost 10 months to get all the parts together and get them shipped over to Ziptar!
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Project update! and catching up in general..... been kinda busy...
First off in response to MontanaGTDs post, many kudos to him. It did take him many months to scrounge a complete setup, communicated all the way was a huge help and could have quit at any time because at times it was a PITA I am sure, he is a great forum member... If he still has the left over ICs someone needs to buy them :D.
Ok, Updates...
As you guys may or may not know, a month ago I took a new job and was moving to Boston. My plan was to drive the Carat up (http://vwdiesel.net/phpBB/viewtopic.php?t=12338), ordered belts and hoses to redo everything before I left but, they got lost in shipment, I was out of time, so I had to go without hoses (I Gorilla taped the iffy ones) and crappy Dayco Belts and a re-used tensioner. What I didn't say in that thread, was I had the car loaded and was literally on my way when I blew the bottom radiator hose 3 blocks from the house :(. so yeah not a good idea at all.
I got it back home and loaded everything into my 03 TDI and drove up.
I had the Carat towed to Fifteen52 (http://www.1552v2.com/) in Sarasota so they could replace ALL of the coolant hoses. Once that was done and we were confident I didn't blow the head gasket, I had Brad check it over and make sure it was good for a run up the East Coast, he got back to me with a list. The brakes were iffy and the suspension, ball joints, etc were pretty much shot. Could have done without any of it or done the minimum.
After giving it some thought and weighing the fact that the place I found up here in Mass doesn't come with a garage I decided to have them redo suspension and brakes with a little upgrading to boot.
Hopefully everything arrives as scheduled and by this time next week it'll be fitted with:
Bilstein HD Shock Set.
H&R A2 8V OE Sport Springs.
VR6 Upper Strut Mount/Bearing Upgrade Kit.
New Control Arms w/ Bushings.
New Late Type Large Ball Joints.
Braided Stainless Steel Brake hoses.
A GLI 10.1" Front Brake setup I bought on eBay (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=320230777686), w/ new Rotors and Mintex Pads
New Rear Discs and Mintex Pads.
New GLI 22MM Master Cylinder.
Assorted sundry filters, suspension hardware, etc.
New Valve Cover Gasket.
New Oil Pan Gasket.
As of today, I have a TD pump and TD Injectors (thanks again, addautomotive!) on the way to Giles for him to work his magic on. I ordered the proper Continental belts, new tensioner, , glow plugs, etc so I can redo it all again when the pump and injectors get here and get rid of the evil that is Dayco.
Oh, and a new set of Hella door handles.
It's allot to spend on an Old Jetta and I have had some raised eyebrows from the wife but, I'll be selling my 03 TDI wagon soon. Now that I am up here and settled I don't really need a car, let alone two. besides for the original ~$500 investment in the EcoDiesel/Carat merge project, I have a bit of room I think.
Our new place is a 5 minute walk to the train station, my whole commute now is all of 30 minutes and the subway drops me 2 doors from office. I decided I liked the MkII Jetta more, Throw some $$$$ into it and keep it until I die :lol:. It'll be more fun to fix up now that I am not depending on it for daily transportation.
I am flying back down to Florida next week to meet the movers and I'll pickup the Carat and drive back up to Mass again.
Right now I am trying to track down a set of Le Castelette wheels I can get shipped to Florida in time to meet me there next week so I can get some decent tires on it before the drive. If not I guess I am coming up on the crappy steelies and the current tires., there are a couple of yards along the I-95 corridor on the way up that show some so maybe on the way.
Oh, about the pics missing from the thread, I switched hosts for ziptar.com, I need to upload them all to the new server. They'll be back shortly.
Thats it for now.
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wow you've been busy. Let me know how those HDs are, I might get a set.
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Let me know how those HDs are, I might get a set.
I will, I have a ~1400 mile test drive planned :wink:. To fully enjoy them I'll need new rubber which means new wheels.
I think I found a set of Le Castelettes at a yard in North Florida, that I can get shipped to meet me in Sarasota in time next week, get some new 195/60-14 tires on it and loose the horrible 185/60-14s. Get a better ride and a few less RPMs on the highway as well.
I wasn't sure which shocks to get, lots of different opinions out there. I was after Stock ride and stance plus a little something extra, nothing too spendy either :wink: . Came down to KYB GR-2 and the Bilstien HDs. KYBs could be had cheap but, what sank it for the HDs was the life time warranty.
BTW: Best Deal I could find on Shocks and Springs was at Parts4vws.com (http://www.parts4vws.com/), their service is awesome as well. I accidentally ordered the wrong ball joints, I called, Mike there was super helpful, got it straightened out, also made sure it all shipped quick and would get there on time when I told my plans.
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Hope your trip is safe and uneventful :D
Please let us know how your Wally-World sound insulation trick worked for the trip. Methinks hours on end in our beloved "buzz-boxes" would help you decide if it's worth it or not. I've got an 87 sitting outside that sounds like 2 skeletons on a tin roof and I need to quieten her down.
Cheers,
Andy
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Thanks, hopefully it is uneventful, after weeks at the shop and lots of money it better be, or the Mrs. won't be pleased. :lol:
I'll keep you posted on the noise, I hadn't thought about that :D.
I am hoping with all of the suspension work it's smooth and quiet. I found a set of Le Castelettes at a wrecking yard in Florida so I ordered a set of 195/60HR-14 Michelin Pilot Exalto all season tires from Tire Rack. The crappy tires on it now make horrible noise. I logged about 10K miles in it before I moved up here, the blue foam stuff seemed to work real well.
Now if the last of the parts arrive at the shop in time to have ready by Friday at the latest, I'll be good to go.
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Made It!
Left Orlando Saturday at 12:30PM made it to Boston at 9:00 Sunday Morning. :lol:
My trip didn't go as smoothly as planned, I had wanted all the parts there and the car done Thursday. Well a couple of mis-orders and delivery mishaps later and the car was not done until 6:45pm Friday night so after the movers finished I picked it up from 1552 and left straight from there. When I say done, I mean able to drive. The Le Castellettes I ordered never left the yard, the trucking company never came to pick them up.
So Friday Night I drove to Orlando stayed with my friend that gave me the Carat and we dug the original wheels that came on it out of the garage. I have read in 89 he should have Castelletes but, he got Montreals, the bottle cap GTI Wheels on his new. That style was used on 88 Carats, the one I have is a really early production year car so, maybe left overs.
Saturday I had the tires mounted and the alignment done.
Anyway. The trip went great, but I burned more fuel than I expected. I haven't sat down with the receipts yet but it looks like I only averaged 35MPG on the trip up. I either have the timing off or I messed something up resealing the pump.Something is also up with my temp gauge, it never moves off the first bar. I think it is a bad sensor because the needle moves around on that first far bar but never above it.
The new suspension, wheels and tires?? OH MY!! WOW!!!
What a difference. It rides better than a new car and every bit as good if not better than my MKIV. It is completely tight, smooth and quiet. Handles and rides like a dream. It looked a bit weird when I picked it up because it had to settle but thanks to the most awful roads ever on the New Jersey Turnpike and I-95 in Manhattan, it was hammered down pretty good. It's funny but, I haven't seen anything on the news about mortar attacks in New York and New Jersey, yet there are shell craters all over the highway.
That being said the Bilsteins are absolute joy, even the worst roads were handled well and my Kidney's are stilll where they belong. The H&R Springs make for really nice crisp handling but don't transfer every bump and vibration up my spine like the Eibach Pro Streets did. I also like that the car is now back to stock height again, The 195 Michelins fill the fenders out much more that the 185s I had on it before so more room was needed anyway.
I absolutely love that little MKII Now. With the old suspension setup 65 was manageable, 70 chattered my teeth a bit, 75 was getting a bit adventurous, 80??? I had to Check both that the Life Insurance hadn't lapsed and my shorts. I did the whole trip at 75-80 and it was an absolute joy and I think it is allot quieter too, while I can here some engine buzz at 70-80 I mostly hear wind and tranny noise, a transmission rebuild is the next big ticket item on the list.
I did a video on the interstate (http://www.youtube.com/watch?v=uE88ckZgJN0) again, if anyone would like to compare to the old other one
Now that I have the bigger tires strapped to the ASF I definitely need some extra HP and boost enrichment now. Inclines at speed are more of a challenge and passing takes allot more planning now with the stock Eco Setup. I need more accelerator pedal :D.
I took a quick shot of it in the Hotel parking lot yesterday morning. It needs a wash, we did even have time to clean the wheels before the tires went on. I'll give her a good spit and polish after we get moved into our place. I also think the front still needs to settle maybe another 1/2 inch or so, then again there is a bunch of tools and parts in the back.
(http://www.ziptar.com/eco_carat_project/MKII_TD_Carat_1_sm.jpg)
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Ziptar, I'm definitely going to be doing much of the same to the '92 Wolfsburg Jetta that I'm converting. Your work with the sound deadening materials was of particular interest.
I didn't see if the whip antenna came already on the car or if you said you purchased it somewhere else - I'm interested in getting one for mine.
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The Fuba Antenna came on the car from the factory as part of the Carat option package. They are cheap enough (http://www.parts4vws.com/catalog/product_detail.asp?PartNumber=FUBA) and easy to add to a Jetta, you just need to drill a hole in the roof.
The blue foam stuff works really well particularly for the cost. After I get the pump , injectors, and intercooler in I'll start scrounging for bits to redo the interior, like carpet, Some Black Leather MkIII Jetta seats (hopefully heated) to swap onto the MkII bases, carpet, etc.
As I redo the interior I plan on stripping the old paint and giving it a coat of POR15. At that point I may lay out the cash for some RAAMmat BXT and some Ensolite MXT (http://www.raamaudio.com/cgi-bin/index.cgi?p=pr). It's allot more money than the blue stuff but, once I refresh the interior and put it back together, I don't plan to ever have it apart again.
OH I forgot something in my earlier post too....
When I found out the wheels hadn't shipped and it looked like maybe the new springs wouldn't show up on time I stopped by a pick-n-pull to see if I could get lucky on the wheels and also see if there was a car I could grab the springs from as a "Plan B".
Low and behold there was 91 Eco there. Someone had already grabbed the IP, exhaust manifold, and K14 :( They left a treasure trove in the trunk, including a recently remand head complete with cam. It's in good shape I think, I couldn't see any cracks between the valves.
I grabbed the head, intake manifold, injectors, injector lines, air cleaner, ducts, vacuum line for the booster (mine was broken), heat shield, glow plug relay, Cam and IP Pulleys, plus a bunch of trim bits from it and a 91 Carat that was also there. Would have grabbed the down pipe too but it had been torched :(. I had a pretty full wheel barrel by the time I rolled up to the cashier window, yard guy looked out the window and said "$100". I just smiled :D and paid.
It killed me to leave the 1.6TD bottom end there when the yard guy told me I could have it for $50 but, I had no tools or time to get it. It had collected some water though and the cylinders were a bit rusty.
If anyone is down that way it's Al's Scrap and Pick-n-Pull on Preymore in Osprey Florida next door to Glueck's Used Auto Parts. It's black and 3 or 4 rows into the foreign on the right. There was also a Dasher Wagon with a 1.5 NA that look like it had just been put out and was untouched. It's on the 2nd to last row on the left.
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Thanks for the update on the sound treatment...I've got 2 mk. II's to do (maybe a third :D ) and cost is a factor. Doing it with aftermarket stuff is not an option on them all. They both need a rebuild.
You're mileage sounds about right for the speeds you were doing, especially if you had a full trunk;changed the gearing with different tranny and tires which may have caused you to be into the boost much more often. I found in 19 years of commuting my mk.2's were really sensitive to any extra weight in the car. Used to check my rear-view mirror for an anchor :D because I couldn't make it to my usual refuel points if I was hauling a trunkload of stuff. I figure a load in the trunk would raise the nose of the car and that's not good for aerodynamics (such as they are on the barn-door mk.2's).
Bottom line? who cares !! you're ride looks great and you're happy with it. All that matters, right?
Glad the trip was safe.
Cheers,
Andy
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Right on, glad to hear that the trip was good.
So what is going to happen with the rims you ordered? Canceling them?
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Is the Giles Super Pump Installed yet? How is it?
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You're mileage sounds about right for the speeds you were doing, especially if you had a full trunk;changed the gearing with different tranny and tires
Forgot about the "Junk in the Trunk" :D I had parts, extra wheel and tire, extra oil, coolant, etc, and luggage.. also did have my foot in it quite a bit. :P
Right on, glad to hear that the trip was good.
So what is going to happen with the rims you ordered? Canceling them?
Already did, Figured once I paid to get new tires mounted and balanced, I wouldn't want to mess with it again. I canceled the order with the yard. Just waiting for the credit back to my card.
Is the Giles Super Pump Installed yet? How is it?
Nope not yet, not finished yet. Giles is on vacation until the 21st, and I am in the middle of moving although, in the new place in mass finally as of two days ago.