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General Information => User's ride Wall => Topic started by: 8v-of-fury on April 29, 2010, 10:29:17 pm

Title: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 29, 2010, 10:29:17 pm
Have never really had any time on TDI stuff, but I wish to learn!

the 1997, did it come with a TDI engine? its not just an IDI 1.9? is it a mechanical pump?

Would it be hard to use for a swap? in terms of sensors and what not?

thanks guys.
Title: Re: 1997 Jetta TDI
Post by: the caveman on April 29, 2010, 10:46:06 pm
I'm pretty sure the first year of TDIs in jettas was 1998. Personally  I would have zero hesitation doing a swap with one [ like into my transporter ] if i could get a complete donor car. I think the worse thing is the throttle pedal, but no biggy.
Title: Re: 1997 Jetta TDI
Post by: 8v-of-fury on April 29, 2010, 10:49:10 pm
I want to put a TDI or at least a 1.9 IDI in to my mk1 Jetta.

I think it will for sure, even at stock settings.. be KILLER.
Title: Re: 1997 Jetta TDI
Post by: burn_your_money on April 29, 2010, 11:06:41 pm
I think Passats had TDIs in 97 but Jettas were 98. MK3 Golfs never got the TDI engine

It is the easiest engine to use (1Z/AHU) because all the mk1 mounts will bolt up to the engine. If you use a ALH (mk4) engine you need custom mounts.
Title: Re: 1997 Jetta TDI
Post by: rallydiesel on April 29, 2010, 11:08:07 pm
'97 was the first year for TDI Jetta's and Golf's. That was the AHU engine. 1996 was the first year of the TDI. It was in the Passat and was the 1Z engine. My plan is to put an AAZ in a Rabbit. I like the simpleness and affordability of parts with the IDI engine.

I got the model info from the worldpac database.
Title: Re: 1997 Jetta TDI
Post by: 8v-of-fury on April 29, 2010, 11:09:30 pm
Ok so any pre-97 jetta, or any mk3 golf claiming TDI is really just a 1.9 IDI?

I don't know which would be better route to go. a good IDI? or a good TDI?
Title: Re: 1997 Jetta TDI
Post by: 8v-of-fury on April 29, 2010, 11:10:20 pm
Jetta tdi's were AHU and Passats were 1Z... why the difference? what was different about them?
Title: Re: 1997 Jetta TDI
Post by: rallydiesel on April 29, 2010, 11:29:16 pm
I think the 1Z was only around for one year. It was the pilot tdi engine. After that year, they went to the AHU for all the tdi models.
Title: Re: 1997 Jetta TDI
Post by: burn_your_money on April 29, 2010, 11:30:45 pm
I've owned a 97 AAZ Jetta. Maybe it's another one of VWs famous half way year changes.
Title: Re: 1997 Jetta TDI
Post by: andy2 on May 08, 2010, 12:18:39 pm
The Jetta did come with a TDI and IDI in 97.The passat came with the TDI in 96.The golf got the tdi in 99-2000 and the beetle got it in 98.

The ALH tdi block still has the same motor mounting holes as the earlier engines.No custom mounts needed it bolts right in.
Title: Re: 1997 Jetta TDI
Post by: 8v-of-fury on May 08, 2010, 09:38:12 pm
the ALH shares the older AAZ and ME/MF  block? Score! So now I gotta find me an ALH ;) when did the switch from ALH to the next one?
Title: Re: 1997 Jetta TDI
Post by: CdnVWJunkie on May 09, 2010, 12:44:01 am
Quote from: andy2 on May 08, 2010, 12:18:39 pm
The Jetta did come with a TDI and IDI in 97.The passat came with the TDI in 96.The golf got the tdi in 99-2000 and the beetle got it in 98.

The ALH tdi block still has the same motor mounting holes as the earlier engines.No custom mounts needed it bolts right in.

The VNT turbo will likely interfere with the rear mount, IIRC.

Title: Re: 1997 Jetta TDI
Post by: rallydiesel on May 09, 2010, 12:50:30 am
Quote from: 8v-of-fury on May 08, 2010, 09:38:12 pm
the ALH shares the older AAZ and ME/MF  block? Score! So now I gotta find me an ALH ;) when did the switch from ALH to the next one?

ALH was the first Mk4 tdi engine. In 2004 they switched to the BEW engine (PD).
Title: Re: 1997 Jetta TDI
Post by: svenakela on May 09, 2010, 03:20:14 am
There must be different model series in the US/Canada compared to the rest of the world. Jetta YM 93-96 (called Vento) was 1Z TDI and YM 96-98 was AHU/AFN TDI. Exactly the same setup as Passat (and Golf).

http://en.wikipedia.org/wiki/Volkswagen_Jetta (http://en.wikipedia.org/wiki/Volkswagen_Jetta)
Jetta III is called Vento
Jetta IV is called Bora
http://sv.wikipedia.org/wiki/Volkswagen_Jetta (http://sv.wikipedia.org/wiki/Volkswagen_Jetta)

http://en.wikipedia.org/wiki/Volkswagen_Vento (http://en.wikipedia.org/wiki/Volkswagen_Vento)
http://sv.wikipedia.org/wiki/Volkswagen_Vento (http://sv.wikipedia.org/wiki/Volkswagen_Vento)
Title: Re: 1997 Jetta TDI
Post by: andy2 on May 09, 2010, 02:51:09 pm
Quote from: CdnVWJunkie on May 09, 2010, 12:44:01 am
Quote from: andy2 on May 08, 2010, 12:18:39 pm
The Jetta did come with a TDI and IDI in 97.The passat came with the TDI in 96.The golf got the tdi in 99-2000 and the beetle got it in 98.

The ALH tdi block still has the same motor mounting holes as the earlier engines.No custom mounts needed it bolts right in.

The VNT turbo will likely interfere with the rear mount, IIRC.





Correct,I only suggested that the ALH block would bolt in.I have an ALH block in my 94 golf.

I have only put AHU's in older cars but I'm thinking that its mabye not much more work to put a drive by wire ALH in.The ALH turbo would be very close to the right rear mount but would it just clear? Or could it be modified to clear? 







Title: Re: 1997 Jetta TDI
Post by: the caveman on May 09, 2010, 04:53:44 pm
Quote from: 8v-of-fury on May 08, 2010, 09:38:12 pm
the ALH shares the older AAZ and ME/MF  block? Score! So now I gotta find me an ALH ;) when did the switch from ALH to the next one?
No the AHU/1Z is the same as the AAZ /ME/MF block, which means a simple slip in and out with all the mounts just bolting up. The ALH will need to be modified somewhat, although i don't how much is involved as i don't care  as i wouldn't want to use one of those later engines anyways...
Title: Re: 1997 Jetta TDI
Post by: 8v-of-fury on May 09, 2010, 07:53:24 pm
Ohh ok.. and the AHU/1Z came in what years?
Title: Re: 1997 Jetta TDI
Post by: Vincent Waldon on May 09, 2010, 09:03:24 pm
Quote from: 8v-of-fury on May 09, 2010, 07:53:24 pm
Ohh ok.. and the AHU/1Z came in what years?

In Canada basically the post-AAZ MK3 years... 1997ish to half way thru 1999.
Title: Re: 1997 Jetta TDI
Post by: 8v-of-fury on May 09, 2010, 11:33:44 pm
Are the AHU/1Z a drive by wire as well?
Title: Re: 1997 Jetta TDI
Post by: Vincent Waldon on May 09, 2010, 11:34:59 pm
Yup.
Title: Re: 1997 Jetta TDI
Post by: 4wheeler on May 10, 2010, 11:03:13 pm
I have 2 running AAZs for 1 donor TDI 97-99...  Anyone wanna trade??
Title: Re: 1997 Jetta TDI
Post by: 8v-of-fury on July 31, 2010, 07:26:22 pm
To dig this back up, a kijiji ad in my area has a rotten bodied 98 jetta with a TDI in it.. ;) ;) 1Z/AHU if my reading through this thread is correct.. a good easy slip in to an mk1. Yes?

Mounts will line up, it will be a full donor car so I will have EVERYTHING i need to do this swap. Yes? How do I re-title this thread? I AM EXCITED.
Title: Re: 1998 AHU --> 1981 Mk1
Post by: 8v-of-fury on July 31, 2010, 07:32:59 pm
is 320k a ton on a AHU motor? I mean if worst comes to worst in a while rebuild it right?
Title: Re: 1998 AHU --> 1981 Mk1
Post by: burn_your_money on July 31, 2010, 10:09:02 pm
At the least I would say you need to look at a turbo since they are so small...

To retitle the thread just edit your first post and change the title
Title: Re: 1998 AHU --> 1981 Mk1
Post by: 8v-of-fury on July 31, 2010, 11:10:28 pm
You don't even like turbo's Tyler! lol that will be in the books. Main goal would be get it in and running which is what I would kinda like to make this thread, for the swap? I wanted to go to AAZ, but I can get this TDI cheap.. so why not right?

What does the AHU put out? I am reading about only 90hp? is this only because of the tiny K03? I mean still a ton more than a 1.6 N/a ;)

If I have an entire donor car, a straight swap, what am I looking at? Will the AHU bolt to the 020 in the car now? What will using the tranny consist of?

I have found this site (http://forums.vwvortex.com/showthread.php?778864) and it consists of a great read. I will have many questions I am sure :)

 (However it is for swapping an ALH.. crap) Anyone got any good AUH --> Mk1 swap threads?
Title: Re: 1998 AHU --> 1981 Mk1
Post by: burn_your_money on August 01, 2010, 11:25:45 am
The tranny bolts up. I would make the 02A work though. (The one on the TDI). It will have a CTN code and it has crazy ratios, they should be perfect for a light mk1. You will need to either convert to cable shift and hydro clutch or use the conversion pieces so you can still use rod shift and cable clutch. The pieces aren't cheap though. I think you will also need to make a custom motor mount to use a 02A in a mk1. There is lots of info on this on vortex

Yes it's around 90hp.
Title: Re: 1997 Jetta TDI
Post by: Rabbit on Roids on August 01, 2010, 05:43:56 pm
Quote from: CdnVWJunkie on May 09, 2010, 12:44:01 am
Quote from: andy2 on May 08, 2010, 12:18:39 pm
The Jetta did come with a TDI and IDI in 97.The passat came with the TDI in 96.The golf got the tdi in 99-2000 and the beetle got it in 98.

The ALH tdi block still has the same motor mounting holes as the earlier engines.No custom mounts needed it bolts right in.

The VNT turbo will likely interfere with the rear mount, IIRC.



in a mk2, it will hit the rear mount. in a mk1, there are no rear mounts so to speak.. i have a vnt in my mk1, no problems.
Title: Re: 1998 AHU --> 1981 Mk1
Post by: burn_your_money on August 01, 2010, 10:07:42 pm
MK3 TDIs did not have a VNT though. They basically have an upside down K03
Title: Re: 1998 AHU --> 1981 Mk1
Post by: Rabbit on Roids on August 02, 2010, 01:25:42 pm
Quote from: burn_your_money on August 01, 2010, 10:07:42 pm
MK3 TDIs did not have a VNT though. They basically have an upside down K03

ALH was the first to get a VNT (1998 new beetle and mk4 in the US)

was in 2000 or 2001 wasnt it?
Title: Re: 1998 AHU --> 1981 Mk1
Post by: G60ING on August 02, 2010, 02:26:43 pm
Quote from: Rabbit on Roids on August 02, 2010, 01:25:42 pm
Quote from: burn_your_money on August 01, 2010, 10:07:42 pm
MK3 TDIs did not have a VNT though. They basically have an upside down K03

ALH was the first to get a VNT (mk4)

was in 2000 or 2001 wasnt it?

The VNt setup was started in 1998 on the mk4 Beetle and then in the mk4 jettas/Golfs in 1999.5

VW started using VNT turbos in 1998 on the AFN TDI (Engine design is identical to the AHU but with a VNT turbo). This motor was used in B5 Passat TDIs, Sharan, Mk3s and couple other cars in europe. I actually have one of the exhaust manifolds at home and I plan on bolting on a B5.5 TDI turbo onto my tdi corrado.
Title: $400 1998 TDI Jetta Daily
Post by: 8v-of-fury on August 02, 2010, 10:11:45 pm
OK so I got in contact with this guy, and he says the car does not run because it requires glow-plugs. He told me he replaced the glow-plugs and the car will still not start.. Judging by the fact he still does not have the car running, shows to me he has no idea what he is doing.. He told me he had the car running one day, shut it down for about a half hour.. came back and it would not start.. now that I really think about this, if the engine were ran half hour ago it would start with zero plugs working.. wouldn't it?

So I figure if the TDI's are anything like the IDI's, jumping a 12v to the stop solenoid (is there one of these on a TDI?) and 12v to the glow plug circuit.. it should be failry easy to give a quick on the spot diagnoses on the spot yes?

Get back to me people on everything to do! I am going to look at it in the morning!

:) :) thanks a bunch!
Title: Re: 1998 AHU --> 1981 Mk1
Post by: Vincent Waldon on August 03, 2010, 12:05:00 am
TDI's don't need glow plugs to start until near freezing, so unfortunately that's not it.

Yes, you should check Relay 109, but the best bet would be to have it scanned for codes... it's probably trying to tell you what's wrong... and there's lots it could be.  Adding a computer makes it a bit more of a challenge to troubleshoot than our beloved IDIs.

Yes, it has a stop solenoid... in fact, you'll find the pump looks awfully familiar.  ;-)
Title: Re: 1998 AHU --> 1981 Mk1
Post by: 8v-of-fury on August 04, 2010, 05:36:43 pm
pump looks awfully familiar except for the drive by wire ;)

Also that other thread can be deleted or kept around for people looking to solve their non starting TDI. I will keep it in this now with all my questions ;D

So I went down today to look at the car after picking up another mk3 (1996 2.0L 5spd). We pull up in two dubs (81 and 96) and we start to diagnosing the problem, fortunately it was the easiest thing possible! lol Multimeterd some things and found no power anywhere.. got under the dash pushed the 109 around heard some spazztic clicking.. got out a wire and some male spades.. plugged it in. got out of the car went up to the guy..

"You want $500 for it right? Well how about because it isn't even running.. I'll give you $400.."
"Deal, because it isn't running its of no good to anybody"
"How about you go turn the key for me if you don't mind.."
VROOM VROOOOOM
"Holy Shi...."
'Yup :P"

So needless to say it appears I'm the smartest guy of four to look at it.. as the other three couldn't get it going.. lol

So what are my plans here guys? I gotta get the shell gone in under a month! so anyone who wants stuff, let me know! everything but the engine is up for grabs.

how do these engines like to come out? top or bottom?
Title: Re: 1998 AHU --> 1981 Mk1
Post by: 8v-of-fury on August 05, 2010, 11:29:32 am
Hello PArty People.

Plans are as follows as of right now.


We need to discuss how this engine comes out, I have seen and removed mk2's and mk1's.. never mk3's. A little guidance please?? thank-you !

Do they have a front cross member that gets right out of the way like the mk2?
Title: Re: 1998 AHU --> 1981 Mk1
Post by: Vincent Waldon on August 05, 2010, 12:05:34 pm
Quote from: 8v-of-fury on August 05, 2010, 11:29:32 am

Do they have a front cross member that gets right out of the way like the mk2?

Yup... pull the bumper, the rad, free up the A/C condenser and swing it out of the way, 6 bolts to pull the bumper cross-member,  and then engine/tranny will slide out nicely on a floor jack.
Title: Re: 1998 AHU --> 1981 Mk1
Post by: 4wheeler on August 10, 2010, 12:41:36 am
So what Turbo came on the TDI you just bought?
Title: Re: 1998 AHU --> 1981 Mk1
Post by: 8v-of-fury on August 10, 2010, 09:52:28 am
im assuming  the tiny K03 as it spools almost instantly at 14-1500 rpms :P
Title: Re: 1998 AHU --> 1981 Mk1
Post by: 8v-of-fury on August 10, 2010, 10:28:13 pm
What is the stock boost setting of a 1998 AHU? it seems to pull pretty hard.
Title: Re: 1998 AHU --> 1981 Mk1
Post by: 8v-of-fury on August 10, 2010, 10:36:34 pm
ALSO I have decided to keep the Car as my daily and put the 81 in the garage to tear it down and redo some stuff that will require it to be apart for a while. I'm stoked!

Got the 98 in my name and everything today, got my plates and got a temp sticker and went driving to make sure nothing breaks, it was a good maiden voyage.. It was actually very disappointing, seems I did not clamp one of the inter cooler lines and it was leaking ALL of its boost, and the car was disgustingly slow... DISGUSTING lol, then i realized it was leaking and HOLY MAN! IS IT EVER FAST! OMFG.
Title: Re: 1998 AHU --> 1981 Mk1
Post by: Vincent Waldon on August 10, 2010, 10:43:36 pm
Quote from: 8v-of-fury on August 10, 2010, 10:28:13 pm
What is the stock boost setting of a 1998 AHU? it seems to pull pretty hard.

12-15psi, depending on how the ECU feels about it.  ;-)

Title: Re: 1998 AHU --> 1981 Mk1
Post by: 8v-of-fury on August 10, 2010, 11:11:04 pm
whats a good in-fuel cleaner to run Vince? I know the older IDI's like ATF, but I'm sure I've read the TDI's dont much like it..
Title: Re: $400 1998 TDI Jetta Daily
Post by: 8v-of-fury on August 12, 2010, 11:15:21 pm
So this car is a temp solution so that I can take apart and fix some issues with the 81 which will be back to my DD hopefully soon! I miss it dearly! ;D

What is a cable shifter supposed to feel like? I would assume its suppose to be firmer and more precise than the 81's crappy crappy rod shifter? It's not. The 81 feels like a the comparison of shifting a fine German automobile to that of one made in some third world country.. (kinda feels like a GM product lol)

Also, for the swap.. If say I want to hold off on the O2A swap.. and just do the TDI mated to the old O2O.. will it suffice? the tranny swap might take it off the road for longer than I am willing to deal with.. lol it may be an option down the road for sure! but right now, i think the 020 will be ok for now won't it?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: burn_your_money on August 14, 2010, 10:55:07 pm
Cable shift usually feels like you are pushing a shovel through slush.

Yes the 020 will suffice but if you launch hard the torque will destroy it. You should look at getting a built one if you are in it for the long haul, or keep a spare box on hand.

I think I said this earlier but there are conversion kits so you can use the rod shift and cable clutch with the 02A. Then you only need a custom tranny mount or two. If you read Shawnb's thread on vortex he covers the mount. I'm sure a search will cover it as well.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: rallydiesel on August 15, 2010, 01:58:08 am
I was talking to Broke about 02a's vs. 020's. Ultimately, the 02a have larger diameter shafts and gears and will outperform a built 020. However, I'm sure you will be fine with an 020 for a while on a stock AHU.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on August 15, 2010, 02:01:30 am
that's what I'm thinking, just for a while. So I don't have to do a TDI ANNNND a Cable shifted/Hydro clutched 02A swap at the same time ;)

However.. this Rod Shifted/Cable Clutched 02A might be a good option... and then finally work up to full cable shift, and hydro clutch. I think I will look in to this more. I mean I have already read a bit about the rod shifted 02A's and people have said bad things.. but what are they comparing too? most certainly not a stock 81 020 box.. lmao

thanks for the replies guys!

ps. Tyler your right, how will I be able to resist the torque!? i'll destroy my FF :P
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on August 21, 2010, 01:40:28 am
Ok, so after amounting all the work this is at once I will be doing it in steps I think...

To start I will be taking a VERY LARGE part of the donor car, damn near everything but the kitchen sink ;)

I'm gonna take;


This is all I can think of for right now.. Can you think of anything else I may want to keep??

Also my buddy Catlin brought up a good point to me (this is why I wanna keep the Central Locking / Anti-theft), which was that the ECU needs to be disarmed to start the engine.. and this disarm action happens when the power locks or key is used to physically hit the micro switch in the door to disarm the alarm.. Its a vacuum system isn't it? Wouldn't be too hard to run the stuff for that to work would it? Probably just have the one switch in the drivers door... What are your thoughts here please!!

So yeah I figure I will start off easy easy easy.. by starting with the adaptation of the TDI and Wiring. Swap motors and get the TDI mounted up to the 020 (and make sure to launch it easy ;)). And then get the wiring swapped over to CE2 and all that in order, while addressing all the body work and assorted fun stuff at the same time. For a start on my swap.. I will be keeping the 02A/Cable/Hydro setup for another day.. I feel as trying to do it all at once will have this car off the road for a very very long time.. I don't think my 1.7 I will be driving has enough life left in her to last that long :P

I think it will be a good start.. who knows I might just stay with the 020 and keep it stock hp/tq #'s... (:P Yeahh Riight)
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: honda_is_the_best on August 23, 2010, 05:17:17 pm
Quote from: 8v-of-fury on August 21, 2010, 01:40:28 am
Ok, so after amounting all the work this is at once I will be doing it in steps I think...

To start I will be taking a VERY LARGE part of the donor car, damn near everything but the kitchen sink ;)

I'm gonna take;

  • Engine & Transmission
  • Intercooler & Piping
  • Cable Shifter & Cables
  • Hydro Clutch Assembly
  • Entire Car Wiring Harness (labeled before dissasembly)
  • Mk3 Cluster
  • Mk3 complete dash (possible future project)
  • A/C Condenser & Compressor (another possible future project)
  • Central Locking System/Anti-theft.. (this I want to incorporate in to the 81.. that would be too cool)

This is all I can think of for right now.. Can you think of anything else I may want to keep??

Also my buddy Catlin brought up a good point to me (this is why I wanna keep the Central Locking / Anti-theft), which was that the ECU needs to be disarmed to start the engine.. and this disarm action happens when the power locks or key is used to physically hit the micro switch in the door to disarm the alarm.. Its a vacuum system isn't it? Wouldn't be too hard to run the stuff for that to work would it? Probably just have the one switch in the drivers door... What are your thoughts here please!!

So yeah I figure I will start off easy easy easy.. by starting with the adaptation of the TDI and Wiring. Swap motors and get the TDI mounted up to the 020 (and make sure to launch it easy ;)). And then get the wiring swapped over to CE2 and all that in order, while addressing all the body work and assorted fun stuff at the same time. For a start on my swap.. I will be keeping the 02A/Cable/Hydro setup for another day.. I feel as trying to do it all at once will have this car off the road for a very very long time.. I don't think my 1.7 I will be driving has enough life left in her to last that long :P

I think it will be a good start.. who knows I might just stay with the 020 and keep it stock hp/tq #'s... (:P Yeahh Riight)

does it matter if your trans has 5 hp or 500 hp going to it if you cant hook it up good and hard? you need lots of traction, and some weight to break it..

if you cant load it very hard, and in a mk1, you cant, then you wont break. a light car is way easier on 020 trannies. the power isnt what breaks them, the car being stopped, and the engine all revved up is what does it. drop hammer. parts fly.

not so in a light car tho. i think an 020 trans behind a TDI would be fine in such a light car. remember this, it weighs like half that of a overweight mk3..

Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: theman53 on August 23, 2010, 08:37:35 pm
Quote from: honda_is_the_best on August 23, 2010, 05:17:17 pm
Quote from: 8v-of-fury on August 21, 2010, 01:40:28 am
Ok, so after amounting all the work this is at once I will be doing it in steps I think...

To start I will be taking a VERY LARGE part of the donor car, damn near everything but the kitchen sink ;)

I'm gonna take;

  • Engine & Transmission
  • Intercooler & Piping
  • Cable Shifter & Cables
  • Hydro Clutch Assembly
  • Entire Car Wiring Harness (labeled before dissasembly)
  • Mk3 Cluster
  • Mk3 complete dash (possible future project)
  • A/C Condenser & Compressor (another possible future project)
  • Central Locking System/Anti-theft.. (this I want to incorporate in to the 81.. that would be too cool)

This is all I can think of for right now.. Can you think of anything else I may want to keep??

Also my buddy Catlin brought up a good point to me (this is why I wanna keep the Central Locking / Anti-theft), which was that the ECU needs to be disarmed to start the engine.. and this disarm action happens when the power locks or key is used to physically hit the micro switch in the door to disarm the alarm.. Its a vacuum system isn't it? Wouldn't be too hard to run the stuff for that to work would it? Probably just have the one switch in the drivers door... What are your thoughts here please!!

So yeah I figure I will start off easy easy easy.. by starting with the adaptation of the TDI and Wiring. Swap motors and get the TDI mounted up to the 020 (and make sure to launch it easy ;)). And then get the wiring swapped over to CE2 and all that in order, while addressing all the body work and assorted fun stuff at the same time. For a start on my swap.. I will be keeping the 02A/Cable/Hydro setup for another day.. I feel as trying to do it all at once will have this car off the road for a very very long time.. I don't think my 1.7 I will be driving has enough life left in her to last that long :P

I think it will be a good start.. who knows I might just stay with the 020 and keep it stock hp/tq #'s... (:P Yeahh Riight)

does it matter if your trans has 5 hp or 500 hp going to it if you cant hook it up good and hard? you need lots of traction, and some weight to break it..

if you cant load it very hard, and in a mk1, you cant, then you wont break. a light car is way easier on 020 trannies. the power isnt what breaks them, the car being stopped, and the engine all revved up is what does it. drop hammer. parts fly.

not so in a light car tho. i think an 020 trans behind a TDI would be fine in such a light car. remember this, it weighs like half that of a overweight mk3..


That and wheel hop is VERY bad. Usually on the 3rd hop the CV will start making appearances :D
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on August 23, 2010, 10:01:08 pm
Well if you really think about it, I can hook it up slowly and then get on it and have 150 ft/lbs going through it before 2000rpm.. which is a whole ton more than it was designed for. If I can score a welder I will be going the 02A and make my own mounts.. and even make the rear mount wide so I can upgrade to a huge turbo and 3" DP down the road :P

Also Lucas, I dunno about them grenading like that. Bro's 84 pulls a mean peel-out and he hasn't wrecked anything just yet.. or is he threatening the life of his tranny!? lmao
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: theman53 on August 23, 2010, 10:10:54 pm
Straight burn outs aren't bad, but wheel hop is. Usually about the 3rd or 4th hard hop the CV says hello by rolling out from under the car :D Or I have a buddy that has twisted a shaft in half and the CVs stayed put :o

Wheel hop usually sounds like a bang, bang, bang, BOOM CRUNCH METAL LIFE SUCKS RIGHT NOW as opposed to a screetch or squeel of peeling them off
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: honda_is_the_best on August 24, 2010, 01:41:24 pm
yea, wheel hop is bad, thank god mk1s dont really suffer from it too bad, least mine dont..
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: Smokey Eddy on August 25, 2010, 02:29:27 pm
a done out ALH TDI in a slammed mk2 jetta, completely blacked out, is my ultimate goal.
my jetta used to wheel hop. not anymore ;)

Gears and stuff can take force. They are designed to. It's when you drop the hammer like the guy said.
CV's can take a lot of twisting force but not sudden force like dumping the clutch and so on.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on September 03, 2010, 02:38:08 am
Today I commenced taking apart the front end and removing the engine wiring harness. Labelling every single vacuum hose, plug, and connector.

Had to shut down shop and wait out a rain lol
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00046-20100902-1911.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00040-20100902-1713.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00042-20100902-1729.jpg)

But there are a few things (which I'm sure are essential as part of the swap) that I just don't have names for, or have no idea on their function. So if you wouldn't mind helping me out a little bit that'd be great.

First off these two switches i'm guessing, both have rubber lines going to them. I believe the left ones lines go down to the cold side of the turbo, and the others go to the intake tract. what are they and what is their purpose? They are slated to make the swap with the engine.

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00041-20100902-1717.jpg)

The next is this little guy that used to reside up near the coolant bottle, and has to vacuum lines running in to it. One from the vacuum pump and the other goes in to the cabin with the coolant lines on the firewall. What does it do?

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00043-20100902-1733.jpg)

Next question is how do i disconnect this monster!? It looks as though it is a connector for most of the front of the engines electrical sources, a very good idea in my mind, one easy connector.. whole engine should be this way. One connector takes the engine off the harness ;). I tried pulling, and twisting, I gave up for fear of busting it.

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00044-20100902-1817.jpg)

Which leaves me with about thirty more questions sadly no pictures though..

Rad sensor and fan wiring, I was thinking to be honest the easiest way of doing this would be to fab up some way to mount the mk3 rad in the 81, as then i would be able to plug and play literally everything. Temp sensor, fan wiring, and the hoses would plumb right up. I was also thinking of using the mk3 coolant bottle as well so that way I could maintain the coolant level device of the ECU. There is some module of sorts underneath the coolant bottle that I have no idea what it is for.. What is its purpose as well?

For the lines that that go from the vacuum pump and then to the switched device, can I use this to supply vacuum to my 81 HVAC??

The brake fluid level checker and brake fluid reservoir. will the reservoir fit on the on the 81's master? as it would make it easier to run the hydro clutch and all that junk I would think.

How do I go about removing the A/c Compressor and power steering pump? I think the Power steering is the only thing on the V belt? or is the WP on there too? Will the alt need a new bracket to fit on the engine without the a/c pump there? Or can it be cut and modified to make work minus the A/c.. ?

What sort of complications will I run in to by weeding out the A/c wiring? Will the ECU see it as a problem?

Also on swapping the car over to complete CE2, what about for the headlight switch? that is a very different switch.. how will there wiring interface?  and such?

that concludes it for today I guess. thanks guys! Get back to me love to hear some feedback.. !  ;D
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on September 03, 2010, 07:00:45 am
Quote from: 8v-of-fury on September 03, 2010, 02:38:08 am

Next question is how do i disconnect this monster!? It looks as though it is a connector for most of the front of the engines electrical sources, a very good idea in my mind, one easy connector.. whole engine should be this way. One connector takes the engine off the harness ;). I tried pulling, and twisting, I gave up for fear of busting it.

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00044-20100902-1817.jpg)


Twist Turn, its screwed in, turn it gently and it will pop off TRSUT ME I'M A MK3 Owner lol
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on September 03, 2010, 07:02:38 am
Oh and most of those little Hoses are for AC and Cruise Control stuff. Youll end up deleting all of that, its what I did with my ABA when I put it in, and No issues
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on September 03, 2010, 08:02:45 am
JUST FOR YOU BUDDY   :-*

Jeremys how to (http://www.youtube.com/watch?v=oEjM5vOZC_s#)
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: theman53 on September 03, 2010, 08:27:59 am
Quote from: catlin_cava on September 03, 2010, 08:02:45 am
JUST FOR YOU BUDDY   :-*

Jeremys how to (http://www.youtube.com/watch?v=oEjM5vOZC_s#)

LOL
Thread win
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on September 03, 2010, 11:35:01 am
I love you Catlin, I would never get by on anything if it weren't for you ;)

You sound like you should be some sort of child show personality :P
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on September 27, 2010, 10:47:26 pm
WOOHOO DIESEL SITE BACK UP AND RUNNING!! I'm so exciteddd!

So I have made some progress in mind and in real life ;)

I have refined how far I am gonna go with this swap, as I don't want to be too overloaded right off the get go here. lol

I was looking at the wiring in my 81 and its pretty much good as new.. so that to me right there is no reason to convert the car over to CE2 wiring. However I will be using a method of piggy backing the fuse-box on to the old fuse-box and have it only run engine management stuff.. and let the old box and wiring run the in car stuff.. and headlights and fan wiring

As for the axles I think I will make up Broke's little gadget to take the flange cups off the trans and swap them out for some 90mm ones off a good donor.. and use my stock 90mm axles and stock hubs (might not be the strongest solution.. but its gonna for sure be the easiest :P)

Exhaust will most likely be whatever the mk1 has on it now... for now.. with plans for as big as possible in the future.

Following up from Catlin's thread about the EGR deletion.. What is the coolant routing for on the TDI engines? Is it to act as a coolant pre-heater to get er up to operating temps quicker and get some cabin heat faster? If so I only wish to stop blow-by getting in to the intake tract... lol to prevent run away and oil sipping.

I miss driving a Diesel.. this 25mpg b.s is stoopid ;)
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on September 30, 2010, 11:57:13 pm
So in thinking back on the wiring mess I have in the car right now I was wondering where is the reader for taking codes from the ECU? Is it a little purple plug that is beneath (or above) the cigarette lighter? I think this will be beneficial to keep eh? lol

So upon really thinking a bout my route of attack here, if I just wanna keep the ECU and engine management part of the box I should only need the cluster harness, the purple plug harness, and all the assorted wiring for the engine correct? Easy Peasy?

Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: Vincent Waldon on October 01, 2010, 12:47:39 am
Quote from: 8v-of-fury on September 30, 2010, 11:57:13 pm
Is it a little purple plug that is beneath (or above) the cigarette lighter?

Yup.

Quote from: 8v-of-fury on September 30, 2010, 11:57:13 pm
I think this will be beneficial to keep eh? lol

Double yup. ;D ;D
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on October 02, 2010, 10:00:42 pm
I noticed that on my two ten days driving the TDI around town and about 500kms roadtrip on the highway one day, that it doesn't smoke much. I mean obviously that tiny K03 spools low and keeps the fuel burning properly, and then the pump keeps the injection happening at the best possible time.. BUT I LIKE ME A BILLOWING DIESEL ;) Bigger Injectors are in my future, me thinks.

Obviously bigger inter-cooler piping will cause some lag, but is it even a problem with the quick spooling k03? intercooler piping will most likely need to be one off, and i was wondering on turbo lag, what do you think?

I was thinking of bigger intake (maf-turbo, turbo-ic, ic-intake) will this even be worth it for anywhere near stock power? Probably not eh, as they don't list an intake upgrade as even suggested till you add like 60 more hp though eh?

What range does the k03 do well in? Obviously its making its peak psi at 1900 where the engine has 150 ft/lbs.. how much does it go outside of its efficiency range at say 4000? Or higher?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on October 02, 2010, 10:52:09 pm
Quote from: catlin_cava on September 03, 2010, 08:02:45 am
JUST FOR YOU BUDDY   :-*

Jeremys how to (http://www.youtube.com/watch?v=oEjM5vOZC_s#)

I feel like I need to bump it
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on October 09, 2010, 09:11:41 am
I was under the impression from BrokeVW's site (which I can't seem to load right now :s) that the later 90mm 020 tranny flanges bolt to and in place of the 02A 100mm flanges..?

so that stock 90mm axles can be used..? anyone got anything on this?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: CRSMP5 on October 09, 2010, 11:00:45 am
dont trust me huh.. look at mods list.. myke_w ask him bout me..

for simple aspect.. look at bently tranny area.. no idea if 98 tdi book has tranny tear down info.. but if all else fails etka the axel flanges.. aka 020 vs 02a.. or go clean the grease from the 02a cup and see how there is no clip/anything in the cup..
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: theman53 on October 09, 2010, 11:21:23 am
you could always contact brokevw. He knows the 020 stuff and some about the 02A. He may know what works with what.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: rallydiesel on October 09, 2010, 05:36:20 pm
You can swap 90 and 100mm flanges between the 020 and 02A all day but make sure the axle lengths are right.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: Powered by Spearco on October 09, 2010, 10:32:07 pm
That does not sound right to me. The flanges don't interchange from 02O to 02A or the other way.
I'm running an 02J trans with 100mm TDI,2.0L gas car trans flanges that bolt in with a single bolt. The 02A all have a C-clip for attachment.
I'm also using 100mm Scirocco 16V axles and 100mm 16V spindles/wheel bearing housings. Sence it is still MK1 chassis.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on October 10, 2010, 12:44:08 am
So by going to these later rocco/cabby spindle/axle assemblies will I have to alter or upgrade the front brakes? I mean yeah cool, I wanna do that at some time.. but not right now... ya'heard'me? lol

Guess i gotta get in to a big u-pull-a-part down in Toronto and see what they got. what years classify as the later years? 85+? Also in these years are there any with 90mm to look out for? if they have the calipers/carriers with them should I grab them too?

I was contemplating just bolting it up to the 020 for now.. I don't launch hard ever and I'm super easy on clutches.. No ricer starts.. just smooth low rpm engagement. only get on the power when im well in to gear. I have faith in the 020... I think this will be my route of attack thus far. keep the 02A for a rainy day.. and buy a clutch for the 020.. maybe a %80 kit too?

Lets switch topics to getting the best out of an 020. not for OMFG POWER! just reliability under normal conditions. the tranny will hold the torque, its the clutch dropping it won't take, so it should do fine yes? what are your thoughts?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: rallydiesel on October 11, 2010, 12:24:04 pm
Quote from: Powered by Spearco on October 09, 2010, 10:32:07 pm
That does not sound right to me. The flanges don't interchange from 02O to 02A or the other way.
I'm running an 02J trans with 100mm TDI,2.0L gas car trans flanges that bolt in with a single bolt. The 02A all have a C-clip for attachment.
I'm also using 100mm Scirocco 16V axles and 100mm 16V spindles/wheel bearing housings. Sence it is still MK1 chassis.


Whoops, thanks for the correction!
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on October 23, 2010, 03:09:21 pm
Upon other readings of people putting modded ABA's and the likes behind older 020's and really making those trannies beg for mercy.. I see no reason why a properly driven TDI (no harh starts, no clutch drops, no intense intens shifts)..

Some would say they have less torque behind them.. I think a modded aba is easily above 150ft.lbs.. even at less torque with crazy starts all the time.. i think would be easier on it to have a smooth driver behind it. Plus all these won't take the torque stories are from people who have put high torque/ high hp motors behind an old 020 and beat it till it bled..

I havent seen any sort of evidence where an 020 has not held up behind normal use... only jack-head-starts.

;) 020 I HAVE FAITH!
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: CRSMP5 on October 25, 2010, 12:14:55 pm
like i said on the whoretex post.. it will work, but plan to go thru the 020 if you want life.. :P

my odd ball 2.0 works the 020 pretty good.. eough to loosen the 5th gear retaining bolt into the main shaft without trying.. :D

yea it has torque.. unsafe in the rain with 14x6 wheels.. rips them free at will.. in snow deadly (only 1 time as cought commin home in 1/4" of snow, could not go or stop).. i added 15x7 back in 98 and that helped some.. but will still rip them free if you try to.. better then 14x6 opps style..

i expect my tdi-m to make more torque though :) and like i said.. i think i am at its logical 020 limit.. stock tdi should be fine.. add more power/torque things will get hairy..

make sure to add a lower stress bar.. even one made from angle iron is better then none.. you will get torque steer... thats hard on the frame horns..
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on January 09, 2011, 12:23:22 am
UPDATE

nothing of any real importance :P but a post none-the-less.

I ordered and received a bunch of new goodies for my Jetta:


On the "To-Do List":


Still pending thought process:


Upon talking it over, going with the 020 transmission would be completely stupid, counterproductive, heinous, and just plain dumb... lol.

Swap will consist of:


so far just stock piling for spring! When the real work will commence! muahaha
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on February 03, 2011, 01:00:17 pm
QUICK QUESTION!

I need to take the timing belt off (I think i do anyways) so that I can fit the mk1 passenger side mount to the block..

I need to cut away some pieces of this little thin tin sheet behind the t-belt so that I can get this mount in there..

Question being, if I do have to remove the belt.. What must I do to maintain a flawless re-install of the timing belt.. It should be as easy as slip off slip on shouldnt it? I have never dabbled in the TDI t-belt area.

Your help is greatly appreciated :)
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: Vincent Waldon on February 03, 2011, 02:54:40 pm
It's pretty much exactly the same as an IDI timing belt... positioning is mission-critical and to the thousandth of an inch.  ;D   The proceedure is exactly the same... lock everything down to TDC, tension the replacement belt with the cam sprocket loose etc... the only difference being that you check and dial in the final timing with software rather than a dial indicator.

In this case you can "mark and pray", as the TDI folks call it,  and likely not cause valve interference... but you're gonna need the right tools to lock everything down some day... and seeing as how this is an AHU engine both the IDI pump lock and cam lock should work for ya anyways iirc.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: RadoTD on February 03, 2011, 11:51:38 pm
Oh man, I need to check the TDI forum more often! Subscribed! :)

As far as the 020 is concerned, my biggest worry would be during a hard 2nd or 3rd gear pull... if you hit a bump and one of your tires jumps off the ground, the force of it coming back down and locking up will take it's toll after a while. Drive sanely for now though and you shouldn't have any trouble!

Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on February 04, 2011, 05:40:41 am
Jeremy, WTH!!! This isn't Finished yet ;)


Just joking Buddy Love ya :-*
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on February 06, 2011, 08:04:32 pm
Vince, thanks a bunch for the informative answer.

Yes I have the cam and pump locks from doing my IDI's, that's good to know they will still have use. If nothing moves while I have the belt off... then theoretically it should slip right back on in place right? With the Mark and Pray method ;). I mean I won't be messing with the accurate part of the pump timing that is by moving the pump at all.. and if the pump and cam are all locked in.. with the engine reading exactly TDC.. that belt should slide right back in to its spot. Hopefully.

On a side note, I got some work done today :D  ;D

Catlin, frigg off lol. You don't finish anything lol.  :-*
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on February 07, 2011, 07:50:59 am
Quote from: 8v-of-fury on February 06, 2011, 08:04:32 pm
Catlin, frigg off lol. You don't finish anything lol.  :-*

I finished 2 out of 4 projects ive taken on lol
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on February 20, 2011, 05:51:22 pm
http://www.youtube.com/watch?v=oEjM5vOZC_s (http://www.youtube.com/watch?v=oEjM5vOZC_s)

 :-*
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on February 28, 2011, 11:14:14 pm
Might be some set backs on this project... >:(  a really intelligent guy who will not be named wrote an amazing post about everything you needed to know in order to fire up the secondary fuse box on the vortex.. and for some reason the guy gets all butt-hurt and deletes the whole damn thing. I mean really? You obviously know your stuff, why did you have to do that?

There was a butt-ton of good diagrams in their outlaying EXACTLY what needed to be connected.. so I dunno where this swap is going to go.. I'll have to buy TWO bentley's now in order to figure out the friggan wiring.. CRAPPP
 >:( >:( >:( >:( >:( >:( >:(
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: theman53 on February 28, 2011, 11:18:50 pm
PM him and tell him he is a god among men...he may show favor and bless you with knowledge. OR ask you for your #. Luckily I have no clue whom you are talking about.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: RadoTD on February 28, 2011, 11:44:57 pm
Use some form of archive (waybackmachine.org, archive.org or google archive) and see if one of those managed to catch it. Save as a PDF then ;)

When was it posted and where was this thread on the vortex?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on March 01, 2011, 12:11:52 am
golf 1 jetta 1

aba mk1 swap 2.0 in to mk1 2.0 in to a1 aba a1 swap thread

doesnt look like they caught it
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on March 01, 2011, 12:32:57 am
I will start a thread on TDIclub, duno why I haven't yet.. and I will see if any of them will be so kind as to scan a few pages of their Bentley for me ;) I only need the back of the fusebox really.

Here is my dilemma. I have the full engine harness, the fusebox, the harness to the cluster, and to the mk3 ignition.

My plan is to run the mk3 cluster which will plug in just fine and dandy.. I am pretty sure %95 of the engine stuff will also plug in to the back of the fuse box. I will run the stock mk3 gear reduction starter, which is part of the engine harness.. so ill need to find which wire is the starter trigger..

There is a butt ton of other connectors that come in from the engine harness, but i dont see how they can be neccessary to my swap, as they go to stuff that was up in the dash, or wherever they came from.. but all the essential wiring should plug right back in to the back of the fusebox... I mean whats even in the wiring harness that needs to plug in? Starter wiring, pump wiring, and ECU power.. all the various sensors in the engine, with regards to speed sensor on the crank that goes back to the cluster, go to the ecu and remain in th eengine bay..  Interesting, with a little thinking this may not be too out of reach after all lol

 
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on March 03, 2011, 12:26:55 am
Thought Id summarize with a bunch of pictures from the beginning to present. What do yall think!

First car I got in 2006, this picure is in 2007
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/Picture125.jpg)

As we were pulling it out of the barn/shed;
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/HPIM1537.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/HPIM1539.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/HPIM1538.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/HPIM1540.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/HPIM1541.jpg)

A little cleaning later and it was half respectable :D
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1101091635.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1101091634.jpg)

However the pump had a shaft bushing leak and I just happened to have a parts motor kicking around that I got out of a wrecked Golf the year prior for the original idea... make my 84 a diesel (which i still might do ;)). So the engine that I had all prettied up for my 84 was ready to become a donor.
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/Picture1210.jpg)

I picked this up from a fellow dubber to make some more power for the swap to my 84 :cool: Yup D-shaped intake ports ;)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/0303091525.jpg)

I had then planned that this would now be my car of choice, as I FELL IN LOVE with this diesel. I named him Douglas Maurice :) lol This is running off a jerry can of 10w30 motor oil, ATF, 2 stroke ashless oil, and a touch of kerosene. Mad retarded timing as well..
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1101091706.jpg)

Since I decided that this was now going to be my car some work needed to be done to make it worthy of being a DD. From my 91 engine I took the IP, pre-warming filter, injectors, hardlines, cam baffle, and cam cover. While I was in there i also replaced all the GPs with Bosch Duraterms and wired in my own manual glow plug system to get maximum voltage to the plugs. It would also appear from sitting the rear shoes came off their brackets.. ***ty.
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1130091342a.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1130091342.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1130091342b.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1204091555.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1204091502c.jpg)

All that new stuff later, and I took it for a nice LEGAL drive lol ;)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1204091546.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/1204091612.jpg)

Then after doing that brake work, they lost power braking.. TIME FOR A NEW VACUUM PUMP. Set up an oil catch can as I wasn't quite convinced it wasn't doing some mad blow-by and was gonna cause a run away. On a side note, check out this awesome vintage horn! what do you think its off of.. sounds like The RoadRunner!
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/Feb2010348.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/Feb2010351.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/Feb2010373.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/Feb2010376.jpg)

Got the car drivable and made the drive from where I was working on it to my home. Gave it a bath. Installed some LEDCheck out the ODO :o! 587!
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/0308001535b.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/0308001242.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/0502002028.jpg)

Started driving the car in early 2010.. about February. And from then I installed a stereo, amps, subs, did front and rear motor mounts, shifter bushings, and made me up a nice CAI in early April ;)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/100_0253.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/100_0255.jpg)
http://s299.photobucket.com/albums/mm307/J_holubek/Diesel/?action=view&current=100_0256.jpg
http://s299.photobucket.com/albums/mm307/J_holubek/Diesel/?action=view&current=100_0274.jpg
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/100_0275.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/100_0259.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/100_0262.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/100_0283.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/100_0285.jpg)

Then I started to really tear in to it and I started driving my 84 gasser again around October, so I started doing some minor body, floor work, and undercoating.
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/IMG00268-20101102-1444.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/IMG00270-20101102-2117.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/0814001150.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/0814001613.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/0814001959.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0527.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/IMG00294-20101111-1541.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/IMG00296-20101111-1542.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/IMG00297-20101111-1547.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/IMG00299-20101111-1548.jpg)

Had some good headliner ideas too :)
(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/100_0315.jpg)

THIS IS WHERE THIS CAR GETS THE RIGHT TO BE ON A TDICLUB THREAD :D

Picked this car up for diiiiiiirt cheap because the DumDum who owned it.. couldnt get it started all of the sudden one day after driving it, what do you think the problem was... lol There was only one thing to do with it. After I drove it around for approx. 20 days to figure out any bugs or anything and make sure its a good swap.
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0478.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0499.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0480.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00171-20101010-1258.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00175-20101010-1615.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/IMG00176-20101010-1703.jpg)

And then finally just this week I started tearing out the suspension because i got new sport springs and struts/shocks, and also took the old motor, trans and axles out yesterday.
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0962.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0990.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0989.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0963.jpg)
Sketchy way to lift a car people!
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0988.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0997.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_0999.jpg)

Quite the dirty deezul bay, it will surely getting at least cleaned.. and touched up. nothing fancy. Function over Fashion.
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1000.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1004.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1009.jpg)

Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: maxfax on March 03, 2011, 12:58:46 am
Quote from: 8v-of-fury on March 01, 2011, 12:32:57 am
I will start a thread on TDIclub, duno why I haven't yet.. and I will see if any of them will be so kind as to scan a few pages of their Bentley for me ;) I only need the back of the fusebox really.

I have Alldata.. What all you need? The engine doaner was a golf, right???
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on March 03, 2011, 09:06:59 pm
Got some more work done today on my day and and the weather was cooperating and beautiful :)

Got all the steering linkages, rods, and shifter out and off the steering rack. Also took a shot of all three mk1's :D

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1016.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1018.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1020.jpg)

Started mocking up the Cable shifter, I was originally planning to run the cables inside the car and out.. totally forgot this car has the a/c air box though, so the cables will have to run outside. Which will run the shifter box lower in the car anyway.. Just what I want :)

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1033.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1032.jpg)

Clean install of some quality 5"x7" tri-axial speakers.

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1039.jpg)

Started to look at the clusters and am thinking its gonna be more work than I originally thought to get the mk3 cluster in.. Greaat lol.

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1029.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1028.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1026.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1025.jpg)

The Wiring Harness ;)

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1046.jpg)

Old and New side by side

(http://i299.photobucket.com/albums/mm307/J_holubek/TDI/100_1047.jpg)
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: theman53 on March 03, 2011, 10:24:05 pm
Love the cougar...my wife should be one in a couple years :D
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on March 03, 2011, 11:54:49 pm
Lucas, your wife is smokin' :) touchč sir ;) Would you have known it was a Cougar without the SunScreen.. lol
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: theman53 on March 04, 2011, 07:22:45 am
only because I have seen it before, but if I hadn't no. I know cars but that was too little for me to identify the old muscle from.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on March 11, 2011, 11:18:35 pm
So if you guys look on the last page and see my pictures, you'll see I have fixed up the rust around the car with a good etching, filling, rust inhibiting primer spots. I think after I get the TDI in there.. I want to strip it all down and spray it all with a few coats of the red oxide primer, but that means i have to follow through with paint...

Ugh I hate body work lol! With a PASSION

WWJD??
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on March 31, 2011, 08:40:51 am
Fired the TDI up today on the stand! Hooked up all the engine wiring, sat the computer aside, hooked it all in to the fusebox. Plugged in the cluster, and the ignition harness. :)

Upon turning the key I can get the IP to get power and click on, and the load relay clicks on. I don't know if the computer gets power or not as the cluster never actually turns on (like when you turn the key and the idiot lights come on..). Turning to start will click off the load relay, but wont engage the starter. Turning the key to Run, and manually jumping the starter post and the engine fired right up after sitting since October :D. So to me, I think if the motor started, and was running.. the computer must have been getting power..?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on March 31, 2011, 05:50:13 pm
Try this, it helped me ;D

http://www.customobsessions.com/modules.php?name=Forums&file=viewtopic&t=30603&highlight= (http://www.customobsessions.com/modules.php?name=Forums&file=viewtopic&t=30603&highlight=)
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: Powered by Spearco on March 31, 2011, 11:29:50 pm
If its a manual trans. then it needs to see the clutch depressed. But good to hear you go it running.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 01, 2011, 11:23:53 am
Catlin, I think your was different because you swapped motors? I mean I have all the stock wiring and everything native to this TDI motor and cluster.. just out of the vehicle. I'm gonna ask about it in your CS thread if you don't mind lol.

PBS, yes it is a manual trans. I labeled the three or so plugs that went on the pedal cluster. However, I don't know which needs to be jumped.. I mean i guess jumping all three wouldn't hurt right? Brake lights that don't exist will be powered.. and the other i have no idea what its for lol.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on April 01, 2011, 05:45:07 pm
Quote from: 8v-of-fury on April 01, 2011, 11:23:53 am
Catlin, I think your was different because you swapped motors? I mean I have all the stock wiring and everything native to this TDI motor and cluster.. just out of the vehicle. I'm gonna ask about it in your CS thread if you don't mind lol.

But I used ALL the 2.0 Harness, does your ODO and Clock light up?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 01, 2011, 05:56:54 pm
Yeah the odo and clock light up, so the cluster is getting a power.. But it never sees the key being turned on.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on April 01, 2011, 07:15:31 pm
Quote from: 8v-of-fury on April 01, 2011, 05:56:54 pm
Yeah the odo and clock light up, so the cluster is getting a power.. But it never sees the key being turned on.

FOLLOWED IT!!!!!!!!!!!!! whats it going to hurt? come on!!!! I hooked up all my cables right and it didn't work, clock and odo worked but nothing else. I jumpped the wires and VOILA!!!!

Do it, I bet you a Coffee!
if it works you owe me a Coffee, if it doesn;'t I owe you one
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 01, 2011, 08:02:50 pm
Ok, so you have to jump those two wires together separate of the fuse box? Why though is my question.. Why doesn't it just work? It worked in the car lol. All the wires that ever went to the fusebox are still there and intact. Makes 0 sense
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 05, 2011, 03:11:40 pm
So I was out fiddling with stuff in the garage and i decided to give this E2-D8 jumping a go.

I DON'T HAVE EITHER THE E OR D WIRING HARNESS.... (insert a whole butt-ton of foul language).. Why do i not have them? Where do these two harnesses go once they leave the fusebox? My friend still has the shell i pulled this all from so if need be I can go give it a look see.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: CRSMP5 on April 08, 2011, 03:17:58 pm
i just wish you would listen to me and do a complete ce2 swap... on myke_w when i wired up his tdi stuff into his ce2.. there are 2 wires that need jumped else you get your issue.. no sorry not been watching.. his 88/89 is ce2 but well did not include the jumper..

if you would just use the complete ce2.. you would have said jumper.. splicing in tails/headlights/heater is far simpler then what your doing...

hit him up for his info... he had dl it from someplace.. and it was a direct walk thru on this jumper and such..
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 10, 2011, 12:07:00 am
Quote from: CRSMP5 on April 08, 2011, 03:17:58 pm
splicing in tails/headlights/heater is far simpler then what your doing...

Hardly :D. It's s'all good, got that ish figured out. Contacted the MASTER of mk3 cluster/engine/wiring/ecu crap to mk1 swaps. The two pins E2 and D8 need to have a wire between them. Problem solved. Please tell me how rewiring the ENTIRE car is far more simple? LoL

I contemplated CE2 swap way back, but there was absolutely reason too. It would have created way more work than necessary, plus the wiring in the 81 is fine.

Thanks for the info man! I'll contact him see if hes got any tips :) Hows your swap coming along?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: CRSMP5 on April 12, 2011, 02:08:09 pm
mine is on hold at moment due to 86 vr6t coupe project.. gotta rearrange the work area to accept the crunched 82 caddy as its storage is going away.. still not found a place to put the extended caddy.. but i still have hopes to have my coupe together by 8th of july weekend for mk1 madness..
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 12, 2011, 07:06:29 pm
I need ideas on how to take my 81 which is nose towards the garage on a hill driveway, turn it around and push it in the garage somehow in place of my Mercury..
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 12, 2011, 07:07:51 pm
Ohh.. The front end is completely dissected.. LoL. Doesn't even have control arm mount on it! .. I guess place a dolley cart under the front frame horns??
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: maxfax on April 13, 2011, 12:48:01 am
A case of beer and some strong friends???  Some variety of dolly is the safest way to go..  A good rooling floor jack will do it, but can slip outta there..  Even if you have to go out and buy one or two they have a billion and one uses.. Real handy for rolling an entire driveline under the car to lift it in..  Mine typically have engines plopped on them for rolling around the garage.. 

I scored a set of crazy heavy ones used at a dairy for rolling crates of milk around..

I also bought 2 of these http://www.harborfreight.com/1000-lb-capacity-polypropylene-movers-dolly-93614.html (http://www.harborfreight.com/1000-lb-capacity-polypropylene-movers-dolly-93614.html)

They work quite nice too...
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: burn_your_money on April 13, 2011, 12:20:20 pm
I built my own with 2x4s and castors from princess auto. I think I have 6 of them. Best tools in my garage...
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 13, 2011, 03:35:27 pm
I have one that I currently tote my TDI around the garage on.. I was thinking of plopping two tires on top of the dolly, and the frame horns on those.. Other than the small lip at the garage-driveway area.. I don't see it being too much work LoL.

What Could Possibly Go Wrong? ;)
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: maxfax on April 13, 2011, 07:46:04 pm
Quote from: 8v-of-fury on April 13, 2011, 03:35:27 pm
What Could Possibly Go Wrong? ;)

Post up some pics when you find out...  ;D
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 17, 2011, 11:35:04 pm
well i propped the front end up on the dolley cart resting on the control arm mounts and frame rails, and pushed it myself up my drive way and in to the garage in place of this beauty;

(http://i299.photobucket.com/albums/mm307/J_holubek/Cougar/Picture7401.jpg)

Which is now sitting under a car cover, getting snowed on. Yes it is snowing in Ontario.. its TOTAL B.S.

Got the rear suspension out and disassembled.. I dunno how this car rode so good.. 4 coils broken off both coil springs, and both shocks just right done in. Yet it rode great, and didn't bottom out with 4 people and the trunk jammed packed full of coolers of ice and several 24's of beer.. Incredible. Got some new shocks and springs, reusing the mounts and spring perches to save on some money. Ground them down and re painted them with rust inhibiting primer and tremclad black paint. Shocks are Monroe Sensa-tracs Mono-tube (Lifetime Warranty), and they will have RACELAND sport/drop springs complimenting them. 20-25mm drop with theses springs, and rates a little stiffer than stock.

Front suspension has been out for a while, but tonight I got the strut housings of the knuckles, and the knuckles off the control arms. I just got a compressor and a 80 pc. air tool kit with a die grinder and assorted grinding tools.. so i will be attempting to clearance my hubs myself to fit the 100mm outer cv's :D. However lacking a vice and a spring compressor.. I will be taking the strut housings and new springs to a shop to have the old springs/struts removed and new ones put in with an ATF back-fill. Will also be getting new front bearings pressed in.

I've got new BJ's, control arms, bushings, inner and outer tie-rods and boots to go in up front. As well as new upper strut mounts.

There is also a ***-ton of fabrication ahead of me here, I will document as best I can.. but getting it done before I roadtrip this bish in June.. I may not have TIME! ;D
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 23, 2011, 06:45:20 pm
Anyone have any luck pounding out the bearings yourself? And using a hammer and appropriately sized socket to hit the new ones in? Trying to save some cash here, as I am currently fighting a BS ticket I got.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: maxfax on April 25, 2011, 02:01:29 am
Those suckers are usually in there TIGHT!  You *might* drive them out with a hammer, but the risk of f..ubarring a bearing on the reinstall is pretty high.. 

Although it is kinda hard to hold the knuckles down (especially w/o a vise) it can be done with a ball joint press if you have a connection for one of those.. Down here most of the "big box" auto parts stores will loan or rent such tools free or dirty cheap.. They'll also usually have spring compressors available too..
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 26, 2011, 01:22:34 pm
Anybody know the shearing force (breaking weight) needed per metric bolt strength to shear it?

Like what will a metric 5 bolt shear at..
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: theman53 on April 26, 2011, 10:41:44 pm
5.5 metric ... don't breathe on it
8.8 is a little better but 10.9 is the only real bolt to use unless a weaker one is called for
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on April 26, 2011, 10:42:50 pm
will 10.9 say 10.9 on the head?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: burn_your_money on April 26, 2011, 10:47:16 pm
Quote from: 8v-of-fury on April 26, 2011, 10:42:50 pm
will 10.9 say 10.9 on the head?


Usually yes
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on May 23, 2011, 10:18:56 pm
Hello Boys and Girls (do we have girl users?)!

Plans have changed, BUT a TDi powered mk1 is still the name of the game.

The original plan was to swap EVERYTHING over and run the TDI, CTN 02A trans, cable shifters, cluster, and hydro clutch in the Gold 81 in my sig.. but plans have changed! I was gonna get rid of the Black 84 I have.. but it was my first car and i've had it for 4.5 years.. I do not want to get rid of it.. you know??

ALSO THE SWAPPING OF 02A TRANS IS A WHOLE !@$% TON OF WORK. :( So I have decided (with great research) that I will bolt this TDI to my stock FN 5spd. I've got two others sitting around if she goes BOOM, so all is well. Yeah I know you think why not do it all now instead of now and later when it goes pop.. Why? This is a project car, not a do it up and live with for years to come.. it will be ever changing :) If i wanted a car to just drive and check the oil, I'd buy a ford explorer.
Using my already there transmission means I do not need to fab transmission mounts, or the cable selector, or hydraulic clutch.

I will be maintaining the electronic aspect of the TDI, and running the drive by wire, cluster in the dash and sensors on the motor. I think this will be a ok combo, as mr.dave ran an 020 behind his ALH for at least 5 years without issue. Obviously it needs to be driven with a lot less abuse than the 02A can take but that is ok as I am easy on my vehicles anyhow. I want the already rolling power, not the burn the tires off power.. eh?

I already have the mk1 passenger side mount on the TDI motor.. so the next step would be putting the 210mm PP and FW I have on with a fresh disc.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on May 23, 2011, 10:51:25 pm
here is a question. The PP and FW that I will use is in ok shape but is disc too suffered from an oil leak and failure. It too had lots of meat left :(

Is it safe to re-use the PP thrust plate and spring ring clip on a different motor? I'm all about the budget builds. I will be getting a new Nickel Plated hub 210mm clutch disk, push rod and to bearing. Can the new pus hrod be used with the old thrust plate? Or does it have a certain wear pattern? New Thrust plate too? ;)
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on July 29, 2011, 12:07:13 am
Ok ladies I's be needing your input. So basically I'm pretty much the most Frugal person you have or will ever meet. To the point of buying something, using it, and returning it.. or even returning something else in its packaging.. yep done it countless times.

So on the frugal note.. I don't want to do a trans swap, instead wish to use an 020 transmission. Possibly a much lower km unit then the one I have. I figure it should also be the tallest geared one I can find. I do believe the tallest usable would be a 3.67fd with a .71 5th. If I can find a usable ACN, I have a .71 5th i can swap in. I have read some have been able to run an ACN in the mk1's and some trans don't have the studs for our mounts.. any insight here fella's?

Using the 020 will make a whole ton of things a lot easier. No cable shifter (which was the easiest part actually to make work.. ;)), No hydro clutch, No 100mm axles (even though i have already clearanced the spindles to accept them), and most importantly! No purchasing of (ridiculous priced) or fabricating motor mounts. Fabrication is not my forte, I don't have any experience with a welder, and it sucks. :(

I would still like to keep the electronics however. This part is my forte :D. I am on the fence of how much to keep.. I don't really want to do the cluster, only because it looks like shat in the mk1 dash eh. What happens if I just don't plug the cluster in to the fuse-box? what will happen? I will use my stock ignition wiring to power up the fuse-box, and the stock wire that tells the starter to turn, so basically i just have to mount the mk3 fuse-box and make sure the pump and ECU get their power. Then hook up the drive by wire throttle and I'm set. Now I want to run mechanical gauges as I like them the best, but I don't think I can cut the ECU off from its readings or it will go BONKERS right? So for the oil and the temp how will I run it? Make a T fitting for the sensor on the side of the head? and then insert my coolant probe in one of the coolant tubes?

Other than that I can't see this swap giving me any more hassle than that.. I will run a straight pipe exhaust me thinks, to minimize ANY extra force the tiny k03 has to work against. As well as short IC piping, Can you say HOOD SCOOP!? A-woooga.

OH RIGHT, clutches. I will need to make the clutch a 210mm and not the 228mm that is on the AHU right now. I was wondering what I should use? I have a 210 FW, so I figure a 210mm clutch kit + FW bolts + push rod will give me all I need eh!? Already did the axle flange seals, and the push rod bearing/bushing. As well as the main shaft bushing. Great success.  ;D :D With faith my tired 700,000+km 81 FN will survive!

(http://img.eautopartscatalog.com/live/W01331600376SAC.JPG) $142
(http://img.eautopartscatalog.com/live/W01331733311FEB.JPG) $19
(http://img.eautopartscatalog.com/live/W01331641735FEB.JPG) x6 $12
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: burn_your_money on July 29, 2011, 12:54:50 am
Frugal [froo-guhl] –adjective -economical in use or expenditure; prudently saving or sparing; not wasteful
Thief  [theef]  –noun -a person who steals, especially secretly or without open force; one guilty of theft or larceny.

I think the latter best describes your actions. :P

A free flowing exhaust can actually do worse for the small turbo because it makes it easier for it to over-spool.

There are coolant pipes that have 2 or even 3(I think) ports for sensors so you should be able to find one that will work for what you need.

For oil I would run either a t fitting or delete the turbo so you can use the oil feed line port for a sensor :D
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on July 29, 2011, 09:40:27 am
As does Frugal, I want to use what i have at hand! Not spend money to have other things lol. but yeah, Thief too lol.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on July 29, 2011, 05:50:10 pm
Tyler, I dunno if I can take your word on turbo's ;)

Hmm, does anyone know the maximum turbine speed of a k03? And how much air must pass through it for it to spin said speed?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: catlin_cava on July 29, 2011, 09:30:28 pm
Quote from: catlin_cava on September 03, 2010, 08:02:45 am
JUST FOR YOU BUDDY   :-*

Jeremys how to (http://www.youtube.com/watch?v=oEjM5vOZC_s#)

<3 ;D
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: burn_your_money on July 29, 2011, 10:30:36 pm
Quote from: 8v-of-fury on July 29, 2011, 05:50:10 pm
Tyler, I dunno if I can take your word on turbo's ;)

Don't worry, it's 935racer's words, not mine.
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on July 30, 2011, 01:01:43 am
ok, well i was hoping i wasnt gonna have to fab the exhaust together.. :(
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on August 11, 2011, 08:22:17 pm
So here's an update, this thread should be called Jeremy can't make up his GD MIND!

I previously wanted to just boost the hell out of my 1.6 and IC it.. I mean it would be awesome, my bros td does well stock in an mk1... So my done up one should do wayy better.

Then I got thinking! Let's just build an m-tdi pump and slap the tdi in there easy peasy.. No wait let's leave it electronic and swap it all in. Which will still be easy. Biggest obstacle will be the mounting and function of the pentiometer for the drive by wire throttle device of the ECU on the tdi motors. I was thnking I'd mount it in the engine bay and use the stock throttle cable to activate it, instead of fabbing a pedal mount which will be hellish, as its mad tight up in there...

From there I will only have to run a couple small gauge wires back in to the fusebox for it. The rest of the electrics are sorted and basically just need installing in to the car ;)

I'll use the stock wiring for exciting the solenoid on the starter, so no need to worry about the clutch switch.. The fusebox will receive power from my stock ignition switch, to tell the ecu and pump to turn the hell on.. And I need to jump two pins on the back of the mk3 fusebox.. Peasyyy, I've had it running on the engine stand off a jerry can, and I could rev it up so everything seems to be working.. Cluster powered up and tach worked, so hopefully all wiL be welll!

What do you thnk?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: 8v-of-fury on August 12, 2011, 04:31:48 pm
What happens to the 1998 TDI ECU when it does not have the cluster plugged in to the fuse box? does it throw a code? or any sort of issues pertaining to the IP and ECU?
Title: Re: 1998 TDI/02A --> 1981 Jetta
Post by: R.O.R-2.0 on August 12, 2011, 06:13:55 pm
Quote from: 8v-of-fury on July 29, 2011, 05:50:10 pm
Tyler, I dunno if I can take your word on turbo's ;)

Hmm, does anyone know the maximum turbine speed of a k03? And how much air must pass through it for it to spin said speed?

i know my VNT is similarly sized to a K03, and its advertised that those little buggers hit 1/4 of a million RPMS..

i imagine the K03 to be right there with it..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on December 07, 2011, 04:02:20 pm
I am leaning towards using all the turbo bits from the tdi to make my na in to a TD motor. But using the k03 turbo, and intercooled. I have a td pump to use.. so it should make some pretty good power, from about idle to 4500.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on December 07, 2011, 11:29:52 pm
tease... LOL... waiting to see if you do this in your down time...
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on January 13, 2012, 05:31:42 pm
still on the down time, and starting to get in to it!

Working out the logistics of the clutch.

Want to use a 210mm disk, and I have heard one can use a 16v PP for more clamp.. why is that. obviously i still need the 8v disk to have the same splines as the trans.

URGENT!! If I order a 210mm 8v kit and a 16v pp separate will it all work together
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: theman53 on January 13, 2012, 07:42:27 pm
The only way to know for sure is 1 pin or 2 pin in the flywheel. That will determine which pressure plate to get. Yes it will all bolt up, and work perfectly as you are thinking it will. The pieces will work together is what I am saying. Just make sure which flywheel you have, as it makes a difference.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on January 13, 2012, 09:10:12 pm
Is it the alignment dowels you speak of Lucas when you say pins?

what is the difference between the 8v and 16v 210mm pressure plates??
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: theman53 on January 13, 2012, 09:21:42 pm
as far as I know there is no difference between the 8v and 16 PP other than maybe clamp force and the pins. I was told that the mexican pp are 2 pin and others are 1 pin... I was also told the MK3 are 1 pin and the rest are 2 pin. Just make sure that you know which pin you have and you will be fine. Also, the clutch must be the small spline IIRC it is 13/16" not 7/8" as the larger was the 16v spline. You will be fine. I have a clutchnet setup just like you are asking for, but not for sale.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on January 13, 2012, 09:26:12 pm
Yeah I need the clutch to be stock, so it will be the weak part of the power transfer.. so that if something needs to give, the clutch will slip.. as opposed to breaking something. I have done a search on the vortex, and it would seem the pressure plates albeit a different part number share every bit of the same pieces. They are completely identical.

That saves me some money then, I can just order a 210mm 8v clutch kit. Here is a good question, will the same 210mm flywheel fit in the 4 speeds? I know general rule of thumb is all 020's will fit the three sizes of 020 clutches.. but you never hear the 4 speeds mentioned. I am using the 4 speed because it is low mileage, and the best geared trans i have for this TDI. It will be able to handle the big jumps between the gears of the 4A 4 speed.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on January 13, 2012, 09:52:35 pm
what about pushrods? Are they 4 and 5 speed specific?
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on January 13, 2012, 10:34:59 pm
yes pushrod is different.. one shorter..

pressure plate... 190/200 is same... 210 different..

flywheel... 210 is 210... 190 is 190... 200 will fit both 200 and 190... the machined part the disk touches is different diameter so a 200 will not work in a 190... but a 190 wil work in a 200..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on January 13, 2012, 10:37:01 pm
I know the disks and all that, i was referring to will the 210 fw fit in the 4 speed 020's. lol. I will just be using a full on 210mm 8v clutch kit. No messing around lol. Shucks on the pushrod.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: R.O.R-2.0 on January 16, 2012, 02:25:45 pm
Quote from: theman53 on January 13, 2012, 09:21:42 pm
as far as I know there is no difference between the 8v and 16 PP other than maybe clamp force and the pins. I was told that the mexican pp are 2 pin and others are 1 pin... I was also told the MK3 are 1 pin and the rest are 2 pin. Just make sure that you know which pin you have and you will be fine. Also, the clutch must be the small spline IIRC it is 13/16" not 7/8" as the larger was the 16v spline. You will be fine. I have a clutchnet setup just like you are asking for, but not for sale.

if you have a mexi flywheel, it has 1 pin.. anything else has 2.

8v and 16v flywheels are the same.. the plate is the difference. the 16v plate has ALOT more clamping force.

i had a 210mm ABA clutch setup once, and i could slip it a tiny bit. thru the 16v plate in there, and no more slip..

in the near future, im going to be changing my clutch from a stock rabbit 200mm unit, to a 210mm mk2 clutch w/ 16v pressure plate..

my PP is off a used junk yard engine. it still had the original machining marks on it after i cleaned it up, so i dressed it with emery cloth, and used it.. worked perfect!

my 200mm unit is starting to slip on hard boost pulls and launches..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on January 18, 2012, 09:50:00 pm
New parts are here!

210mm clutch kit -$140

(http://img.eautopartscatalog.com/live/W01331600376SAC.JPG)

Cast impeller Bosch Waterpump -$25

(http://img.eautopartscatalog.com/live/W01331804182BOS.JPG)

Some trans seals -$10

(http://img.eautopartscatalog.com/live/W01331641999ELR.JPG)
(http://img.eautopartscatalog.com/live/W01331642355KAC.JPG)
(http://img.eautopartscatalog.com/live/W01331643177KAC.JPG)


Going back to the spin on filter -$8

(http://img.eautopartscatalog.com/live/W01331634096BOS.JPG)

New motor mount -$8

(http://img.eautopartscatalog.com/live/W01331636392FEB.JPG)

I've also started the tear down of the TDI pump. Everything is the same inside, except for the throttle which is an interesting setup. Anyway it looks like everything will swap over very easily in to my 1.6 pump with no issue. I should be able to get that all done up and everything the day i pull my motor.. Hmm better yet, I think I will pull the pump off my motor a few days prior to the scheduled motor pulling and get the pump all built up and back on the TDI and running pre-swap.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Powered by Spearco on January 22, 2012, 11:09:33 pm
Um, the motor mount looks a lot like the trans mount insert. Could be wrong though.

Also, FYI, if you didn't know, you can use the water pump gasket from a 2.0L gas water pump  that is metal with rubber. I use them every time instead of the paper one. Makes a better seal too.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on January 23, 2012, 12:42:13 am
Quote from: Powered by Spearco on January 22, 2012, 11:09:33 pm
Um, the motor mount looks a lot like the trans mount insert. Could be wrong though.

It is a trans mount.. lol (its one of the four of what I call motor mounts lol)

Also, FYI, if you didn't know, you can use the water pump gasket from a 2.0L gas water pump  that is metal with rubber. I use them every time instead of the paper one. Makes a better seal too.

Didn't know that, thank-you very much for the insight. Will be picking one up.

Thanks for looking.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on January 23, 2012, 01:25:04 am
fel-pro makes one ~$11... i also only use the metal/rubber one.. if i do not order one i pick up at zone... else it german brand.. but all honesty.. either works... ive taken apart both styles/brands on factory engines.. aka one golden with black ribbed rubber (german).. other silver with grey rubber (fel-pro).. not seen one fail.. and seen both as oe...
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 08, 2012, 08:03:43 pm
3.67 ACN BABY. Paid $60. Set up for mk1 use, However I am torn as to whether I will install the .71 5th gear i purchased?? or just remain with the .75 that is in the trans?? It will only drop the revs like 250 anyway right? I got the entire 5th gear from an FN for $30 :D For the trans I have a full clutch kit, pushrod, all the seals (mainshaft, pushrod, flange and axle), couple of throwout bearings for free ;), and I will be running synthetic trans fluid.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/100_1504.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/100_1502.jpg)

Now my question to you on this flywheel is.. Would Jesus Run It? However, if you are not biblical, would you run it? lol.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/100_1499.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/100_1498.jpg)

Still need to scribe TDC mark in to it, and remove the TDI's transmission and clutch assembly. Change out the water pump, and mount the VR6 water pump pulley. Then figure out what length belt I am going to need as I have deleted the A/C and power steering.

From then it is literally a matter of getting my car down to the shop, and tear the motor out so I can get the pump off of it and get to work building my m-tdi pump :)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: RadoTD on February 08, 2012, 08:15:04 pm
new RPM = old RPM * .71 / .75
3000*.71/.75=2840

And that flywheel looks good to me! Scuff it up with some 120grit if it's smooth and throw it in!
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: catlin_cava on February 08, 2012, 08:42:27 pm
is this not done yet? and it better be at

MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!!
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 08, 2012, 09:03:03 pm
So yeah only 160rpm drop.. not too too worth it I don't think. Scuffin I will do.

CATLIN, FRGI!
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: theman53 on February 08, 2012, 09:41:29 pm
Sell it to the guy going for the land speed record. How long have you been at this??? Still would have liked your wiring harness and such, oh well.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 08, 2012, 10:46:10 pm
I have had this motor since.. September 2010.. Lmao. I am sorry I had to sell those electronics, was getting screwed by the government, and needed cash. I sold it all for a fair penny.

Swapping a TDI in to your daily driving 84 is no simple feat. It didnt get done right away because originally I wanted to do the whole shebang.. and if it werent my daily.. I would have..

Woulda swapped the whole car over to CE2 and used the entire 98 wiring harness. Kept the 02A cable shifted and hydraulic clutched. Kept it fully electronic, used the mk3 cluster.. blah blah.

OH WELL! THIS IS STILL GONNA BE FRIGGING AWESOME. I see no reason why 110-115hp is not reachable with a fully turned up 1.6TD pump and the K03 giving its all at 18psi. :D
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 08, 2012, 11:08:13 pm
(http://i299.photobucket.com/albums/mm307/J_holubek/Random/LegendaryThread.jpg)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 16, 2012, 07:17:51 pm
So today I received my DGK-121 Bosch reseal kit from The One They Call Giles, he also threw in some of those pesky little E-clips on the governor shaft! After doing those pumps up that I resealed, 2 of the 3 received fully shimmed governor mods.. thus me loosing all the ones I had in reserve! lol

Tomorrow morning I will be getting the one piece rear main crank seal, throwing that back together with the new 210mm clutch kit :) New pushrod, throw out bearing, and all the tranny seals. YAY :D. Tomorrow when my brother is off work I hope to pull the pump off my engine and leave my car at the shop over night.. Bring the pump home and build the M-tdi pump out of it, and then slap it on the motor and get it timed and running prior to swapping it in to the car, which hopefully will be saturday!!
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 16, 2012, 08:41:36 pm
So here is a question for the masses :) Being that it will be an M-TDI, using all of the same pump internals Making this pump fully capable of whatever a TDI pump should be able to do yeah..

So injectors and turbo are in my future when I get the 02A tranny in there ;)! My question is what turbo would run well on the AHU with fuelling out its ass.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: RabbitJockey on February 17, 2012, 11:34:37 am
for a cheap easy to find turbo i vote for volvo 740 t3.  50 trim compressor and a .48 a/r exhaust housing.  so slightly bigger and newer than the mercedes t3 i know a few people have run and liked them on their tdi-m (such as hillfolk) and joe rabbit gtd guy also ran one i believe
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 18, 2012, 01:14:21 am
Good Luck to you 8V.
Hope its a great weekend and all goes well.

^5
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 18, 2012, 02:35:14 am
It is 2:20am, and I just completed the M-TDI pump. Holy Hell. She put up a fight this time, lol. However I was up before the ass-crack of dawn this morning.. so nearly 24 hours later, I guess I was just tired. Would you believe these were taken with my phone..

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-18020412.jpg)

Got some Purtty pump im working with :D. Very clean inside.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-17211334.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-17211318.jpg)

One will note the SUPERAWESOMEHEAVYDUTY springs that are found in the DI pumps (the ones in my hand ;));

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-17220106.jpg)

And my completely random assortment of three pumps worth of pieces!! Woowee! There is another full pizza box to the left of this shot, with even more pump parts on it.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-17211833.jpg)

And in case your up for a read :)

http://mebonty.monobasin.net/vepump.html


Got the motor and my car sitting in the shop waiting for the am to roll around, which is in about 4-5 hours! LOL better get some shuteye!
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 18, 2012, 07:04:40 pm
Well my brother and I spent 5 hours at the shop today. Got id say 80% of the work completed at this time. All that is left is bolting the down pipe to the turbo, putting the pump on and timing it. :)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on February 18, 2012, 11:29:20 pm
and making the shift linkage miss the turbo...
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 19, 2012, 12:28:52 am
Quote from: CRSMP5 on February 18, 2012, 11:29:20 pm
and making the shift linkage miss the turbo...

Covered. What do you think I am, an amateur.. lol
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: maxfax on February 19, 2012, 12:41:28 am
Quote from: 8v-of-fury on February 19, 2012, 12:28:52 am
Covered. What do you think I am, an amateur.. lol

I'm not going to say what I think you are...    :-X
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 19, 2012, 12:46:22 am
Apprentice Plumber.. lol

haha, Chris.. I not only modified where the shifter lever is in relation to the turbo, I also made it a short throw ;).
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 19, 2012, 06:02:54 pm
He's been brain-tanking this deal pretty hard and faithful for a while.
He won Rookie of the Year his first year in.
I bet he pulls it off - maybe not this weekend - but maybe so.

If this Inj Pump fires and runs this weekend - i'm way beyond Impressed.
If it fires runs drives and all is well - he deserves a medal of honor, badge of courage, event T-Shirt, front/rear TDi emblems, and a bumper sticker.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 19, 2012, 07:16:33 pm
oh yeh just in case you didn't lengthen the DownPipe a couple/few inches -
and it won't clear under the steering rack -

Mount it 180* upwards like a periscope on a sub
wanna hear this heap is running tonight !
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 19, 2012, 10:07:52 pm
I'm gonna be needing that medal of honor, badge of courage, event T-Shirt, front/rear TDi emblems, and a bumper stickers. :d

8 hours worth of work and its running and moving under its own power ;).

The only thing is I had to time it by ear as the tdi distribution head does not accept my timing gauge.. meh. I did lengthen the dp and it is only the downpipe. Started up just fine fire not having run I'm however long. Love no glow plus!!
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 19, 2012, 10:42:32 pm
Hot diggity damm way to go Man
I'm way the heck beyond Impressed.

How does the initial drive feel ?
60 HP - 70 HP range ?
- or do you think you're getting closer to the full 90 HP ?

Pretty dammd cool you made your own M-TDi Inj Pump ... and it works on the first trial. We should all be very proud of you and what you've been able to accomplish on this adventure. You went for the Gusto and grabbed it by the horns.

SALUTE


ps - i forgot those newfangled turbos have the wacky exhaust exit - and won't allow the periscope mount on the DownPipe. Good thing you didn't need to improvise on that.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: srgtlord on February 19, 2012, 10:53:50 pm
Hmmmm this M-TDI pump conversionsounds more plausable now :)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 410 on February 19, 2012, 11:39:03 pm
Good job man.  I knew you could get that pump working too.  I take it you didn't modify the governor lever?
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: R.O.R-2.0 on February 20, 2012, 05:19:22 pm
now that it runs, start looking for replacement 020 trannies.. that TDI will kill one in short order.. guarantee it.

maybe not.. idk.. we will see whos right by next year this time!
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 20, 2012, 07:46:12 pm
I do have plans to get the 02A in there, so no worries. I got four more 020's ;).

BVZ, the initial drive was probably about 20hp lmao. Pump still needs tweaking for sure and the turbo was not hooked up yet. The hose i was gonna use didn't work out for me. I am going to be running it sans inter-cooler for the initial part of my swap, to ease with headaches for the time being. So it was a naturally aspirated 1.9 DI still pushing a turbine for restriction, bummer on power! lol Thank-you for the SALUTE my friend, it has been one hell of an awesome adventure.

410, Without your help buddy it wouldn't have been thinkable. You answered about a trillion of my questions with your superb knowledge of these pumps. I owe you a cold Kokanee good sir.

k3vo, Naw man, be cool. There been plenty run the 020 behind high torque motors, in heavier cars. I dont drop clutches, or do burnouts :).
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 20, 2012, 10:37:55 pm
Still real happy and xited for you - looking forward to more updates on further progress with the tune.

Between my good friend just buying a nice 98 AHU Jetta, and what you've done on your M. swap - i'm becoming a little more interested in TDI than before.

My brain rattled a flashback of a 96-98 Passat TDI i ran across this past summer at a guy's house my mother bought a travel trailer from. Chatted briefly about it due to it being VW Diesel - but i don't like big pig Passats - and had no desire for electronic TDI stuff.
Or $1000-2000 M.TDI inj pumps.

It either wasn't running or not running right iirc - didn't push for any details and made no offer or effort at all.
Didn't even open a door or pop the hood. LoL

I might go back and check into it.

You changed directions a lot.
There is obviously a lot of info and dialogue missing here.
Do you have links to other threads on other sites you exercised along the way about the ins and outs ?

I've got some questions too ....  ;)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 20, 2012, 10:49:49 pm
Question #1 -- open to all comers in the know.

You said your dial gauge adapter wouldn't fit the TDI pump head.

Can a faktry stock AHU TDI (98 Jetta) Inj Pump be fine tuned/timed with a dial indicator - just needing a different adapter than what we use on IDI ?

As in - set/verify Injection Timing mechanically - versus VagCom.

(and any specs on thread size needed for TDI hole)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on February 21, 2012, 01:07:35 am
the rover pump resolves 1-2k pumps for tdi-m... 2-300ish.. almost direct fit and such..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 21, 2012, 01:10:40 am
Quote from: Baron VonZeppelin on February 20, 2012, 10:37:55 pm
You changed directions a lot.
There is obviously a lot of info and dialogue missing here.
Do you have links to other threads on other sites you exercised along the way about the ins and outs ?

I've got some questions too ....  ;)

Question #1 -- open to all comers in the know.

You said your dial gauge adapter wouldn't fit the TDI pump head.

Can a faktry stock AHU TDI (98 Jetta) Inj Pump be fine tuned/timed with a dial indicator - just needing a different adapter than what we use on IDI ?

As in - set/verify Injection Timing mechanically - versus VagCom.

(and any specs on thread size needed for TDI hole)


Yes, I did change directions a whole bunch of times.. Which I am horribly sorry for. BUT it was needed to fully wrap ones head around how EVERY SINGLE PIECE was to work. lol.

These are some other threads I had with other sites, sadly they too are fragments of my progress.. with many jumps to different directions. :( When I get it all buttoned up perhaps I will edit this one, and link the other two to it.

http://forums.vwvortex.com/showthread.php?4976461-Mk1-TDI-O2A-swap

http://forums.tdiclub.com/showthread.php?t=321991

http://forums.tdiclub.com/showthread.php?t=310270&page=2

Yes the dial gauge adapter that screws in to the small plug in between the four injection lines on the pump is too small, the thread in the  10mm DI head is larger, but appears to be the same thread.. probably the next size up?

Yes the AHU pump CAN be tuned in the exact fashion as we do on our IDI.. But I see no reason to, as the computer can change all the timing values at any given time by itself. All the parts are there for the gauge to physically follow the plunger in its movement. However upon thinking about it, it almost seems to me that the AHU pumps may be set initially by dial gauge.. and then fine tuned with VagCom, else why would they have the ability to put a gauge in the end of them right?

Now I realize I did change directions WAY TOO MUCH. However where I ended up is fairly simple :). I used a 1.6 pump, a 1.6 transmission and 210mm clutch setup, a vr6 water pump pulley, and a mk1 gas passenger side motor mount so I could retain the AHU pump mount. The front, rear, and driver side mounts are all stock mk1 pieces, gas or diesel.

I have what I believe to be the easiest way to swap a 1.9 1Z/AHU TDI engine in to an mk1 or mk2. Mk2 being even easier, because you could use the mk3 mounts that came on the motor then. So even less work to do.

CRSMP5, I do believe that will be my next endeavor :) After I get everything else buttoned up and tidy, I'll be looking in to one for sure. Perhaps if you have literature as to what you have done to yours, ie. build thread or what have you, you could link it in here for future reading?
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 21, 2012, 01:52:50 am
No doubt about it 8V
You definitely formed the easiest cheapest quickest simplest mechanicalist 1Z/AHU Mk1 Mk2 swap imaginable. ^5

I understood while reading why most of the direction changes were happening. But right at the end you booted from piggybacking CE2 box and using electronics - to converting a 1.6TD pump into a M.TDI

i missed that part of the story and the specifics that brought that into the picture - lol

Guess that was a last hour revelation.
And what brought it together to go forth at this time.
Also the part i'm most interested about ....  ;)

And the Rover pump too. As a side bar prospect.

I'd want to do the same thing you did if i did it on Mk1 or Mk2.
Fully mechanical completely simplistic and reuse as much existing as possible.
Even sans I/C to begin with were my thoughts too.

Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 21, 2012, 02:20:58 am
Quote from: 8v-of-fury on February 21, 2012, 01:10:40 am

Yes the AHU pump CAN be tuned in the exact fashion as we do on our IDI.. But I see no reason to, as the computer can change all the timing values at any given time by itself. All the parts are there for the gauge to physically follow the plunger in its movement. However upon thinking about it, it almost seems to me that the AHU pumps may be set initially by dial gauge.. and then fine tuned with VagCom, else why would they have the ability to put a gauge in the end of them right?



I'm going to do the timing belt, bring all maintenance to fresh start, and some misc... on my friends new 98 TDI. Starting on it either Tuesday or Wednesday. I don't have VagCom or know anyone locally who does.

Would like to know (or feel like i know) that the initial timing is back spot on after the belt job - via dial indicator - if that were an option. Your postings make me think that it is. I am about as anal on things as my tools will allow - if they can take me there - i'll go.

This will be my first TDI to work on.
Have not even taken the engine cover off yet to eyeball anything.

Later on i could travel to another town where there are some known VagCom'ers. Want to do the EGR reduction trick via VagCom at minimum anyhow.

Just guessing .... the initial injection spec is around same as TD ???
Any input from anyone ??

I'll test it first thing right off before i touch the belt - and see where it stands - if i can source an adapter for my adapter. Its probably going to be a lil low as is due to age/stretch of belt - as a guess.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on February 21, 2012, 02:28:46 am
never tried dial indicator on a tdi.. i use vag-com

i gave you link a few pages back.. its like fitting a alh pump on a ahu.. then a gov mod, some throttle cable mounts/manipulations and making up the rear mount.. my inital pump timing is 118... and has no advance cable.. it is really easy... now since i could not score the ALH pully/hub set up i had the AHU pully modded like a gasser adjustable cam gear.. $100 machine shop simplicity.. which eliminated shimming the pump and such.. i actually think ill get another pully modded for my 1.6td never have to turn the pump again..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 21, 2012, 04:23:21 pm
Quote from: CRSMP5 on February 21, 2012, 01:07:35 am
the rover pump resolves 1-2k pumps for tdi-m... 2-300ish.. almost direct fit and such..

Bear in mind that it is an apples to oranges comparison.  Most $1000+ mTDI pumps are either rebuilt or brand new.  A rover pump @ $200-300 will most likely be a used pump of relatively unknown condition.  If you consider the cost of rebuilding/dialing in a rover pump plus the initial $2-300, it will cost more than the $1000 one.

I am currently building and selling Brand New Bosch full aneroid mTDI pumps for $1000 with all the bells and whistles.  12mm plunger, 20mm shaft, proper advance, governed to 5,000 rpms, installed, tested and tuned.  Definitely considerably more torque/hp than stock e-TDI.  If someone is a serious potential purchaser, then PM.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 21, 2012, 07:35:58 pm
Libby that sounds unbeatable, for SURE.
Thanks for the info on that.

:::::::::::::::::::::::::::::::::::

8V, i couldn't source anything locally to adapt from 8mm to 10mm today.
But here is the needed item - will do 8 - 10 - 12 .
Looks like about $20 to the door.
My adapter isn't the most civilized anyway - i'll be going for one, soon.

Seems like all M.Tdi users and abusers would need to do dial gauge timing.
Could you find out the spec for 1Z/AHU from tdiclub.com ?
I'm not a member yet

http://www.ebay.com/itm/VW-Bosch-VE-Fuel-Injection-Pump-Adapter-Timing-Tool-/400211393244?pt=Motors_Automotive_Tools&vxp=mtr&hash=item5d2e753adc

and

http://www.ebay.com/itm/VW-Audi-Diesel-Bosch-VE-Fuel-Injection-Pump-Timing-Tool-/260960128660?pt=Motors_Automotive_Tools&vxp=mtr&hash=item3cc26f8e94
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: maxfax on February 21, 2012, 07:51:08 pm
Ya know, I think Burnyourmoney had a thread about tuning TDI pumps with a dial indicator some time ago (years I think).. I don't exactly remember all the content, nor could I find it in a search..  

Edit:

Okay it wasn't Tyler, but here is the thread I was thinking of: http://www.vwdiesel.net/forum/index.php?topic=22004.0 (http://www.vwdiesel.net/forum/index.php?topic=22004.0)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 21, 2012, 08:16:37 pm
Many many thanks for looking that up Max. :beer:

But damm that sounds awful awful low
0.70mm +/- .05

Maybe an affluent TDI'er could brief us on that spec - and why its low

The "make-your-own" 8mm-10mm adapter from an old temp sender is something i might try. Would like to get a reading from this car before i pull the TBelt tomorrow.

Next issue is the pre-set tensioner was overset by last technician.
Wondering if the computer will be able to re-compensate enough on its own when i put the new belt and new tensioner with correct setting.

I'm guessing they didn't know about the pre-set marks alignment on the tensioner ..... ? I'll post a pic after while.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 21, 2012, 08:21:47 pm
Quote from: Baron VonZeppelin on February 21, 2012, 07:35:58 pm
Seems like all M.Tdi users and abusers would need to do dial gauge timing.
Could you find out the spec for 1Z/AHU from tdiclub.com ?

You can sorta find out a plunger lift setting from an eTDI but you must bear in mind that the computer adjusts the timing on the fly.  Any baseline dial indicator reading off an eTDI will just tell you that the timing is within the range of what the computer can adjust (provided it's not tossing a code).  Best way IMO to find a proper spec is to use a dyno repeatedly and find where the setting where power peaks.  One could probably do a decent job of it using a smart phone and dyno app.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 410 on February 21, 2012, 09:14:04 pm
I found I had to set my mtdi 1.2mm to 1.4mm to get it to run right.  I had originally set it to .9mm and I could barely get it started and would smoke like crazy when running.  I did most of my adjusting by feel and how it sounded.  The bigger the pump head and the bigger the injectors the more sensitive it got to timing.  Just the slightest change would make all the difference.

.7mm would be a good spec for an e-tdi but not enough static advance for a mtdi.

On another note, the end caps on the pump head are interchangeable so you can swap a cap from a 9mm pump head to your tdi head and check your timing.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 21, 2012, 10:12:07 pm
Quote from: libbydiesel on February 21, 2012, 04:23:21 pm
If someone is a serious potential purchaser, then PM.

We will be in touch my good sir. :D

Quote from: Baron VonZeppelin on February 21, 2012, 08:16:37 pm
Next issue is the pre-set tensioner was overset by last technician.
Wondering if the computer will be able to re-compensate enough on its own when i put the new belt and new tensioner with correct setting.

I'm guessing they didn't know about the pre-set marks alignment on the tensioner ..... ? I'll post a pic after while.

Wuh-oh, what is this you speak of? Nearly two years of research and I missed something!? Blasphemy. Do tell, I have it in and running so maybe i lucked out and got it correct???

Quote from: libbydiesel on February 21, 2012, 08:21:47 pm
Best way IMO to find a proper spec is to use a dyno repeatedly and find where the setting where power peaks.  One could probably do a decent job of it using a smart phone and dyno app.

Why you so smart! This sounds like a good idea, and probably better than any set digit anyhow. Would you just use an acceleration app that tells you 0-60 times? or something along those lines?

Quote from: 410 on February 21, 2012, 09:14:04 pm
I found I had to set my mtdi 1.2mm to 1.4mm to get it to run right.  I had originally set it to .9mm and I could barely get it started and would smoke like crazy when running.  I did most of my adjusting by feel and how it sounded.  The bigger the pump head and the bigger the injectors the more sensitive it got to timing.  Just the slightest change would make all the difference.

.7mm would be a good spec for an e-tdi but not enough static advance for a mtdi.

On another note, the end caps on the pump head are interchangeable so you can swap a cap from a 9mm pump head to your tdi head and check your timing.

Well she starts up and runs great even around 0c with no glow whatsoever.. So I must be somewhat close to a good setting. I don't hear any of the old diesel clatter that I did with the IDI either.. The end cap information would have been useful a couple days ago 410.. LOL! If and when I ever have the pump back off, or I build another, I'll remember this for the future :).

Pre M-TDI;

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-17200258.jpg)

Post M-TDI;

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-18020412-1.jpg)

Only picture I have from the actual swap.. there is a reason I got it done in 6 hours ok people! lol. I didn't frig around. ;D

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-18150428.jpg)

Pretty much 96% finished in this next shot. Just to tidy the wiring up that was a mess from before anyway, add the manual boost controller, and get a boost gauge and SHES GOLDEN! Air filter will be getting a thin aluminum surround fabricated, to allow it to draw its air from down under the washer bottle. and not get road gunk from the belt on it.

ps. You know you love the ABS piping inter-cooler delete ;) It works ok, and it cost me like $4.. This is an extreme budget build.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-21163707.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-21164124.jpg)

400 Liters of free fuel and I got the drums for free too. Paid $100 total with shipping for this air powered drum pump, something like 20 Liters per minute? it flows real quick through the nearly 1" outlet. This is my introduction to WMO ;).

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-16122507.jpg)

Video of it purring away :) Love the turbo at idle ;).

http://www.youtube.com/watch?v=OeLP_OaT2gA&context=C39a8f52ADOEgsToPDskKOZzD-Gyz5hOZJZJrP3ZuS
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 21, 2012, 10:19:02 pm
Really appreciate you guys and your knowledge sharing - so much.

Excellent tip on exchanging the end caps !
But as soon after i made last post - i went and made an adapter from an old Mk1 coolant sensor like Vince's suggestion in the thread that Max linked.

I'ma be full-on-the-ready in the morning.

Will update tomorrow night on what the existing E.TDI spec comes out to be.
Will spec it before pulling belt - just for the knowing and factoid.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 410 on February 21, 2012, 10:37:04 pm
Watch out with your abs piping.  The air is so hot coming out of the turbo that it can melt the abs.  You might get away with it for the winter but come summer time the inside might start melting and possibly get ingested by the engine.  I've seen it first hand.  I assume it's only a temp thing until you get an intercooler figured out.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 21, 2012, 10:46:14 pm
It is temporary for sure, and I will not be boosting the crap out of it until I get an inter cooler anyway.. so I feel I will be ok for now. The stock IC pipes were ABS from factory and they held up for 430k on this engine.

I think I have read somewhere ABS is fairly heat resistant, up to quite a temperature.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 21, 2012, 11:17:26 pm
8V , i wasn't letting your question blow by about the tensioner.
I needed to D/L some pix to tinypic to post first.
I've got turtlecharged internet and it takes me a while to do anything.

First pic is borrowed from tdiclub A3 timing belt tutorial.
These tensioners are way more deluxe than our A1 A2 stuff.
Have a pre-set tension spec built into them - you line up the notch with the groove. Hold it steady and tighten.

(http://i42.tinypic.com/2vshteh.jpg)

On this car (phone camera) - it appears last guy not only overtightened it - he pegged it to the limit. sob
Belt appears to be low mileage (maybe 15-20k tops)
Hopefully not much or too much wear placed on bushings.
Will know more tomorrow.

{ EdiT } [i should have rotated this pic before posting it. it needs to be turned about 90* to the left to be closer to actual appearance in parameters] 

(http://i41.tinypic.com/24vs6zc.jpg)


I'll test existing setting tension as it is.
Then test it reset proper.
Then test it after new belt/tensioner/roller.
Just for more factoids.
A1 A2 is 12-13 units


Make you one of these adapters.
Its almost like its in the design for it to be converted into an adapter.
Even inside the bottom its concaved to a point like a ready-made center punching for the drill bit. I stepped up bits about 6 times from 2mm to 6.5mm then ran a tap through it.
The interior body requires no drilling/boring.

(http://i43.tinypic.com/33wm9sw.jpg)

(http://i43.tinypic.com/91c38p.jpg)

(http://i43.tinypic.com/152z3x1.jpg)

(http://i44.tinypic.com/2zozo1j.jpg)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 21, 2012, 11:27:56 pm
Hmm, I did not know there was a spec on the A3 tensioners. I definitely did not torque it down like mad, I did the whole 1/4 turn on the belt like I have always for the 1.6's. And then the added roller above the pump adds a little bit more tension.. So I think I lucked out ;).
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 21, 2012, 11:54:04 pm
8v, that ABS will melt at stock boost pressure.  I have seen it firsthand.  The stock pipes are not the type ABS you get in the plumbing section at home depot.

There are a bunch of various apps I've seen for measuring hp/torque.  Google is your friend on that.

I use a snap-on diesel pulse adapter and set the pumps to 12-14° btdc at idle.  That method sets the start of injection accurately while taking into consideration injector break pressure and pump wear, etc... and is faster and easier than the dial indicator.  I haven't measured the plunger lift on a stock AHU camplate or with the stock 10mm plunger.  I have measured the TDC plunger lift for that setting with the 12mm plunger and cummins camplate and it works out to 1.40-1.50mm.

Also, you need to remove the cold start lever from the pump or it will disassemble itself all on its own.  The sharper DI vibrations will cause the circlip to fall off and it will fall apart at the most inopportune time.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 21, 2012, 11:57:36 pm
BVZ did you check that tensioner with the cam sprocket loose on the cam? 

Regardless, belt tension won't affect timing of cam or pump provided they were set correctly with the tension/slack loaded the direction of being driven by the crank.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 21, 2012, 11:58:11 pm
Quote from: libbydiesel on February 21, 2012, 11:54:04 pm
8v, that ABS will melt at stock boost pressure.  I have seen it firsthand.  The stock pipes are not the type ABS you get in the plumbing section at home depot.

Well its a good thing I didn't spend to much on it then eh.. :(

What shall I do to resolve this problem? How come the rubber couplings do not melt?

Well now that I have it completely set out in the ABS, I guess I can pop it off and have a metal one made up EH!? I have  successfully made myself a jig :) Always a positive.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 22, 2012, 12:18:24 am
Quote from: libbydiesel on February 21, 2012, 11:57:36 pm
BVZ did you check that tensioner with the cam sprocket loose on the cam? 

Nope.
Everything is still untouched as found -

I made it up to point of where crank pulley and lower timing cover are next things to come off. And stopped for the night - in hopes of more data/facts about initial timing spec.

Got lucky with some spec info, and tip on making an 8X10 adapter.

I just want the factoids and be able to compare/verify actual findings with them. Baselines etc ..

Libby or anyone, do you know if they specify a belt tension spec in units for A3 TDI - Like they do for A1/A2 1.6 ?
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on February 22, 2012, 02:05:39 am
i agree sir libby.. can only take the landy pump as a "core" as you have no idea if it works or not.. its a gamble.. but vs sending 2 pumps off to others for 1000$+ to make you one... you can sell the 2 you have... and if required at that point will cost less..  :o

but i am glad to hear your 1k option.. as well that is a viable option.. and we need them...

what i want to see is one of you pump guys cracking open a landy pump.. and see why out of the box they produce lots of hp.. vs rumor 90 or less hp from the franken pumps..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 22, 2012, 08:29:02 am
BVZ, the spec is to tension the tensioner with the cam sprocket able to turn.  This tensions the belt all the way from crank through cam through injection pump (which can also turn) and back to the other side of the crank.  When the cam sprocket is snugged up it changes the alignment of the tensioner.  The alignment of your tensioner looks correct.  Regardless, the amount of tension on the belt won't change the timing of a running engine which has the crank driving the pump and cam and all the slack (or lack) in the tensioner area anyway, provided the cam and pump timing were set only turning the crank clockwise and keeping the belt loaded in the same way it is when the engine is running.  I'm not aware of a tension spec given in units.

CRSMP5, to be clear, at this point I don't require any other pumps to be sacrificed.  I haven't pulled apart the rover pump but certainly have ideas as to why they would produce more power than franken pumps.  That said, the pumps I have available are not a limiting factor with power and have the ability to produce well above stock power.  The limiting factors would be the amount of air you could cram in, the amount of fuel the injectors could flow, the amount of power the clutch cand trans could handle and the actual power that the engine can handle without self-destructing.  The pump would not be the limiting factor.   ;)

8v, the ABS probably won't self-destruct dramatically but rather gradually deform and your clamps will keep getting loose and the ends pop off.  Get the right stuff - silicone couplers and aluminum tubing and install the intercooler.  Bead the connections.  It's worth the $150 in parts to avoid the issues.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 22, 2012, 12:46:33 pm
Quote from: libbydiesel on February 22, 2012, 08:29:02 am
8v, the ABS probably won't self-destruct dramatically but rather gradually deform and your clamps will keep getting loose and the ends pop off.  Get the right stuff - silicone couplers and aluminum tubing and install the intercooler.  Bead the connections.  It's worth the $150 in parts to avoid the issues.

Yes, I agree. Thank-you for the advice :). It is merely a get it running and driving right now solution. After all it is my daily driver that I have done this too.

My next issue on the chopping block is the serpentine belt.. I added the water pump to the serpentine belt with aid of a vr6 pulley. However to do so, I had to grind down a lip on the crank pulley a few thou, and use some washers to space the pulley out so the belt would track correctly. I used a short belt for my mock up with the engine on the ground, and life was good. But now that I have it running I feel the belt is too short and putting too much strain on the alternators bushings.

however running too much longer of a belt is going to make the tensioner bring the belt down and touch the top of the water pump pulley. I think I am using roughly 41" belt right now..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 23, 2012, 08:41:07 am
8V, don't ignore the bit I said about removing the cold start advance piston cover.  It will leave you stranded.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 23, 2012, 11:25:02 am
Quote from: libbydiesel on February 23, 2012, 08:41:07 am
8V, don't ignore the bit I said about removing the cold start advance piston cover.  It will leave you stranded.

Can I replace that back cover with the front cover off of another pump :) ?
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 23, 2012, 12:31:34 pm
Yes, but better, IMO, is the flat steel plate from the AHU or similar engines.  Every time the engine returns to idle, the advance piston hits that plate.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 23, 2012, 12:34:36 pm
Perfect I should still have one on my ahu pump.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 25, 2012, 02:19:35 am
As things went along - i gained more knowledge and some factoids about these 1.9 TDI 1Z / AHU. Just to share in case it helps anyone.

The tensioner marks that i thought meant it was way over-tightened, actually were just the opposite. It was WAY too loose. During some pre-emptive testing - the Inj Pump jumped 3 cogs on the belt - when i was cheating by turning engine some with Inj Pump bolt.

I've used the cheat many times before - but never jumped the belt.
So thats when the pre-emptive tests stopped and i got more involved with the tensioner / belt specs. lol

To refresh - this is where the existing tensioner was set.
(http://i41.tinypic.com/24vs6zc.jpg)


This is where the tensioner should set initially - with cam sprocket loose.
(http://i40.tinypic.com/4fzfh0.jpg)


This is where it moves to, after cam bolt is torqued.
(http://i44.tinypic.com/2e6dn3o.jpg)


This where it settles to, after about 20 revolutions.
(http://i40.tinypic.com/2gsrga9.jpg)


And this is the tension spec - after about 20 revolutions - with the idler/roller removed from belt path. Practically a perfect 13 units.
For reference - 1.6 spec is 12-13 units.
(http://i39.tinypic.com/33w8kzo.jpg)


Luckily for this 116k pristine low miler , this condition was caught.
New Belt, Tensioner, and Roller for a fresh new start.
And an intermediate shaft seal too.


8V have you checked your tensioner setting yet ??


Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 26, 2012, 08:26:17 pm
Swear to god, I have magic fingers. (it is what she said) This was the first attempt from when I did the swap.. took the picture tonight. With out knowing at all, I had the belt tension dead on. ;)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-26180009.jpg)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on February 26, 2012, 09:56:05 pm
mmmmmm gasser motor mount... i HOPE you put a shim behind the front 2 bolt holes... the step in the mount is for the alt/ac bracket... and no shim it will BREAK those bolts/block..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 26, 2012, 10:00:56 pm
Yessir, it allowed me to use the AHU pump mount for my IP.

No sir I did not use shims, It had no shims on my original mk1 gas motor.. why do I need them now?

Fwiw, that step in the mount was stock to ALL gas mk1 mounts AC or not. No shims were on my mount when I removed it from the stock gas motor.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on February 27, 2012, 12:12:25 am
ac or alt bracket is behind that to be a shim... trust me on this... you need to do something.. it will vibrate and BREAK the mount, bolts or block.. you need to fill that gap...
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 12:37:01 am
Quote from: CRSMP5 on February 27, 2012, 12:12:25 am
ac or alt bracket is behind that to be a shim... trust me on this... you need to do something.. it will vibrate and BREAK the mount, bolts or block.. you need to fill that gap...

You know, you might be on to something here. ;D Would it hurt to write in proper sentences? lol Whenever I read your posts, I think of somebody who has just run a couple of blocks and is out of breathe. Then they try and tell their story, and it has pauses after every three or four words. lol
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on February 27, 2012, 03:49:38 am
makes it hard to read when all the words are too close together...

ive seen what happens when the ac unit on a mk1 gassers start to pop bolt heads.. why i asked on the shim... :D it needs/requires something there to prevent the mount from flexing.. gotta be solid.. else that bolt head will pop off and fall into the timming belt..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 11:14:18 am
Quote from: CRSMP5 on February 27, 2012, 03:49:38 am
makes it hard to read when all the words are too close together...

but it flooowwwsss lol

ive seen what happens when the ac unit on a mk1 gassers start to pop bolt heads.. why i asked on the shim... :D it needs/requires something there to prevent the mount from flexing.. gotta be solid.. else that bolt head will pop off and fall into the timming belt..

Sir, yes sir. I will look in to this today, as I will have the belt and pump off anyhow :).
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: Baron VonZeppelin on February 27, 2012, 04:13:14 pm
You were damm close on the tensioner setting.
I'd have been happy to find it like that - if not knowing beforehand.
Probably within the 12 unit zone.

Since you're having it loose again - this time go for full spec.
Marker should move south of the notch a little bit, after cam bolt torque.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 04:25:42 pm
Will do. :)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 05:48:15 pm
Andrew, I just realized with my pump on the bench that removing the cold start advance mechanism will affect how much idle adjustment there is with the little spring inside of the pump.. I will have to crack the lid of again and remove that little spring won't  i..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 07:25:00 pm
Ok so the front cover from the 1.6 pumps will work, as it is flat for the advance piston.

Also for using the tdi advance spring, cover..I must also use the tdi advance piston??
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 27, 2012, 07:49:18 pm
Leave the inner spring and the upper idle lever.  Get rid of the lower cold start lever assembly.  One of the 1.6 front covers will work as a back cover, but longer term I'd be concerned about wear on the cover from the piston hitting it repeatedly.  You can't use the AHU back cover because it is held on with four bolts/holes and your pump only has two.  The Cummins pumps have a nice 1/4" thick steel plate.  Source or make one of those and you're in business.

Did you jump another spline w/ the accel lever yet?
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 07:54:47 pm
The front cover should work without a doubt. It its still flat for the advance piston to slam against.

And what of the advance piston?? Is the tdi spring of lesser spring rate??
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 08:46:03 pm
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-27183839.jpg)

Check out my old 1.6 spring, half blue half green.. what the heck. What are the advantages of running the TDI spring, piston and cover? Is there more advance to be had with this setup?
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 410 on February 27, 2012, 09:46:20 pm
Yes there is more advance with the tdi spring and cover.  The advance curve is also different.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 09:50:10 pm
Quote from: 410 on February 27, 2012, 09:46:20 pm
Yes there is more advance with the tdi spring and cover.  The advance curve is also different.

While I have the pump off the car I might as well go ahead and swap in the TDI piston, spring and cover :). Got a line on a couple of cheap pumps. One is an AAZ pump. M-tdi v2.0 will commence soon ;).
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: CRSMP5 on February 27, 2012, 10:19:17 pm
if you need a scrap tdi pump.. i gots one.. all i know on it is it did not make fuel.. i did steal the injector line valves though.. no idea what shipping to canada is.. but id donate to ya for shipping costs if you interested..
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 27, 2012, 10:22:04 pm
Quote from: CRSMP5 on February 27, 2012, 10:19:17 pm
if you need a scrap tdi pump.. i gots one.. all i know on it is it did not make fuel.. i did steal the injector line valves though.. no idea what shipping to canada is.. but id donate to ya for shipping costs if you interested..

PM'd buddy :).
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 28, 2012, 06:40:54 pm
1.6 front plate on in place of the timing advance mechanism.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-28131008.jpg)

The AHU TDI front plate, advance piston and spring. :)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-28130940.jpg)

2 hours from that point everything was back together and running smooth. I had an issue with a leaking delivery valve that for some reason worked itself loose? Thought I got it tight enough when I had the pump off yesterday, but it still leaked when I got it back on. So instead of taking the pump back off and re timing, I frigged around for a half an hour trying to tighten that one delivery valve.. lmao. oh man hah.

Here is a quick question, can the 1.6 or 1.9 IDI delivery valves be used on the TDI head for DI operation? or are the valves DI and IDI specific?
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 410 on February 28, 2012, 07:09:26 pm
The 1.9 idi valves are roughly the same length as the tdi ones so the hard lines fit okay but the 1.6 delivery valves are too short.  There is a difference between idi and tdi valves but jimfoo used the idi ones on his tdi with no issues. 

I suggest you use the tdi specific ones since you have them.  I read in my Bosch manual that they are different but I lent it to my buddy so I can't reference it right now.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: libbydiesel on February 28, 2012, 07:50:16 pm
The shorter 1.6 valves are what fit the AHU lines (or at least they fit mine...).  The TDI delivery valves are different.  They have an added check valve in them.  I've personally used both 1.6 delivery valves and AHU delivery valves and have not been able to discern a difference in performance.

8V - did you jump another accel lever spline yet?   :)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: chopper03 on February 28, 2012, 08:53:51 pm
Quote from: 410 on February 28, 2012, 07:09:26 pm


  I read in my Bosch manual

410, which bosch manual do you have and where can one be bought ?
                                                                         chopper
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 410 on February 28, 2012, 09:58:50 pm
Hey chopper, I couldn't find it on the Bentley site but I did find it on amazon.  It's been a really good reference. 
http://www.amazon.com/Diesel-Engine-Management-Robert-Bosch-GmbH/dp/0470026898
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: whoabeats on February 28, 2012, 11:25:24 pm
I have that book in my truck right now. It is a must for any diesel head that wants to know as much as they can. I'll see if I can look up the info on idi vs di dv's tomorrow.
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: 8v-of-fury on February 28, 2012, 11:55:46 pm
Quote from: 410 on February 28, 2012, 07:09:26 pm
I suggest you use the tdi specific ones since you have them. 

The only reason I ask is because I have a few 1.6 distributor heads left over from two parts pumps.. and if the DV's will work I'll keep them around.

Quote from: libbydiesel on February 28, 2012, 07:50:16 pm
The shorter 1.6 valves are what fit the AHU lines (or at least they fit mine...).  The TDI delivery valves are different.  They have an added check valve in them.  I've personally used both 1.6 delivery valves and AHU delivery valves and have not been able to discern a difference in performance.

Ty Ty

8V - did you jump another accel lever spline yet?   :)

Not yet my good sir, my improvised exhaust is giving me some hassle.. so until I get that worked out (hopefully Saturday) the exhaust is pointing right at my firewall where my fuel lines run across.. So I can't be making too much exhaust heat just yet lol.

Thank-you for the advice on the advance mechanism, that woulda blown chunks to have come apart on the road somewhere..

I can already tell the splines will be the ticket.. just by removing the cold start advance and the fast idle being set all the way down allowed me to crank the fuel screw in another turn. A good chunk of power came from just doing that. I am still at this point further out than stock fuel screw settings. Fully shimmed GOVERNOR :)
Title: Re: 1984 Jetta , TDI WE MUST!
Post by: whoabeats on February 28, 2012, 11:59:26 pm
I'd definitely keep them around and look into grinding a couple sets, for possible increased performance. Its an excellent mod used all the time on inline pumps.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 29, 2012, 12:20:21 am
Quote from: whoabeats on February 28, 2012, 11:59:26 pm
I'd definitely keep them around and look into grinding a couple sets, for possible increased performance. Its an excellent mod used all the time on inline pumps.

oh? Please, do explain my friend :).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 05, 2012, 12:57:04 am
(http://i.ebayimg.com/00/s/NzY4WDc2OA==/$(KGrHqZ,!lgE8iN8VervBPU(P40LG!~~60_12.JPG)

I am looking at getting this kit for my inter cooler piping.. Is this the normal standard for inter cooler piping? Any configuration should be achievable with the bends provided in this kit?

More than likely will be doing a front mount, I will have to possibly find a way to move my radiator backwards and towards the passenger side a bit to get some room on the driver side for the pip to pass through.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: Baron VonZeppelin on March 05, 2012, 02:08:33 am
What about the extra fueling exercise on this dealio ?
Where's the approx HP level at now ?

60-70-80-90-118 ?

Anything good going on yet ?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 05, 2012, 02:11:20 am
Nothing at all happening. Gotta get my down pipe sorted. NO welder is making it hard.. I have been driving it for short trips around town. But the exhaust points straight at the firewall, and fills the cabin with exhaust. So I cannot be giving it too much pedal anyway.

However, after removing the cold start mechanism all together and putting the flat plat there it allowed me to back the idle down even further.. and thus turn the fuel screw in some more. I am still out a few turns from stock on the fuel screw, so there is PLENTY of fuel left in this pump. Once I get the exhaust sorted, I'll start laying down some power.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on March 05, 2012, 07:32:23 am
I spoke with many and they said for the air needed in our engines, especailly if you have a smaller turbo for dialy driving, the piping should be no more than 2". Other than that info that I can't tell what size it is, the kit looks fine.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on March 05, 2012, 09:10:55 am
being that the intake hole is 2"... pipeing 3" into a 2" hole  is stupid.. so i stuck with 2" on my toaster... no issues at all..

you need to invest in a welder... a cheap mig with fluxcore wire will do lots for you.. may not be best.. but better then nothing...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 05, 2012, 09:55:56 am
It is a 2.5" kit.. but if 2" will do its alot cheaper :)

Yes I know.. a welder is my next investment!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on March 05, 2012, 10:30:15 am
Aki-76 said 2" for daily. 2.25" for drag race.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 05, 2012, 11:02:22 am
GAH, I thought the 2" kits existed on Ebay.. but in reality the smallest good kit I can find is 2.5"
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on March 05, 2012, 11:35:29 am
Maybe this (http://www.ebay.com/itm/CXRacing-2-DIY-INTERCOOLER-PIPING-KIT-MANDREL-BENT-PIPE-SILICON-/380376077054?pt=Motors_Car_Truck_Parts_Accessories&hash=item58902e52fe&vxp=mtr) along with a vice grip beading tool like this:

(http://i13.photobucket.com/albums/a269/libbybapa/100_1446.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 05, 2012, 11:37:49 am
Ah, that is nice. Is this what you would use? I like that it has a variety of pieces, seems it would make life easier.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on March 05, 2012, 11:39:14 am
Link is fixed.  The kit I linked is a little different.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 05, 2012, 11:41:09 am
I like that one.

Funds are tight at the moment, so Ill have to wait a week or two to get that kit. And a welder maybe the next week.. LOL. They need to bring that full on kit back to Canadian tire.. so I can use my master card and make payments for 12 months no interest.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on March 05, 2012, 12:06:29 pm
The kit libby linked to is the exact piping I bought and have 0 issues with...other than a car that isn't moving right now. I did get the huge intercooler they sell as well. Want to say it was 28x7x2.5. The ID of the 2.5" inlet is 2" so all worked well except I asked them to put 2  90 degree 2" to 2.5" silicone couplers in it so it would all work. The only other thing I had to get was from silicone intakes and that was an adaptor to go into the intake. I highly recommend silicone intakes stuff.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 05, 2012, 12:50:18 pm
Actually the stock stuff had 2" silicone adapters to the intake and turbo exit, so I will not need a silicone coupler there.

Silicone intakes, I looked at there stuff.. Very nice stuff. Little out of my price range though.. :(
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: rallydiesel on March 05, 2012, 01:13:46 pm
Did you modify the internal throttle lever? Just wondering as you mentioned you didn't have a welder. Good job on the swap!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 05, 2012, 03:54:41 pm
Quote from: rallydiesel on March 05, 2012, 01:13:46 pm
Did you modify the internal throttle lever? Just wondering as you mentioned you didn't have a welder. Good job on the swap!

I actually have a great pump man working on it for me, as I don't have welder. 410, a member on here in Alberta. He also sent me one of his boost pins to try out. Hand ground goodness :)

(http://i1128.photobucket.com/albums/m488/410-photos/Picture318.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 07, 2012, 03:33:39 pm
Does anyone know if the 4 prong coolant sensor in the front coolant neck (upper rad hose) of the 98 TDI will work the same as the older style 2 prong? ie. One lead to coolant gauge, and the other is grounded?

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 07, 2012, 06:35:23 pm
ALSO,

Quote from: libbydiesel
There are a couple limiting factors to some of the 1.6TD bits. The accelerator lever part that attaches to the governor spring capsule has a short offset and limits the total pull of the accelerator lever. Also, the fulcrum of the control collar lever assembly is closer to the collar, again limiting the max fuel. Anyway, those parts being what they are there are still things you can do. First step would be to jumper the accelerator lever to shaft orientation one spline so that the shaft goes clockwise and the lever goes anti-clockwise. Then readjust the max fuel and idle screws. That should give you a better idle setting and allow you to seriously increase the max fuel. Jumping another spline relaxes the idle spring and allows it to be adjusted again. There is way more fueling adjustment in the max fuel screw than in the idle screw. When you run out of idle, jump a spline for more adjustment, then adjust the max fuel for more fuel. Give it a try. It works. If it doesn't do what you want you can always put it back.

I tried doing this today after I put 410's fuel screw in. And it would seem that doing it the way Andrew stated seems to reduce power, yet I turned the max fuel screw in more.. ? It makes no sense. So I went another spline, and pushing the accelerator would bring the idle down... What the hell is going on in there? So I attempted going back the other way a spline from where I had it originally.. it shot the idle WAY UP, and I had already bottomed the idle screw out. So the only thing to do from there would be to back the max fuel screw out.

Hmm, I need some brainstorming on this one guys. lol Can't quite wrap the ol' noodle around it.  
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on March 07, 2012, 08:03:20 pm
I suggest pulling the top of the pump off and removing the idle spring that goes to the lever on the side of the pump.  This will reduce tension on the throttle lever and allow you to turn the fuel screw up more while retaining your idle.  You can also shim the governor a little but that requires removing the pump from the engine.

The coolant sensor from the mk2 and three will pop right in to the coolant flange on the ahu.
 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 07, 2012, 08:15:41 pm
Ahh yes, shimming the governor. I have heard this referenced in my travels. Care to explain a little further if you posses the knowledge? Thanks man.

It looked as though the coolant sensors would swap over.. I may try that. I only did not want too, lose coolant as it is in a tricky spot. Bottom side of that neck. Genius place.. lol Why not on top?!

Don't suppose you have any knowledge on the rest of the AHU electricals?? I left that big plug on the engine for now, and it is still hooked up to the sensors, glow plugs, and what not. Does anyone know which of those pins are the two glow plug pins?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on March 07, 2012, 08:35:14 pm
Quote from: 8v-of-fury on March 07, 2012, 08:15:41 pm
Ahh yes, shimming the governor. I have heard this referenced in my travels. Care to explain a little further if you posses the knowledge? Thanks man.

It looked as though the coolant sensors would swap over.. I may try that. I only did not want too, lose coolant as it is in a tricky spot. Bottom side of that neck. Genius place.. lol Why not on top?!

Don't suppose you have any knowledge on the rest of the AHU electricals?? I left that big plug on the engine for now, and it is still hooked up to the sensors, glow plugs, and what not. Does anyone know which of those pins are the two glow plug pins?
I wouldn't worry about shimming the governor until you get your modified throttle lever.  
If you change the coolant sensor when the engine is cold you lose very little coolant.  I would also eliminate the engine plug all together.  Once you remove it you'll see where everything goes.  

Do you remember if you still have that idle spring in your pump?  You can also back off the one set screw on that side lever which will back off your idle a little but it's worth it to pop the top off and remove it.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 07, 2012, 08:42:21 pm
Yes the small spring between the upper cold start lever and the throttle lever inside the pump is still in there. Side lever is right backed out, no more adjustment there. I will be removing the pump lid tomorrow. I will also give the engine harness a look see. I don't know why I didn't remove it when i had the engine out and on the ground.. IDIOT.

Will hold off on the governor, until the throttle then. But be prepared. I will pick your brain when that time comes lol.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on March 07, 2012, 08:52:59 pm
Couldn't you keep the plug just in case? You could stick a wire on the Glow plugs and then to the big plug and test for continuity? I am just thinking if someday you wanted to go to E TDI then it would be plug and play right?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 07, 2012, 08:57:18 pm
Lucas, that was my plan. just a dirty female connector on the plug spade. lol I haven't needed the gp's yet.. -25c the other day.. fired up without to much trouble..

I think I am pretty much as far away from a plug and play swap as I was when I had the 1.6 in the car. LOL! I have gotten rid of all the electronics, and everything associated with them. I mean I guess I could keep the engine harness around..?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on March 07, 2012, 09:02:30 pm
Just thinking, if it is as easy to put it in as it is to pull it out then ... Well do what you need to do, just me thinking. I would leave it be if possible and do a quick test. If not yank it.

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on March 07, 2012, 09:06:23 pm
Quote from: 8v-of-fury on March 07, 2012, 06:35:23 pm
ALSO, I tried doing this today after I put 410's fuel screw in. And it would seem that doing it the way Andrew stated seems to reduce power, yet I turned the max fuel screw in more.. ? It makes no sense.

Each time you jumper a spline to get more idle adjustment you need to screw the max fuel in a lot to compensate.  If you don't screw the max fuel in a bunch, then it will indeed reduce power.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 07, 2012, 09:32:57 pm
Quote from: libbydiesel on March 07, 2012, 09:06:23 pm
Quote from: 8v-of-fury on March 07, 2012, 06:35:23 pm
ALSO, I tried doing this today after I put 410's fuel screw in. And it would seem that doing it the way Andrew stated seems to reduce power, yet I turned the max fuel screw in more.. ? It makes no sense.

Each time you jumper a spline to get more idle adjustment you need to screw the max fuel in a lot to compensate.  If you don't screw the max fuel in a bunch, then it will indeed reduce power.

Increasing the max fuel screw more brought the idle up, and doing another spline made it so pushing the accelerator would  bring the idle down. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on March 07, 2012, 09:42:03 pm
maybe you lever isn't working right? Maybe to get it where it needs to be it is putting it back to the spot where it is going backwards? Just guesses
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 07, 2012, 09:45:46 pm
Hmm, It is possible. I don't see how though. I had used my old throttle lever (external) and it had marks scribed in it from when I indexed it properly from removing my n/a pump lid.

However thinking back.. I am pretty sure I did what Libby said WAY back about moving the throttle lever over one spline to get more max fuel screw.. HMM
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 22, 2012, 01:44:09 am
LAdies and probably just gentleman, I need info on shimming the governor assembly.

I have the pump (1.9 aaz) tore down and ready for assembly, so I figured I could do the shimmed governor while I am in there. Not the shimming of the springed governor cage, I already know all about that. ;).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 22, 2012, 09:28:11 am
If no one else chimes in I'll get back to you tonight after work about shimming the governor assembly.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: carrizog60 on April 22, 2012, 11:50:58 am
if you remove the side spring that ataches to the lid how do you control the idle?alteast my pump doesent have any more springs to do that on the governor assembly...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: carrizog60 on April 22, 2012, 12:09:25 pm
me and allesslowbudget took a couple of pics and thoughts regarding advance mecanism,if you like go check at the IDI section
http://www.vwdiesel.net/forum/index.php?topic=30518.0

dont know if it serves for TDI but i guess that the same theory is valid on both aplications
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: R.O.R-2.0 on April 22, 2012, 05:49:04 pm
Quote from: 8v-of-fury on April 22, 2012, 01:44:09 am
LAdies and probably just gentleman, I need info on shimming the governor assembly.

I have the pump (1.9 aaz) tore down and ready for assembly, so I figured I could do the shimmed governor while I am in there. Not the shimming of the springed governor cage, I already know all about that. ;).

the author of "HOW TO PROPERLY MOD YOUR GOVERNOR" needs advice on shimming his governor? wtf?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 22, 2012, 07:38:14 pm
So here is the debut of M-TDI v2.0, it is an early 1.9AAZ body (17mm shaft), AHU rollers, cam plate, timing advance piston and spring, distributor, distributor head, and a 1.6TD lid with a custom hand ground boost pin. Oh its also painted PimpSchliten GOLDMEMBER. :D

oooh yeah baby. Came out WAY better than expected.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-21003103.jpg)(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-21133918.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-21152602.jpg)

Here is the modified internal throttle lever, you can see the bottom "pin" has been moved out and the fulcrum point has been modified as well. The whole assembly will know sit higher in the pump, and the fulcrum point and longer pin will allow more travel of the collar on the distributor. As well as the grinding necessary to the case for the new lever to fit properly, because it sits higher up.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-22150658.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-22150804.jpg)

As can be seen by this side by side comparison there was quite a bit of material taken off of the modified 1.9 pump body, but nothing to crazy.. Just a simple round sander bit in my die grinder and about 2 minutes of my time.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-22165420.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-22165412.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-22165229.jpg)

Side by side comparison:

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-22165525.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-22165608.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 22, 2012, 08:10:55 pm
I hope you didn't grind too much.  The head seal uses that pump surface but I'm not sure exactly where it sits.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 22, 2012, 09:08:47 pm
Quote from: 410 on April 22, 2012, 08:10:55 pm
I hope you didn't grind too much.  The head seal uses that pump surface but I'm not sure exactly where it sits.

Hmm, good point! Oh well, I guess we'll see eh? Governor shimming?? :)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 22, 2012, 09:43:55 pm
Looking at the pictures again I think you'll be fine for the head o-ring.  You can see where the o-ring sits.  

You'll want to shim the governor out about 1mm.  It's pretty easy to remove the governor assembly but you have to keep in mind that the shaft has another and very important function.  It also advances the timing under high load conditions.  It does this by covering a bleed port on the governor shaft which increases internal pressure.  So adjusting the position of the shaft [which is the adjustment on the front of the pump], you change when the timing advances compared to the amount of fuel being delivered.

So long story short, measure the amount of threads sticking out from the lock nut on the front of the pump.  Take it all apart, add your 1mm shim and reassemble.  Then turn the shaft in 1mm from your initial measurement and you now have a good starting point.  

To make adjusting this shaft easier down the road, drill a hole in the pump mounting bracket so you can make adjustments with the pump in the car.  The only way to adjust it accurately [without a flow bench] is with a gauge that reads internal pump pressure.  You can actually see a jump in pressure when the bleed port gets covered under high load conditions.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: carrizog60 on April 23, 2012, 05:37:50 pm
Quote from: R.O.R-2.0 on April 22, 2012, 05:49:04 pm
Quote from: 8v-of-fury on April 22, 2012, 01:44:09 am
LAdies and probably just gentleman, I need info on shimming the governor assembly.

I have the pump (1.9 aaz) tore down and ready for assembly, so I figured I could do the shimmed governor while I am in there. Not the shimming of the springed governor cage, I already know all about that. ;).

the author of "HOW TO PROPERLY MOD YOUR GOVERNOR" needs advice on shimming his governor? wtf?

hes asking about the governor flyweights assembly,not the springs i guess.

why shimm the flyweights assemby?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 23, 2012, 07:36:40 pm
You need to sim the flyweight assembly because the point of contact has moved toward the back of the pump.  The contact point moves about 1mm because of the modifications to the lever.  Most times when you change something in these pumps it affects something else.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: carrizog60 on April 24, 2012, 08:03:29 am
makes sense.
would this lever mod only be a must do on M-tdi or IDI can also benefit from this?
and what about removing the side spring(the bigger or smaller or both?) that goes on the lid?how would the idle be controled?

i had a 1.6 pump that had the spring on the governor spring assembly to control idle,but the 1.9 i have doesent have this spring...


sorry to some sort of highjacking lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 24, 2012, 12:14:58 pm
Quote from: carrizog60 on April 24, 2012, 08:03:29 am
makes sense.
would this lever mod only be a must do on M-tdi or IDI can also benefit from this?
and what about removing the side spring(the bigger or smaller or both?) that goes on the lid?how would the idle be controled?

i had a 1.6 pump that had the spring on the governor spring assembly to control idle,but the 1.9 i have doesent have this spring...


sorry to some sort of highjacking lol

i do not think there is much to be gained if any on an idi. The idi's stock can fuel more than the injectors and engine can handle. At least i am pretty sure. more than enough fuel for an idi.. but not enough for a tdi.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 24, 2012, 12:16:49 pm
Also removing the top lid spring will make it act just as it always did. as that is how the early pumps did it. the one without the idle bump on the cold start lever.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 24, 2012, 01:46:21 pm
Quote from: 8v-of-fury on April 24, 2012, 12:16:49 pm
Also removing the top lid spring will make it act just as it always did. as that is how the early pumps did it. the one without the idle bump on the cold start lever.
This only works when there is an idle spring on the governor.  I always use 1.6 tops so this is never an issue.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: carrizog60 on April 24, 2012, 01:58:49 pm
i dont have the 1.6 spring,so i assume that the one that goes to the top is controlling idle,right?

as for fuel demands in IDI vs TDI:is there such a diference?i mean,there are IDI´s running more than 240hp so the fuel demand is big,way bigger than a tdi with same power(tdi more efficient so will need less fuel)

i am not planning a 300hp IDI lol but i would like to fuel it properly on the entire rpm range and reach above 150/160hp so my fuel demand already is high ::)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 24, 2012, 07:46:08 pm
Here we have a 1.9AAZ governor assembly and a 1.6NA governor assembly, Notice the 1/8" different lengths?? The cages are identical in size, but the actual shaft differs.. why is this? Weird, thought I would point it it out that they are not the same. I will be using the 1.6 one with the 1.6 lid and all.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-24181435.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: carrizog60 on April 25, 2012, 02:21:40 pm
N/A shorter ???
maybe because N/A dont have the LDA shafts?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 25, 2012, 09:52:32 pm
Quote from: carrizog60 on April 25, 2012, 02:21:40 pm
N/A shorter ???
maybe because N/A dont have the LDA shafts?

No, the longer of the two on the left is the 1.6 N/A governor..! lol. I did end up using the shorter one.

Alright to the minds out there, I got the pump all back together and ready to install yesterday after work.

From this!!
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-23161110.jpg)

To This!!
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-24213329.jpg)

Today after work I got it installed and timed up (not to any actual setting as I do not have a dial adapter that will fit, yet.). I put it roughly at the middle point of the settings for moving the pump and left the bolts just snug so I could still move the pump around once I got it primed and running. My electric pump primed the system no problem so that I only had to crank may be 5 times and it was running, from a bone dry system.

So after I get it all together, I attempt a start. It catches but races away with a HUGE, THICK cloud of smoke. I mean, tractor pull thick.. the kind to block out allll sunlight. So I shut it down with the key, I had the clutch ready to be dumped and the brake pedal stomped though ;). So I figure to my self, hmm I must have the idle set to high and the max fuel in too far as I just set them in the ballpark for initial stat up and then tune once running. So I back them both off, and advance the timing a good amount as it was smoking ALOT. The advance helped with the huge cloud of smoke, to a degree.. but the engine still catches and races away. I cannot tell how many rpm's because of my completely open exhaust, and tiny k03.. all you hear is turbo even at idle :D. I even tried indexing the throttle arm to throttle shaft a few spots back to release tension on the governor if there was any, didn't seem there was as it didn't change anything.

So what exactly is happening in there?? Do you figure the shorter governor shaft is messing with stuff? It couldn't possibly be making it that bad.

I have one idea as to what it could be.. Could the newly modified throttle arm be sticking the fuel collar in the more fuel position??
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 25, 2012, 11:35:03 pm
Try backing the max fuel screw waaaay out.  Like to the point where it is just starting to push on the lever and try again.  If then you can't get it to start, slowly turn the fuel screw in until it idles.  If you find you have poor control with the throttle lever at this point there is something binding on the inside  See next paragraph.  If you have good throttle response then the fuel screw was turned in too far but you're now at a starting point for adjustments.

I assemble the top of the pump without the lever springs and install the lever.  You should be able to feel when the  governor springs get compressed as you get close to the full throttle stop.  If you feel any binding the lever assembly is rubbing something in the top of the pump.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on April 26, 2012, 09:03:25 am
What about that other part that you have to access from the gear side of the pump? The nut that isn't painted gold on your pump right behind the gear. I thought that helped control the gov. some?

8v...I think you maybe a bit north for the stars and bars. I lol'ed when I saw that as I have people that have said the same to me and I am in Ohio.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 26, 2012, 08:25:51 pm
Quote from: 410 on April 25, 2012, 11:35:03 pm
Try backing the max fuel screw waaaay out.  

I had it backed considerably out.. but not like crazy out or anything.. DAMNIT. Wish i read this before I pulled the pump lol ;). I seem to recall on assembly that it may have felt weird, but didn't have another to reference.. I have another stock pump tore down so I will reference its throttle movement and see how the m-tdi is.

Quote from: theman53 on April 26, 2012, 09:03:25 am
What about that other part that you have to access from the gear side of the pump? The nut that isn't painted gold on your pump right behind the gear. I thought that helped control the gov. some?

8v...I think you maybe a bit north for the stars and bars. I lol'ed when I saw that as I have people that have said the same to me and I am in Ohio.

Yes the governor shaft, it never changed. The shaft and locking nut were indexed the same as before removal.

Stars and Bars, never heard them call that. I think of this ;) http://www.youtube.com/watch?v=Pqaf2wP7hQE&skipcontrinter=1 (http://www.youtube.com/watch?v=Pqaf2wP7hQE&skipcontrinter=1) That decal is on the bottom of my beer fridge lol!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 26, 2012, 09:08:06 pm
The adjustment at the front of the pump is not related to fueling.  It only affects timing under load.  Which might seem strange that it adjusts the shaft that supports the governor.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on April 26, 2012, 09:11:55 pm
odd
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 26, 2012, 11:31:40 pm
Quote from: 410 on April 26, 2012, 09:08:06 pm
The adjustment at the front of the pump is not related to fueling.  It only affects timing under load.  Which might seem strange that it moves the shaft that supports the governor.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on April 27, 2012, 12:47:45 am
410  Can you elaborate on how turning the shaft in or out changes the timing under load?  I thought it controlled the top RPM as it allows the governor to extend to the point where it pushes back on the fueling collar mechanism.  Or do I have that wrong? 

Can I adjust the hex head of that bolt to make timing changes come earlier or later than I would normally expect them.  Like twisting the IP does? 

Very interesting if that is the case.  So please explain this function for us if you will?

thanks.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on April 27, 2012, 02:03:14 am
The shaft is hollow and leads to the timing piston.  The little piece that fits over the governor shaft (the part that rides against the control collar and indexes with the four flyweights) has a little bleed hole that is covered/uncovered depending on the position of that piece.  Because the position of that piece is dependent on accelerator position/load, it allows load dependent timing advance.  The position of the shaft determines when the bleed hole is covered/uncovered. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: carrizog60 on April 27, 2012, 03:24:05 am
its all about pressure.
open hole=less pressure=less advance.

or do i see it wrong?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on April 27, 2012, 01:03:37 pm
Libby, If I have an early 82 or late 81 IP does it have that hole?  I really don't remember it when I took my pump apart about a year or more ago. 

Being that it is just under the cover I suppose I could get to it with less trouble than more but won't do that if there isn't one in the first place.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: R.O.R-2.0 on April 27, 2012, 01:30:30 pm
Quote from: ORCoaster on April 27, 2012, 01:03:37 pm
Libby, If I have an early 82 or late 81 IP does it have that hole?  I really don't remember it when I took my pump apart about a year or more ago. 

Being that it is just under the cover I suppose I could get to it with less trouble than more but won't do that if there isn't one in the first place.

EVERY BOSCH VE pump has that feature.. no matter the age..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on April 27, 2012, 03:41:28 pm
Nope, most of the 1.6 pumps don't, but I've seen a few that did.  The telltale sign is if there is a ball bearing blocking a hole drilled into the surface just above the governor nut, right behind the timing pointer).  If the ball bearing is not present and there isn't a fitting there like on the AAZ pumps, then it does not have load dependent timing advance and the position of the governor shaft is not critical.  
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on April 27, 2012, 03:47:03 pm
Awesome,  I can look and not even touch and determine this one.  I do have a 1.6 NA engine and the car build date was August of 81.  So it has some but not all the features of an 82.  Another couple of months and I bet I would have had the upshift light and W terminal combo.  I can see the arrow on the dash but there is no bulb or socket behind it. 

That is the answer I needed.  And my memory is as good as I remember it.  quote that. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 29, 2012, 08:42:51 pm
Alright so Thursday I took the pump back off the engine and tore it back down to make sure I had not done something wrong inside in terms of clearancing for the modified lever. I only had time on Thursday to dismantle the pump and verify with another open stock pump that I had in fact clearanced everything correctly, and it was moving freely inside.

I was then away all weekend, so tonight I got the pump together, back on the car and running within the hour. From there I messed with the fuel screw and idle screw. I had the fuel screw backed all the way out so that it was just pushing on the arm of the internal throttle. I also had the idle screw backed all the way out, so that the external throttle was just resting on it. I got the car running and idling, but it did seem that the idle was completely erratic and seemingly uncontrollable.

The idle almost seems to hang like it does to people after they have done the governor mod. I had the external throttle lever indexed so that it would be the same every time, but using that mark i could not get low enough on the idle. Even having both the throttle stop screw and fuel screw backed all the way out. So I moved the throttle one spline over to release tension on the governor cage. Now I have a lower idle but it is uncontrollable. It is either idling like 13-1400 or it idles so low when i put the clutch in that it stalls.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on April 29, 2012, 10:28:23 pm
Quote from: 8v-of-fury on April 24, 2012, 07:46:08 pm
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-04-24181435.jpg)

You've done enough swapping that I can't keep track.  What spring setup did you use?  The assembly on the left doesn't have an idle spring installed on it.

As far as your idle symptoms, it sounds like your idle spring is too weak.  When it is too high, the idle spring is at the collapsed and you are engaging the main/intermediate spring part of the capsule.  I have seen that before on a used Cummins pump.  I pulled the spring and stretched it out a bit, reinstalled it and voila, idle was @ 850 with room for adjustment.   ;D 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 29, 2012, 10:33:40 pm
Lol, Andrew sorry man. Yes I agree I can't even keep track of my own shizz.

I used the setup on the right. It is an AAZ governor cage with the idle screw added, inside a 1.6 throttle shaft. So I did not have to wrestle the e-clip back off the solid governor one. It is a stock 1.6 idle spring on my governor assembly. Interesting, so you think the spring being too weak is a good candidate for the symptoms eh? Hmm, it ran the pump just fine before the modified internal throttle though??
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on April 29, 2012, 10:55:24 pm
The following is just conjecture on my part.  You changed the lever assembly and altered the fulcrum significantly.  That will change all the spring ratios.  The governor assembly will now be pushing closer to the fulcrum on the assembly and so any motion of the governor will have an increased impact on fueling and could account for the idle spring now being out of range. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 13, 2012, 06:57:17 pm
So as it would seem the stock wastegate was really holding back.. Today i got the pump back together for the 6th or 7th time! Various issues with the modified lever binding up and not acting the way we wanted.. I had a sputtering issue that prompted thevlast tear shown of the pump, and as it would turn out there was some snarff that was in the high pressure pickup.. but it was not the reason of the sputter. It would seem theorizing was retarded and thus causing too low pressure at higher rpm, making a sputter.

i also dissconnected the waste gate to see if the boost was holding back the power to 10Psi or so.. it totally was! Not even pushing the peddle now causes the boost lines to blow off!!!! so gauges and my manual boost controller are next!!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 19, 2012, 11:07:45 pm
10mm distributor head timing gauge adapter :) A drilled out and tapped oil pressure sensor.

(http://i299.photobucket.com/albums/mm307/J_holubek/Diesel/2012-05-19164547.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 21, 2012, 10:07:08 pm
So with that gauge adapter in my last post I finally remembered I made it today and went to check my timing for ***s and giggles. Its running great, but i figured why not since when I initially set it back in March/April it was by ear.

As it would turn out.. the pump was timed to, are you ready for it?? 0.083" or 2.108mm! JESUS. How was it even running? and so well!?

I have since re-timed the pump down to a more conservative 0.050-0.053", and I must say.. I am down on power and there almost seems to be a miss.. Interesting it ran so well with the timing that jacked up.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on July 21, 2012, 10:31:10 pm
i have my disco set to 118... so try that.. others w discos say 135ish..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 21, 2012, 10:45:57 pm
I set it somewhere between 1.30 and 1.35. It was missing a bit, smoking and down on power. So i loosened the pump, started it up and tapped it advanced a bit more. So I am sure I am at 1.40-1.45 easily.

Weird eh?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 21, 2012, 11:14:40 pm
I mean I had it at 2.10mm!!! and it ran great.. but then i got to reading about how the cylinder pressures at this point would be ridiculous.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on July 22, 2012, 12:51:34 am
I have found that they run best with start of injection at 12-13° BTDC.  Because I have a diesel pulse adapter, setting any pump to that regardless of custom internals is very easy.  Without a pulse adapter, with a non-stock pump, IMO, the best you can do is time it by ear or dyno app on a smart phone.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 22, 2012, 10:15:53 am
So with the pulse adapter, it simply measures cylinder #1's injection pulse through the injection lines? Nice. I assume the DI stuff would still be clacky with too much advance, am I wrong to assume this? FRom the 2.10mm setting it started, idled and ran through the rpms just fine.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 25, 2012, 11:15:07 pm
SO with it timed somewhere between 1.30 and 1.35mm I have more white smoke than I have ever seen before out of one of these things. Only when starting for the first time of the day, or sitting for 8-10 hours at work. Plumes and plumes of white smoke. Any throttle and it misses like a mofo and produces WAY MORE SMOKE. What the hell? timed ridiculously retarded at 1.35mm?

So I loosened the pump off and started it up, I then advanced it quite a bit. Probably was around half of the adjustment in the bracket at 1.35mm, now it is near 3/4 or more. Sounds a bit better, the engine was already operating temperature so I don't know how it will react cold yet.

I also installed my dawes valve with it set to somewhere around 15psi (trying to get it to pop with my air compressor was more than difficult without the right size tip.. lol The turbo screams a lot more, and there may even be some more power. However I am having no black smoke whatsoever.. What does that mean boys and girls?! We need more fuel! :) Injectors are on order as I type. Veg Injection .216's ;) Which are actually like a .238? Awesome!

I also have a T3 here on the shelf that will either get a rebuild.. or just be bolted on. I am looking at FMIC kits, and also looking to get an 11mm or more likely a 12mm Veg Injection pump head for my M-TDI v2.1 build :) :) With this I could then theoretically run butt tons of boost, and fuel from like 2300-3800 (probably 4000 max for the 12mm head).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: golftd412000 on July 26, 2012, 02:27:19 am
i send you an mp...

your 11m is good for 245ch and 500/525nm with other big nozzle and good pulverisation

in a m-tdi pump the most important is a good dynamic timing pump not fuel.
you can win +25hp with a good dynamic timing with no more fuel.


Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 26, 2012, 06:07:16 pm
Ahh yes, sorry I never replied! I have a 10mm bosch head right now. I have the veg injection nozzles coming.. and I am sorry but I cannot understand most of your PM at all :( lol!

Dynamic timing. How do we make it top notch?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: golftd412000 on July 27, 2012, 06:20:40 am
i replied of you'r pm.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 29, 2012, 03:03:31 pm
TDI is down for the count... again.

On my trek home today after a party last night I made it just coming in to my town on the highway when the car started bucking whilst I was decelerating in 5th gear. I thought maybe it was starting to take off and runaway as I was having some oiling issues as of late you may have read about. So I kept it in gear and got ready for the ride.. it never came though. It was not a runaway but just a bucking like one would experience while running out of fuel almost. I shut it down and coasted down the huge hill i was on in to town! Awesome luck that was lol. But then it would not restart once I had stopped and checked everything over. I have a clear line before and after my filter with an electric pump in line, so I can see that I have fuel moving in to the pump.

I am thinking of going back to the car with a jug of diesel and taking the stop solenoid out to completely rule out the fuel system and a bad stop solenoid. There is nothing else I can think of then a fuel related issue. If that doesn't fix it I guess I'll be popping the pump off and bringing it home to tear down yet again..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on July 29, 2012, 03:32:03 pm
I'd also make sure it hasn't jumped time.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 29, 2012, 03:34:51 pm
Pump time or belt time? Good idea, might as well check that before I rip in to it. Any other things you can think of that would cause what happened?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on July 29, 2012, 09:19:16 pm
Does sound more like a timing, belt problem than fuel issue.  Had that happen on my recent head rebuild.  Must not have had the tensioner down tight and when the valves touched the piston on startup I think it jumped a notch.  When I shut it down and turned it by hand I started picking up on a click just before TDC on #1 cyl.  Knew something was amiss as it wasn't like that when I checked it prior to hitting the started.  Found two valves were out of spec by about 10mm, open to much.  New shims of the proper width fixed it. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 29, 2012, 11:28:36 pm
Well, I found what was wrong. It was fueling related ;) and it was not pumping any fuel at all.. because of this; :( T'was a custom piece.. now I'm kinda screwed.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120729_212338.jpg)

Also check out the scoring on my cam plate, the rollers are perfectly fine all the way around however. There is also a significant chunk out of the outer most edge of each of the four cam lobes. There was no metal pieces to be had inside of the pump upon dissemblance, so I do not know if the lobes were like that before or not.. I am pretty sure the whole surface was not scarred though.. I mean I am still going to run it lol but w.e. 

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120729_212605.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on July 30, 2012, 01:16:05 am
That cam plate is exactly how mine looked when Giles sent it back. I would see if you can get it cryo treated. I know a lady that does, but she is in Ohio. Good luck on getting it going again.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on July 30, 2012, 10:47:34 pm
yepper, you screwed now buddy.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 30, 2012, 10:49:59 pm
So I found out what was causing the scarring on my cam plate, and I got the lever welded back together today :) The cam plate was rubbing ever so lightly on the governor assembly! It would seem I shimmed the governor about 1/32" too much. So the scarring is from metal shavings.. lol whoops.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120730_112346.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120730_132013.jpg)

So I took 1/32" of shim off of the governor, and also removed 1 shim from the advance piston while I was in there to try and get some quicker dynamic advance. J.F (410) and I speculated that the fracture was due to the fact I was running a fully shimmed governor assembly and I had the max throttle screw backed out to literally full internal throttle movement. Thus over stressing the internal throttle lever causing it to break. I am now running a completely stock 1.6 governor spring assembly.. with a slightly stretched out idle spring (furthest right) for a bit more idle control.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120730_134637.jpg)

I am now running a completely stock 1.6 governor spring assembly.. I now have absolutely no power at all :(. I get an ok off idle power, i dont have a tach but anything over 1500-ish feels non existent.. Pump setting never changed a bit as I have them all indexed for quick removal and installation. It is completely gutless.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 03, 2012, 07:40:53 pm
So I finally made myself a pressure gauge and threaded out bolt to test the pressures inside of my pumps :)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120801_233505.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120801_232052.jpg)

However it is a wee bit low, WAY LOW on pressure inside of the pump. This video shows my pump idling on pure 2 stroke motor oil and no electric pusher pump at 10-12psi. I had 17-19psi on diesel with my electric pusher pump. Tapped the regulator WAY in and had absolutely no pressure change at all. I am not running the front AAZ solenoid so I do not know where the pressure is bleeding off to? or if it is just simply really worn in the vane pump?

http://www.youtube.com/watch?v=_wzm_VIJxUA
Title: M-TDI v3.0 :)
Post by: 8v-of-fury on August 04, 2012, 08:41:35 pm
Remember my cam plate was missing chunks on all four cam lobes?? Yeah well those metal shavings were circulated throughout the pump and probably are the reason my CandyCoated pump is now dead :(

So now on to Version 3.0!!! Can you guess what it is??

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/imagejpeg_3.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/imagejpeg_2.jpg)

That's right.. A mechanical Land Rover Discovery 300TDI ;) alllrriigghhtt 8) When I get it I will be tearing it down, cleaning it, painting it  ;D. and resealing it. I might go with a metallic purple, haha. Or that speckled stone, yeah I like that. :)

Plans are as follows;

I am going to have to have my pump bracket snout hole enlarged, as the LR Disco pump is like that of the later AAZ and ALH pumps (weird that the AHU was not the same.. being in the middle and all). While I am at it I was thinking of either having the pumps mount holes on the face of the pump slotted like the IDI stuff, or slotting the holes in the pump bracket. I do not want to use the mk4 style pulley with twisting it to change timing, and I may be able not too. The LR pumps driveshaft/mainshaft has a slot for the key, so I should be able to use my original AHU key and 20mm AHU pulley. I'll use my AHU rear pump bracket, and swap the delivery valves to AHU as well. Bolt in swap ;).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: R.O.R-2.0 on August 04, 2012, 09:29:03 pm
Quote from: 8v-of-fury on August 03, 2012, 07:40:53 pm
So I finally made myself a pressure gauge and threaded out bolt to test the pressures inside of my pumps :)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120801_233505.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120801_232052.jpg)

However it is a wee bit low, WAY LOW on pressure inside of the pump. This video shows my pump idling on pure 2 stroke motor oil and no electric pusher pump at 10-12psi. I had 17-19psi on diesel with my electric pusher pump. Tapped the regulator WAY in and had absolutely no pressure change at all. I am not running the front AAZ solenoid so I do not know where the pressure is bleeding off to? or if it is just simply really worn in the vane pump?

http://www.youtube.com/watch?v=_wzm_VIJxUA

jer, that gauge wont return to zero.. its no good, and certainly not accurate..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 04, 2012, 09:31:30 pm
Yeah I dropped it, its alright anyway got a newer 160psi guage. Pump pressures can spike as high as 150psi when in higher rpms. I measured my pump with the latter gauge not this one pictured. It was more to show how I had done the setup.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on August 04, 2012, 10:58:56 pm
i keep thinking of rigging up a electrical 10bar/150psi oil pressure gauge to mine.. just to see these pressures..

your rover pump dirty.. also not same as mine..

do you know how easy a adjustable pully is vs twisting the pump?? i want to get some built for my 1.6s... but yep stock valves/gear fiit no issue.. but imagine using a wrench on pump nut.. while looking at dial indicator.. so smooth.. so simple... vs big pair of pliers trying to twist the pump..

ohh also do not be like me.. add a hole to pump gear for the locking pin.. the original hole will have pump snout in it... i just used the "notch" to line it up.. cannot be locked on mine.. but i have 2teeth of adjustment with my pully.. so i had a cheat factor if i happened to be a tooth off..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on August 04, 2012, 11:03:36 pm
(http://www.crsmp5.com/2012_photos/1_16_12/6.jpg)
my rover pump..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 04, 2012, 11:10:47 pm
Your pump is dirty as well, or painted poorly.. lol I Cannot tell the difference.

I never have to use pliers to twist the pump? I keep my bracket/snout relationship lubricated for easy pump twisting, aka by the touch of a finger.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on August 04, 2012, 11:18:59 pm
giles will clean it for me... some day when i find it needs work.. and no paint.. good uk oil/soot/enviroment... saw no reason to chance knocking crap into pump.. plus... 50/50 chance on if it worked.. testing required.. why invest time till you know it works...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 16, 2012, 12:35:53 am
So the CandiPump has met its maker. She is really running rough, lots of cold start smoke, and pitiful performance. Pump is getting a full tear down tomorrow morning, and I will be building another M-TDI pump to get me by until my Rover pump gets here in the next few weeks. Yup N/A pump with a 10mm head and DI internals ;) Who needs an LDA!?


(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120715_213143.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120801_231852.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120801_231935.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120801_231920.jpg)


Oil pressures fantastic though! Cold idle first, Hot idle second. 0w40 full synthetic. Taken from the head.


(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120815_100607.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120805_114820.jpg)


LOVE the HD capabilities of my phone!


(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120807_164721.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 23, 2012, 11:09:00 am
So look what i found in the bottom of my oil bucket.. Been there since february!

 (http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120823_110435.jpg)

How has my tranny not imploded yet??
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: golftd412000 on August 24, 2012, 04:19:48 am
aie!

i drive with 15w50 and i have 10w60 in stock.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 02, 2012, 06:39:13 pm
Well I built up another M-TDI pump while I wait to get my siht together for my Rover pump swap; (which by the way I'm gonna need the power more now than before, see below ;)) This is a 1982 1.6 NA pump, with no modifications to fit that 1991 1.6 TD lid on it. It has my 10mm AHU internals and custom throttle lever as well. It has the ability to make proper pump pressures unlike the other did!

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120829_220209.jpg)

I need the power to tow this! :) Its nice not having to have to drive the truck and fuel it up too lol when gas is $1.34/L ($5.09/Gallon).

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120902_112643.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/399162_10151012029332204_419504165_n.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120902_121240.jpg)

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 16, 2012, 02:07:28 am
Did a good highway haul tonight, averaged 130km/h (3100 rpm with my ACN). Although I have the k03 on there the waste gate was probably wide open at this point so there was no turbo restriction on the exhaust. I did about 285km on the highway at these speeds on 1/4 of a tank too :)! That is 10L for me in my 84. She's got alright power, and great economy. Single digit celsius this morning, cold starts are doing good too.

But, ALAS I am on to better things!!! This is the real M-TDI v3.0.

Veg Injection .216 nozzles

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120916_014929.jpg)

"classic" Rover Pump

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_131052.jpg)(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_131130.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_131312.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_145552.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_145545.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_145710.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_145658.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_145634.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_161422.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_161429.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_161707.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_161608.jpg)


Oooh yeah, I'm thinking this one stays polished. With about 23 coats of clear sprayed on ;) and left to cure for a week before handling. The next picture shows the Rover governor assembly on the left and a 1.6/1.9 IDI governor on the right. The length of pivot points between throttle shaft and governor cage is ever so slightly longer on the Rover one, and the entire governor shaft it self is substantially longer as well. The springs all look the same though. I was lucky enough to unknowingly buy one that had the conventional caged governor style, instead of the Cummins single spring.

Rover Left, Vw Right.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_133626.jpg)

A reseal on the rover pump this weekend, and a modified injection pump bracket hopefully very soon as well could have this thing thrashing the roads in a few weeks :). Next is an inter cooler, and then after that? A T3 turbo upgrade ;). Here's a question, does anyone know if a 1.6TD oil pan will work on 1.9 AHU ? Being that it will have a bung for the drain.. I have the T3, manifold and drain line.

Gotta say, I'm pretty freakin' excited :)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 16, 2012, 02:19:10 am
A 1.6TD pan will work with the AHU, but you'll have to plug the block drain.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on September 16, 2012, 05:50:10 am
taller lock too.. so oil return length may be a issue... id just mod the return to use stock return hole in block..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on September 16, 2012, 07:47:48 am
i have a question, couldn't you have switched pump bodies since you took it all apart anyway and then you could have timed it very easily?  also good luck with your t3, i recommend something bigger than the vw t3 especially since you will have the 12mm pump, talk to hill folk about his old setup, he ran the vw t3 on his tdi-m then he had the mercedes t3 on there, and it spooled surprisingly fast. and he also ran low 14's on 175 tires.  i would look into what alcaid recommend the he211w or he221w, they are sized similar to the t3's that i recommend on here but far more advanced and built much stronger.  regardless, the vw t3 should be a bit of an upgrade for you, can't wait to hear how it runs


blakes old setup!!!

(http://imageshack.us/a/img19/7751/hpim01959he.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 16, 2012, 10:41:49 pm
@$%$#^!^$@%&

I have written out a lengthy reply to this twice Trav, and both times it was lost! First a power outage, then a browser update.. JESUS! Gotta be kidding me. I am unsure of what you're asking,

Quote from: Trev0rbr
i have a question, couldn't you have switched pump bodies since you took it all apart anyway and then you could have timed it very easily?

?? lol. As it would seem, the same metal that had trashed my vane pump in the AAZ body also trashed my 10mm head as some issues from the other pump have persisted on the new pump I put together. The rover pump is 11mm so it won't be a crazy attempt at power, after all.. I am still going to run my ACN 020! LMAO The only reason I want to run the T3 is because 1. I have it here for free, and 2. I want better high rpm drive ability mostly. Anything over 2300 and the k03 is singing loud and proud. It doesn't mind it, but I do.. lol The T3 should be a mega upgrade over the k03, as this pump should be able to spool it quick anyway

Forgot about the taller block of the 1.9L, so that is ok. I will make the block drain work for me.

Got the rover pump all back together! Score. Love me a shiny Injection Pump :)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120916_182842.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120916_182938.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120916_191037.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120916_191049.jpg)

She's all ready to go.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: golftd412000 on September 17, 2012, 04:16:20 am
good work!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 17, 2012, 09:40:51 am
The long delivery valves won't fit the AHU lines without bending them.

I haven't dealt with the Rover pump, but it looks like the ALH sprocket/hub will work without any modification, no?

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 17, 2012, 11:54:47 am
Yes i am aware the delivery valves wont work. I cleaned them up for the photo shoot and so i can store them for later use.

I do believe the ALH sprocket may need modification, crsmp5 used an alh sprocket and had to mod it. Whether it was necessary I do not know. I was going tp use my original AHU 20mm sprocket and maintain the twisting of the pump.. But i may look in to the ALH further.

Thanks for the kind words, it looks beautiful.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on September 17, 2012, 09:17:36 pm
Why did you lock it??? I am unlocking now LOL.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 17, 2012, 09:18:15 pm
WTH, must have did it on my phone by accident.. STUPID.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on September 17, 2012, 10:33:37 pm
<----sent him pm to fix his info... i used the stock 98 jetta pully for ahu?? dont feel like trying to figure out which one.. we call it a 1z.. :P

had it modded to work as later alh? mk4 style requires shimming the pump towards the tranny, machining the face off it to clear the cover and still need to get the later hub put on in proper place... ohhh also spend the coin to buy hub/sprocket too

my modded pully was 100bux out the door... simple in design, still used the key way... no need to worry bout shimming... and the cover fits no issue.. also when cover off it looks tits.. like some crappy ricer with engine add ons.. mmmmmm allen bolts in to pully..... mmmmmm race ready...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 18, 2012, 10:14:59 am
So the 1Z/AHU pulley fits.. But you modded it only because you wanted to maintain the pulley style pump timing eh? I am thinking of opening the rover pump mounts to maintain twisting pump style timing.

If the pulley fits and works stock then im golden here. :)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on September 18, 2012, 02:38:02 pm
Yeah but think how easy it would be to time with a pulley like his, just get everything at tdc and install the belt, then rotate the engine until the pump is where you want it, loosen the modded pulley, turn the engine back to tdc and tighten the pulley, the only thing I'd be worried about is how sometimes the spring tension in the pump doesn't just keep the input shaft where ever you set it.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 18, 2012, 06:18:49 pm
You bring up a good point, I have an ALH hub avaialble to me.. so now I just need an ALH pulley..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 18, 2012, 09:02:19 pm
Quote from: CRSMP5 on September 17, 2012, 10:33:37 pm
<----sent him pm to fix his info... i used the stock 98 jetta pully for ahu?? dont feel like trying to figure out which one.. we call it a 1z.. :P

had it modded to work as later alh? mk4 style requires shimming the pump towards the tranny, machining the face off it to clear the cover and still need to get the later hub put on in proper place... ohhh also spend the coin to buy hub/sprocket too

my modded pully was 100bux out the door... simple in design, still used the key way... no need to worry bout shimming... and the cover fits no issue.. also when cover off it looks tits.. like some crappy ricer with engine add ons.. mmmmmm allen bolts in to pully..... mmmmmm race ready...

I don't understand your post.  I have not dealt with the Rover pump first hand, but I have only ever seen two different shaft lengths (long snout, short snout) and two different pump shaft diameters (17mm and 20mm).  My understanding is that the Rover pump has the larger 20mm shaft and the long snout shaft length just like the AHU/1Z/AFN and ALH pumps which all have the same pump mounting surface to sprocket offset distance.  I don't understand why the ALH sprocket AND HUB would require that the pump be shimmed, etc, etc...  Looks like a bolt-on to me.  I can understand that the face of the ALH sprocket sticks out a little further and so the sprocket face or the timing cover might need to be modified, but I don't understand the rest of what you were saying was an issue. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 18, 2012, 09:25:24 pm
Quote from: libbydiesel on September 18, 2012, 09:02:19 pm
I don't understand your post. 

Does anyone?.. Ever? ;) kidding.

I too am unaware as to why you had to go through so much B/S to make that work out. I am going to the garage to snap some quick pics. :)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 18, 2012, 09:41:37 pm
My only explanation is that he was trying to use the ALH sprocket with the Rover hub which is thicker than the ALH hub.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on September 18, 2012, 09:49:41 pm
where ever my original rover education post is... there is a link to how to fit say a mk4 pump into mk3... it talks about shimming tnhe pump over.. with pics... i never tried it as i never had later to test fit...

rember rover pump on mk3 is like fitting mk4 onto mk3
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 18, 2012, 10:16:52 pm
I have a mk3 and mk4 pump right in front of me at this moment with the hub removed from the Mk4 pump and bolted to the mk4 pulley.  The Mk3 pulley and Mk4 pulley/hub will swap to either pump and result in the same space between the sprocket and the mounting face of the pump.  I still don't get what the issue is.  The Mk3 pump fits into the Mk4 bracket except that the snout is too skinny.  Bolt holes all line up.  What's the link to your 'rover education post'?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 18, 2012, 10:33:05 pm
I found your 'rover education' thread and the link to the TDI thread.  The guy who shimmed his pump just didn't understand how to adjust the belt tracking.  There isn't a difference in the pulley offset.  DOH!   (http://www.thesamba.com/vw/forum/images/smiles/eusa_doh.gif) Some people just make things hard on themselves...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 18, 2012, 10:40:57 pm
Nope, Andrew you are right. No difference.

1.6 NA pump, I have one of these bodies on my AHU bracket right now with a 1.6 pulley.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120918_221544_zps20af9a0f.jpg)

The rover pump and AHU 20mm pulley.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120918_221554_zpsa5f0de6e.jpg)

So yeah, not enough to matter at all.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 18, 2012, 10:42:28 pm
The only problem I can see would be the using of the AHU pulley would require me to cut a hole in my timing cover to clear this..

The nut sticks out nearly 18mm.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120918_221642_zps2bd7b744.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 18, 2012, 10:56:32 pm
I'd get the ALH sprocket and hub but that's just me.  Are you sure you'd need to mod your timing cover?  Is yours an AHU cover?  It bumps out there.  How is that different from a stock AHU pump nut offset?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 18, 2012, 10:59:01 pm
Good point, I guess it would stick out the same. Well then I would not have to modify the cover then.

However I do have an ALH hub available to me if I want it.. I do not have a pulley, nor do I even know where to obtain one without an ALH pump hanging off the back of it ;).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 18, 2012, 11:44:45 pm
There are several ALH sprockets without the hub on eBay or a wanted add on TDI club would get you lots of them.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 21, 2012, 10:34:02 pm
So there is this guy, and he is a pretty happenin' dooood. He has been the biggest help with my very recent journey with the Bosch VE fuel injection systems, and I thank him 1000 times over. He is a member on this board, and he goes by the name of 410. He has helped immensely with my hurdles, and is THE MAN (sorry Lucas ;)) So here we have a 1Z TDI injection pump bracket, it has had its opening bored to ~68mm exactly (yes approximate exactness). It is pictured with an ALH pump, but they are the same size as the Rover snout. Pretty awesome right ;D.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/IMG_0351_zpsbb5243f4.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/IMG_0354_zpsf7c5afd2.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/IMG_0353_zps1c107045.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/IMG_0352_zps37f11cc4.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 26, 2012, 10:33:22 pm
And the bracket arrived Tuesday, not too shabby for across the country in a day lol. With a perfect mirror finish on the snout-hole.. There will never be an issue twisting my pump ever again! ;)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120925_174546.jpg)

So as it would sit, I am just in need of getting my pumps mounting holes ob-longed to match the old style 1.6 and 1.9 pumps. Mind you the right pump in my picture is a 1.9L AHU TDI pump. And this bad boy is ready for some serious action. OH BOY.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120918_215513_zpsb77dcd2d.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 28, 2012, 11:52:13 pm
Rover pump has been slotted and is awaiting installation first thing in the am!!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on September 29, 2012, 11:55:24 pm
And???
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 30, 2012, 07:30:16 pm
Quote from: Trev0rbr on September 29, 2012, 11:55:24 pm
And???

Annnddd I got that Rover pump on there... Timed it to 0.047" which is 1.2mm. Stock Rover settings caused it to start and runaway with a huge cloud of smoke. Well, they are what I assume to be stock rover settings.. the throttle stops all looked like they had been in that spot for a LONG time. and the fuel screw still has its collar. I indexed the throttle lever as well, so it all went back together perfectly the way I got it.

I had to back to fuel screw out like 5-6 full turns to have it not run away, and then it wouldn't idle. but taking it in some more would cause it to run away.

Its kinda cold, and im tired from last nights camping excursion lol so I didn't give it too much effort unfortunately..

I ended up putting a 9mm end cap on the head so I could use my M8 timing gauge, and I had to use 1.6 delivery valves over my AHU ones.. because I lost a very very very small piece from one of them.. They are the same internal style as the Rover valves I took out. The lines matched right up with no issue, and it timed up well with only one tooth more on the IP pulley over stock marks on the pulley.

I cannot think of what is going on inside the pump. When I can get it to run by holding the pedal, I have no throttle response.. but if I put in the fuel screw it runs away. I tried backing out the idle screw, but it didn't change anything drastically. I didn't want to go off all half cocked changing settings until I had some more time to think on the subject.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on September 30, 2012, 07:59:21 pm
Sounds like the accelerator shaft to lever orientation is wrong.  Go a couple notches clockwise with the shaft ccw with the lever.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 30, 2012, 08:49:51 pm
Quote from: libbydiesel on September 30, 2012, 07:59:21 pm
Sounds like the accelerator shaft to lever orientation is wrong.  Go a couple notches clockwise with the shaft ccw with the lever.

It is possible that someone may have messed with it before I got it. I did re-install everything to exactly where it was when I took it apart. Seems like there is no way this pump would have run the engine it came off of.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on October 01, 2012, 02:47:42 pm
i had to turn my stops way in..... still not touched my fuel screw... but it would run away till i dropped my stop..

my idi dial gauge adapter fitted right into my 11mm tdi head/pump... you sure on the 9mm thing??
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 01, 2012, 03:12:21 pm
When you say you had to turn your stops way in?? You mean you had to increase the idle??

I had to back my max fuel out 6 Full turns to stop it running away. I also backed out the idle set to see if it would help but got nowhere near the adjustment. I will be removing the throttle arm and spring to test for governor cage compression and then set it there and try again.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on October 01, 2012, 04:40:18 pm
aka lower idle
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 01, 2012, 09:53:32 pm
Cannot get the pump to react well no matter where any of the settings are. How disheartening this is. LOL

I thought I had it good, but then I had no power under load. Well then I got the power there, but the idle was erratic and starting to hang between gears. And now I am frustrated.. as I spent over 2 and a half hours at every possible combination of settings it would seem.

Just for clarity, this pump has no back of the lid throttle adjustment. Just the two throttle stop screws and the max fuel screw is all. Nice and simply complicated.

I've had it at all different settings of throttle arm to throttle shaft orientation, however even the most relaxed setting of this relation is still not relaxed enough to need the fuel screw to be in as far as it was stock when I got it.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on October 01, 2012, 11:37:14 pm
Ignore the settings where it was at.  Get it to idle.  If it is then gutless, then increase the max fuel.  If it starts to hang between shifts or you run out of idle adjustment before you get decent power then jump one spline with the shaft going clockwise and lever going CCW and bring the idle adjustment up until it will idle again.  Then adjust the max fuel screw to have more power.  Then adjust the idle back down.  Etc...  After you've done this routine on a few pumps it becomes easy and natural.   
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 02, 2012, 07:28:50 am
Quote from: libbydiesel on October 01, 2012, 11:37:14 pm
After you've done this routine on a few pumps it becomes easy and natural.   

I have done this countless amount of times, that is why it is so frustrating lol. I do not feel it is behaving normally.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on October 02, 2012, 06:07:52 pm
what return orifice you using if you have the one from the vw etdi pump this would cause the problems you are having ,i think the LR injectors have a 220 bar brake , so you would only need to back off the max screw 1 or 2 turns and wouldbe fine, i am going to fit a landrover tdi pump to one of my 1zs and see how it runs compared to my built Mtdi pump .
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 02, 2012, 06:34:35 pm
I think i am using the one that the LR pump came with for out bolt.

So far it definity runs good. Nice and smooth sounding for sure.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on October 02, 2012, 09:52:50 pm
So it's running good now?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 02, 2012, 10:44:20 pm
It runs good, but it is not performing good lol. The settings are very sensitive with this one and I am having quite the frustrating time with them... haha

I am having troubles setting a solid idle, and then still having good throttle response with no hanging. If I can get the good idle and not a ton of hang (like I have now) it doesn't feel like its got any balls.. some, but not what I had with the 1.6 DI Franken pump, sadly.

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 02, 2012, 11:21:54 pm
1996 300TDI rover pump, 1998 1.9 AHU pulley and key. Slotted the pump mounts for twisting style pump, fits and times up no problem. All I did was insert the dial gauge first, so I could see where I needed the pulley to be based on cam plate lift. It turned out to be two notches on the belt towards the front of the car from the stock 1.6/1.9/TDI pulleys.. so all in all not a problem to time up. I have it set at 1.2mm and it sounds great, like a big 12.1L I6 Volvo D12.. man do they sound nice.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120930_212218.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on October 03, 2012, 12:15:36 am
Quote from: 8v-of-fury on October 02, 2012, 10:44:20 pm
If I can get the good idle and not a ton of hang (like I have now) it doesn't feel like its got any balls..

I don't want to sound like a broken record, but here goes.  The following is EXACTLY what you need to do to adjust it.

1.  Get it to idle well.
2.  If it is gutless at that point, then turn in the max fuel and turn out the idle to bring it back to the same point.
3.  If you run out of idle adjustment before you get to a decent power setting, then jumper the shaft to lever orientation so that the shaft moves CW and the lever moves CCW one spline.  When you jumper that spline it will initially run like crap.  You will then need to turn up the idle to get back to a decent idle setting and it will give you more room  in the idle adjustment.  You will also have to turn up the max fuel a bunch to get it reasonable, but you end up with A LOT more max fuel adjustment and yet still are able to get an idle setting.  

I swear, that's the step by step on how to adjust from the point that you describe.  What step is giving difficulty?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on October 03, 2012, 06:16:53 am
i have swaped all the bits from a LR pump in to a nother body to bolt strate on to the vw 1.9tdi , and it only felt 110hp so shimed the gov spring , and changed the small idle spring right at the end to a 1.9 td one its a bit softer , lda mod  and cracked in the max screw , it hangs on reves a little but still fine ,and she has good torque now the idle is 700rpm .
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 03, 2012, 07:28:55 am
Quote from: libbydiesel on October 03, 2012, 12:15:36 am
I don't want to sound like a broken record, but here goes.  The following is EXACTLY what you need to do to adjust it.

1.  Get it to idle well.
2.  If it is gutless at that point, then turn in the max fuel and turn out the idle to bring it back to the same point.
3.  If you run out of idle adjustment before you get to a decent power setting, then jumper the shaft to lever orientation so that the shaft moves CW and the lever moves CCW one spline.  When you jumper that spline it will initially run like crap.  You will then need to turn up the idle to get back to a decent idle setting and it will give you more room  in the idle adjustment.  You will also have to turn up the max fuel a bunch to get it reasonable, but you end up with A LOT more max fuel adjustment and yet still are able to get an idle setting. 

What step is giving difficulty?

Thus the confusion.. Doing all that and then jumping one more spline, without changing anything else, it will still idle... It does not affect it like it has every pump before hand.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on October 03, 2012, 10:28:52 am
What that means to me is that with the jumping of one spline from where it was, the idle spring is not totally relaxed.  Great.  Just adjust the max fuel in a bunch for the new setting, then set the idle where it needs to be and you're off to the races.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on October 03, 2012, 03:40:02 pm
Libby your description has been given a few times here now.  I wonder if we should make it a sticky?  Seems to be a common problem when we go opening up the pump an tweaking on the parts. 

Thanks for writeup  DAS
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 03, 2012, 09:23:52 pm
Still giving me a world of troubles.. Clearly something is all tomfoolery. Where i have it right now I have an idle (that fluctuates between too high and stalling intermittently), i have some power (not enough to spin in the rain..) and i have somewhat of a throttle response..

Now following those instructions to a damn T.. This is the best I can get it out of all other combinations. I cannot relax the governor springs (jumper throttle shaft anoher CW) without screwing everything up. Relaxing the throttle does NOT require the max fuel to be turned in at all. I have it so relaxed that there is a ton of free throtle with no affect to the idle.. And turning the max fuel in or out controls the idle fully. Regardless of idle screw position.

This has gotten me on the ground beaten and discouraged. I am losing will to keep trying to get it running.. Lol. No matter what i do i cannot get a solid idle at all. I can move the throttle shaft several positions fromnwhere it is now with no affect to idle.

Furthermore, normally backing off on the throttle arm means more max fuel needed. Not true in this case. It is totally not acting the way it is intended.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on October 03, 2012, 09:28:57 pm
What kind of cage does this have in it? Sounds almost like a bad gov mod or gov springs that are nowhere near what it is needed for this engine. Doesn't it,
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 03, 2012, 10:34:54 pm
It has a traditonal style gov cage. Very much the same as the vw one just slightly longer. Bigger springs too. Frig man. I just popped the lod off. Found out my lda was stuck.. So i was gettimg no boost enrichment.. It will most likely go better now!!!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on October 03, 2012, 10:40:06 pm
Well, not what I was thinking but that is the direction I was guessing. Something being wrong in there, stuck spring, shim, something messed in the gov...The lda stuck would give little to no boost power. Hopefully this works out for you now.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on October 03, 2012, 11:44:50 pm
All of us are praying for rain and a good solid idle with plenty of power on load here.  Come on man fix it for us. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 04, 2012, 07:46:26 am
Holy baby Jesus... I got a taste of it last night.... WOWWWWWWWWW i almost puked with joy lolol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on October 04, 2012, 12:48:05 pm
whats it taste like
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on October 04, 2012, 05:05:48 pm
I'm glad to hear you got it working better.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on October 04, 2012, 11:34:11 pm
Tastes like diesel with a hint of oil aftertaste.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 05, 2012, 12:32:04 pm
It tastes like mad torque steer, traction issues in all 5 gears when wet and 3rd when dry.. It also tastes like a lottla hondas eatin smoke ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on October 05, 2012, 01:54:29 pm
Now get an intercooler on there and a turbine that you can at least fit your thumb into and you'll experience some real power.    :P 8)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 05, 2012, 02:31:56 pm
Quote from: libbydiesel on October 05, 2012, 01:54:29 pm
Now get an intercooler on there and a turbine that you can at least fit your thumb into and you'll experience some real power.    :P 8)

I have a full T3 setup as one of my next steps.. ;) Intercooler and my .216's are next for sure. Then probably an 02A.. Lmao
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 06, 2012, 12:39:56 am
SO. All the B/S that was totally unresponsive to proper tuning? The governor shaft getting hung up internally.... fml.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/imagejpeg_2-1.jpg)

I could feel that I had popped the cage out of the lever with my frigging around so I needed to remove the lid anyway and have a look. The cage was out of the lever, and then I saw the gouge marks.. apparently it wasn't seated properly in its slot. Live and learn. Next time I get that symptom?! I've got it covered! lol.

So anyway, I have the throttle shaft at its most CW position and the idle screw backed physically all the way out. I then have the max fuel screw in roughly 2-3 full turns from factory LR settings (had paint and collar on it). Chris, you need to get that fuel screw in! HOLY CRAP!

I am non intercooled and running stock boost/waste gate. Got lots of smoke.. so I got lots of room for wayyy moorree booost :)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on October 06, 2012, 08:39:39 pm
Quote from: 8v-of-fury on October 05, 2012, 02:31:56 pm
Quote from: libbydiesel on October 05, 2012, 01:54:29 pm
Now get an intercooler on there and a turbine that you can at least fit your thumb into and you'll experience some real power.    :P 8)

I have a full T3 setup as one of my next steps.. ;) Intercooler and my .216's are next for sure. Then probably an 02A.. Lmao
Libby that is funny!  Get a bigger compressor Jerome
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on October 06, 2012, 11:15:53 pm
Does size really matter?

I'm sure you guys know I HATE lag and prefer smaller turbos to big ones, but, IMO the K03 is just too small for a 1.9.  Even at stock boost pressures you can feel the top end hurt from it.  On the other hand, my VNT15 is physically as small, but with the vanes open it flows better than turbos that are physically much larger.  With the vanes closed it boosts faster than a k03.  Before too long I will be fitting an 1852v to an ALH.  Mmmmm....
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 07, 2012, 01:41:48 pm
Quote from: libbydiesel on October 06, 2012, 11:15:53 pm
Does size really matter?

So my girlfriend keeps telling me.. ;)

Now you guys gotta remember I am still on an 020 trans here, and at stock boost.. I can hear my waste gate open with a little more than 1/3 pedal. So an inter cooler, my bigger nozzles (Veg .216) and up the boost to 18-20psi and it should be about all the 020 can handle. Then before too much else, I guess I gotta get the 02A I have sorted out as well...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 08, 2012, 05:07:41 pm
3rd gear, dry pavement, traction issues.

What is all involved in installing a diff kit in to an 02A? I figure I might as well start thinking big picture here and go for broke...

Peloquin Diff Kit (http://www.peloquins.com/products_02A.html)? comes with everything needed to install it it would seem, including the $100 ARP bolt kit.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on October 08, 2012, 06:09:27 pm
From what I gather the wavetrack are supposed to have more traction than the peloquin models. Just going from what broke vw has told me on his tests. He also said they were supposed to change the hardening process as the last one he installed cut the splines off of the arp bolts when they were pressed in. He was worried they wouldn't have enough bite to tighten them or keep them in there, so he contacted them and they said they were softening them a bit. That was the bolts would have the splines left and it would be a tighter fit.

As far as the install, if it is like the 020, then I believe you have to pull everything to get to the ring and pinion. If it is different then I do not know what would be done.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 09, 2012, 06:31:14 pm
I fully expect a full tranny tear down.. I'm not afraid to tear in to anything, and I always have good results with my endeavors. Hey I wouldn't have an M-TDI daily if I weren't a person who likes to open siht up and take a peek ;)

I will look in to the Wavetrack stuff and start to get a feel for what I am looking for.. TDIclub will probably be a huge resource. Is it all basically the same for 02J stuff as well? I see them listed together usually when talking about anything to do with either.   
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on October 09, 2012, 09:34:58 pm
From what I gather the 02a and 02j are basically the same. There are some differences but I cannot think of them at the moment. After seeing my 020 apart I think I could do it as long as I knew what the backlash should be and any other spec that isn't in the bentley BUT I would want to do it in a weekend or have enough space to lay every part out where it goes. Until I would do enough of them I wouldn't want to chance coming back to the project a week or 6 later and have to put the puzzle together. Or not get the backlash correct and fry the gear set in less than 1,000 miles.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: steveG on October 14, 2012, 10:54:04 pm
Hi been following your thread fot quite a while now I'm bussy putting an ahu in my 81 caddy I got the rover pump a few weeks back when I was over in England.

Already got the mk4 pulley and hub from the alh and the delivery valves from the ahu did you do any other mods to the pumps internals?

And if you get a chance could we get some more bay shots  :)

The 02a is hanging in the bay right now biggest hurdle is hydro clutch and I'm still on the look out for the early corrado speedo cable. Were you able to get the tac to work with your gauge or do you need some sort of optical tac?

Thanks
Keep up the good work.

And thanks to crsmp5 for his help and every one that contributed to making this site such a great soured of knowledge.

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 15, 2012, 12:29:09 pm
I am using a stock Rover pump for now with the AHU pulley bolted to an opened up 1Z/AHU pump bracket with 1.6 NA delivery valves.

I have no tach, and am using the stock 020 tranny with my stock gauge cluster. All mechanical gauges to keep an eye on things though.

Get some more shots after work today.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 15, 2012, 09:38:58 pm
1.6 N/A delivery valves.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20121015_181553.jpg)

300 TDI Land Rover pump.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20121015_181434.jpg)

Original 1998 AHU pulley, with my AHU key as well. Apparently the key way in the Rover shaft does not line up with the AHU shaft? I just found pump TDC with my dial gauge in the end of it during belt installation.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20121015_181458.jpg)

Full bay shot, mind the wiring. Got a lot of temporary things going on in this shot. Not swap related of course, but a bunch of other things! Stereo, Bi-Xenon HID setup, Fan relay, Pimped glow setup from my 1.6.. (havent had to use the AHU glows even in -20c.. ;))

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20121015_181656.jpg)

Now that it is all up and running good.. (until the next stage ;) ) I can tear it all back down and clean clean clean and make it pretty again. lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on October 15, 2012, 11:22:49 pm
rover pump keyway/pully line up dead nuts... mine did at least... just pump pully lock no work... snout of pump in way on bracket for stock lock... and i doubt he drilled his pully for the pin lock they used..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 16, 2012, 12:21:21 pm
Well i had heard reports of the rover pump being off about 10 degrees over the 1Z/AHU.

So I just used my dial indicator to tell me where the pump internals shpuld be at TDC regardless of pulley or shaft position.

I dont use locks when I time these anymore.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 05, 2012, 07:50:17 pm
Guys, I need some help lol! This extremely efficient engine does not put out enough heat! What do I do!? How do any stock TDI powered vehicles make enough heat to keep the window de-iced in the winter?

I had trouble keeping the windshield not covered in ice build-up last winter when it was a 1.6 NA.. this engine has even LESS wasted heat in to the coolant system.

What do you guys suggest?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on November 05, 2012, 08:03:00 pm
put a piece of thin plywood in front of the radiator.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on November 05, 2012, 08:04:44 pm
If your engine temp comes up but you're still not getting any heat in the cab I would suspect your heater core is plugged.  If the engine is not getting up to temp and your rad is warm, it's probably your thermostat.  For the heater core, you can unhook the heater core lines and use a garden hose to push fresh water through both ways.  It's pretty amazing the stuff that comes out.  Be careful though because too much pressure can cause an already weak heater core to leak.  The m-tdi I had in my toyota truck could defrost the windows with 15 minutes of idling and once driving produced more than enough heat to keep me warm.  There's 3 glowplugs on the drivers side of the head on the coolant out port that you can power up using a switch but they're not that effective.  They do load the alternator a bit as well but still the effect is minimal.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on November 05, 2012, 08:09:33 pm
Quote from: bbob203 on November 05, 2012, 08:03:00 pm
put a piece of thin plywood in front of the radiator.

Provided your thermostat is working right, then a piece of plywood BEHIND the radiator will work just as well as a piece in front of the radiator.  The temperature of the coolant in the radiator is completely irrelevant to engine temperature up to the point where the thermostat is completely open which pretty much never happens in cold weather.  The benefit you get from the piece of plywood (or cardboard, etc...) is from blocking the cold air from flowing over then engine, not the radiator. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 05, 2012, 08:21:40 pm
I can visibly see the thermostat open at 180f on my mechanical coolant gauge. The engine takes forever to get up to temperature unless I am on the highway. I am pretty sure the thermostat is working correctly because the lower rad hose dose not get warm until 180f is reached.

It was about 20f for my 45 minute drive to work this morning, I did not have operating temperature for about the first 15 minutes of that drive.. which by the way is highway. Not 125km/h hwy, but 85km/h two lane. I think a coolant drain, heater core flush and a new hotter thermostat are in order as a pre-winter maintenance tune up.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on November 05, 2012, 08:22:52 pm
It really hasn't been cold enough here yet to justify covering the rad so I suspect there is another problem.  Even if you do cover the rad, there is still a lot of airflow in the engine compartment unless you have a belly pan or skid plate.  The newer tdi's are actually quite insulated using the belly pan, the plastic cover on the engine is also insulated as well as the hood.  The main reason for the insulation is for soundproofing but does help to retain heat in the winter.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 05, 2012, 08:34:47 pm
I have a stock mk1 hood pad from an old parts car. Looks like it will be making its way on there :)

Anybody got an AHU engine cover ? :)

My gf's 88 with the stock 1.6TD makes INCREDIBLE heat, like too hot to hold your hand in front of the vent hot!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on November 05, 2012, 08:50:48 pm
My high top vanagon made incredible heat with the 1.6TD.  The mTDI takes a long time to get decent heat.  My two biggest gripes from that engine are that it's too powerful (makes my clutch slip) and too efficient (heater output stinks).  I guess there are worse problems you could have...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on November 05, 2012, 09:02:16 pm
Maybe try hooking up those three glowplugs.  It can't hurt. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 05, 2012, 09:08:34 pm
Yes I am pretty sure I felt my 210mm clutch slip on Friday.. its brand new too.. lol!

Efficiency does have its down falls I suppose. Funny part? My DieHard-V8-fanboy best friend, chastises the cars inability to make heat for several miles of driving.. I'm like yeah, it IS THAT more efficient than your supposed 50mpg 2012 gas engine..

I was going to be hooking those up some day after work this week. A nice light up switch, and a relay under the hood.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on November 05, 2012, 10:10:16 pm
There is a harness kit u can get for glow plugs I think geebee used it in his caddy it has something to do with ford
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 05, 2012, 10:18:54 pm
Fortunately, GeeBee has money for perfection. ;)

I will very easily make up my own system that will work for what is needed. Each plug is like 9 amps, so a 40 amp automotive relay should have no problems with that load.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: steveG on November 07, 2012, 12:08:38 am
The service manual had some thing to say about how they turned on and the different combinations that they turn on in and showed the relays that operate them i could send you a photo of it.

good thing about efficiency less heat less wear longer engine life   :)

Personal i was looking at some ones Toyota swap where he made his own coolant flange witch totally deleted that whole cluster of wires plugs and sensors looks like it would make for some good bay cleaning. Down here in Florida it doesn't get that cold :P so ill probably end up ripping those out.

erg delete kit, water pump, timing belt and tools should be here tomorrow :D thanks Metalnerd and Diesel Geek.

I cant seem to find a decent source for oem engine parts i need a complete gasket set and have read horrible things about hans diesel and was looking at going with parts place inc but have also read bad things about them  ??? ??? ???

sorry to drop in on your thread again ill start my own soon just want to get the project a little off the floor first and have my parts gathered.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on November 07, 2012, 08:07:31 am
Told you about that TDI heat. Sucks doesn't it?

Steve G, I would take that GP water neck off your hands if you are not using it.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on November 07, 2012, 09:49:16 am
I have a couple extras Lucas.  The glowplugs out of the idi's work in them too.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on November 07, 2012, 11:43:36 am
Quote from: 8v-of-fury on November 05, 2012, 10:18:54 pm
Fortunately, GeeBee has money for perfection. ;)

I will very easily make up my own system that will work for what is needed. Each plug is like 9 amps, so a 40 amp automotive relay should have no problems with that load.

i don't remember it being expensive.  The vw relay is actually really cheap i think i got one for 30 bucks new, then all you'd have to do is build a harness.  not sure what you're planning, we all know a manual switch works just as well haha.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on November 07, 2012, 11:48:14 am
did a quick search and i didn't see it anywhere anymore
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 07, 2012, 12:24:46 pm
Lucas, The hell you need heat for in holmes county?? LoL.

I will be doing up my wiring this weekend hopefully for all my under hood stuff. Got a nasty nasty ground issue I am dealing with.

Gonna be golden. All I have to do after that is move my fuel lines and filter back to the passenger side and call it done for now.

Mr. TRAV i will be doing a manual setup for sure.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on November 07, 2012, 12:32:32 pm
Quote from: 8v-of-fury on November 07, 2012, 12:24:46 pm
Lucas, The hell you need heat for in holmes county?? LoL.

It can get below zero in neoh and central oh.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on November 07, 2012, 01:45:31 pm
Yeah I have been low of 28 and high of 37 for the last couple days. The rest of the week it is supposed to warm up to 45. But pretty much from Dec - Feb it is highs in the high 20s and lows wherever. On colder years it will get down further. 3 years ago in Jan. we had a high of -5 and low of -22...this is all in F...which stands for Fing cold.

Obviously it isn't winnepeg but it can get cold.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 07, 2012, 02:04:39 pm
Lucas you want a new neighbour?? Those temps are my favourite!!!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on November 07, 2012, 02:07:32 pm
Quote from: theman53 on November 07, 2012, 01:45:31 pm
Yeah I have been low of 28 and high of 37 for the last couple days. The rest of the week it is supposed to warm up to 45. But pretty much from Dec - Feb it is highs in the high 20s and lows wherever. On colder years it will get down further. 3 years ago in Jan. we had a high of -5 and low of -22...this is all in F...which stands for Fing cold.

Obviously it isn't winnepeg but it can get cold.

DUDE that winter sucked.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on November 07, 2012, 08:21:46 pm
Quote from: 8v-of-fury on November 07, 2012, 02:04:39 pm
Lucas you want a new neighbour?? Those temps are my favourite!!!

I only take new neighbors if they have a beautiful wife/girlfriend. Send me the pics PM and I will decide.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 07, 2012, 09:40:15 pm
PM SENT ;)

I have a weird idle issue. Since well.. installation of the TDI engine LoL. So just so we get up to speed on where my pump settings are. I have throttle lever set up so that the internal throttle is at its most relaxed position (throttle shaft as far CW to the levers CCW orientation as possible). With the external idle setting backed all the way out, I set my idle with the max fuel screw. Then adjusted the max screw out 1/4 turn and brought the idle up with the idle set screw. So my issue is this, If I leave it where it is to get a nice low hot idle I have like a 400rpm cold idle.. (no tach so I am just making a number up). If I raise the idle screw so that I have a cold idle, it is a few hundred rpm higher than I would like when it gets up to temp.

There does not seem to be a happy medium. Just as a note, I have had this weird idle issue forever. With the stock 1.6 pump, with the three different hand built m-tdi pumps, and now with this rover pump as well.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: QuickTD on November 07, 2012, 10:13:50 pm
 In order for the idle governor to work properly there needs to be a certain amount of preload on the idle spring. This preload pulls the governor lever and increases the fueling as the engine slows and the governor weights retract. Conversely, when the engine speed increases the governor weights push against the spring and decrease fueling. The net effect is a balance based on the spring tension working against the governor weights.

 By setting your idle using the max fuel screw, you effectively take all the tension off the idle spring (1.9TD pump) or the governor capsule which incorporates the idle spring, rendering it useless as a speed governor. You need to allow more room on the low end of the range.

 Best practice is to back off the idle lever stop on a 1.9td pump or the throttle lever stop on a 1.6 style pump and then set the max fuel screw to barely idle or even stall. Next bring the idle speed up using the idle lever stop or the throttle lever stop until you have a satisfactory idle speed. You won't give up much fueling on the high end but you will get a stable idle using this method.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 08, 2012, 09:46:31 pm
Ahh thank-you very much sir, this would be the exact reason it seems. I have always set them more or less the same way.. with the max fuel screw controlling idle lol. However, out of the three diesels in my driveway the AAZ is the only one that idles the same speed cold or hot, alternator load or not. It is set the same way, as I set it. The 1.6TD also has a bad cold idle issue, but does not have a throttle bump on the cold start at the moment due to a leaking throttle bushing.

I will try resetting both to the way you described. Thank-you for the advice.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 11, 2012, 10:18:54 pm
So I tried and set it the way you mentioned QuickTD, and it did not help the problem at all. Unfortunately.

I reset the M-tdi and the 1.6TD. It helped the 1.6 a bit, but did not help the AHU. It will still idle, just ridiculously low. So I am not quite sure what is up there.

Also check this out! My rover pump is eating shut off solenoid plungers!

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20121110_165034.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20121110_165233.jpg)

I replaced it last night with the one on the right.. and today it has yet again broken. I got a few weeks out of the first one, and it seems the pump ate it. I got 5 or 6 shut offs on the newer one from last night.. and it is yet again not killing the engine. Apparently it allows enough fuel past it still to not hinder running at all.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: QuickTD on November 12, 2012, 06:38:23 am
Is there anything about the rover pump that would cause the housing pressure to be extremely high? I can't think of any reason for the broken plunger other than extreme housing pressure causing it to "extrude" into the plunger fill port. I would look for a blocked "out" bolt or plugged return line. Maybe make up an out bolt with a fitting in it to measure housing pressure. Something is fishy there...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on November 12, 2012, 11:22:47 am
Looks like cavitation to me.I wouldn't be surprised if this is caused by your delivery valves.  IDI delivery valves have a completely different design then DI delivery valves.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 12, 2012, 03:13:20 pm
Quote from: 410 on November 12, 2012, 11:22:47 am
Looks like cavitation to me.I wouldn't be surprised if this is caused by your delivery valves.  IDI delivery valves have a completely different design then DI delivery valves.

I dont't know about that. The DI Rover valves were identical to the 1.6TD valves inside. From what I could see anyway.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on November 12, 2012, 03:44:54 pm
It's not from the delivery valves.  The TDI delivery valves are a different design but there are a massive number of DI engines using the earlier style of delivery valve.  I've used them for a long time (a couple years) in my mTDI without any issues and have even swapped between the 1.6 delivery valves and the TDI ones and after making a little max fuel adjustment cannot notice any performance difference whatsoever.  
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on November 12, 2012, 07:17:17 pm
What does the seat look like now in the head?  Is it also worn just as bad?  That might be the reason why the second plunger no longer works.  Have you checked the voltage at the stop solenoid when running and when you shut it off?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 12, 2012, 07:44:59 pm
Quote from: libbydiesel on November 12, 2012, 03:44:54 pm
It's not from the delivery valves.  The TDI delivery valves are a different design but there are a massive number of DI engines using the earlier style of delivery valve.  I've used them for a long time (a couple years) in my mTDI without any issues and have even swapped between the 1.6 delivery valves and the TDI ones and after making a little max fuel adjustment cannot notice any performance difference whatsoever. 

Yes I saw no problem running them as they looked like an identical valve compared to the DI Rover ones.

Quote from: 410 on November 12, 2012, 07:17:17 pm
What does the seat look like now in the head?  Is it also worn just as bad?  That might be the reason why the second plunger no longer works.  Have you checked the voltage at the stop solenoid when running and when you shut it off?

The seat for the plunger? Or the rubber tip itself? The second plunger worked perfectly for two days lol. Then the same thing again.

I have not checked voltage, what do you suspect is happening?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 14, 2012, 06:14:18 pm
So I thought I lunched my k03, it were a sad morning.. It was making a very weird metal on metal sound when higher boost was reached..

BUT when I got to work I found out that I had just broken my EGR cooler! YAY. The two broken pieces of pipe were I guess wiggling on each other when manifold pressures got up there, and causing gnarly sounds. Luckily I have a delete kit I bought anyway, so this is a perfect opportunity.

Pheww.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 17, 2012, 01:31:21 am
Removed my EGR cooler tonight, broke a damn stud off in the exhaust manifold too.. it has definitely been on there since factory.. ~500k kms ago..!

So needless to say it leaks, i was hoping the one may seal it.. but no chance. Now I have to fight with that stud.. some sticking out but not really any room to work vice grips. I also do not own a welder.

Crrrap.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on November 17, 2012, 08:22:58 pm
It might be easier to replace the manifold.  If it were me and I had to save the manifold I would file the stud flat, center punch it, drill and tap it.  I doubt that the stud will come out using any other method.  
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on November 17, 2012, 08:28:44 pm
Sounds like a good time for a turbo swap.   8)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 18, 2012, 12:05:29 pm
I got about a thread and a half up when it broke off.. I was working it back and forth lots of quality penetrating oil, pisshed.

I honestly really love the k03, and I'm "never gonna give it up, never gonna let it down, never gonna turn around and desert it". Lmao. It is an extremely well suited turbo for 100% of my driving, 90% is like 75km/h and the other 10% is like 120km/h tops. It moves enough air to still have good power when you punch it at 120km/h which for my trans and tires is 3000rpm.

Yes I have been bitten by the nasty animal they call power addiction, but I was hoping to wait until spring.. haha
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on November 18, 2012, 12:19:21 pm
looks like it is somehow "completing" a ground and welding/arcing the plunger.....

good laugh for ya... got back fri... a few nights ago i turned it off to fill up and it did not die... scratched my head.. tried again and shut off... im like hmmmmmm... well sat i goto take a passenger home.. no go.. nothing.. no smoke.. but got power... need to pull mine now to see what wrong.. my guess stuck.. since it stuck open... few nights ago... but 6500ish miles.. 10 days of driving...

oil... all i can say i hate little turbo... the 10-15psi constant boost for 6k+ has caused oil consumption issue... started before towing... but a good 2500 in... ~1qt to 250ish miles... or a oil seal failed in the turbo... every boost pipe connection is moist... breather too..

she gettin few days off... deserves it... only screwed me thurs am... checked my coolent level wed.. pinched the rad cap o-ring.. this made a leak.. abt 1am in bfe i camped at wally world till i could find a solution... junk yard next day, $20 bill... parts stores = 8$ but 2 days away.. used cheap vs motel... freeken cold...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 18, 2012, 12:54:28 pm
Haha yeah man I read your thread and checked out your site! Awesome roadtrip!!

The plunger is fully rubber so I dont see arcing as the issue.. Ill be pulling number two today to check it out.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on November 18, 2012, 02:02:37 pm
Maybe that rubber is the issue? The one in my Giles pump I swear was all metal.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 18, 2012, 02:24:28 pm
How would metal seal off the fuel flow?? I an sure you just thougt it were metal. So did I until recently.. And Ive had like 75 of these apart lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on November 18, 2012, 10:34:22 pm
no, I am not 100% sure, but I swear it had the black coating peeled off to reveal a shiney substance underneath. Probably not, but could swear it was.
If yours is getting ate that bad, you should find it easily. I would wonder if the 12v is consistant. Maybe run a jumper for 3 days and pull it to see if there is any kind of wear. Easy enough to try. I am guessing that maybe if it is not getting the perfect ammount of 12v it could be half open and just eating away?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on November 19, 2012, 12:26:58 pm
The end that seals against fuel flow is rubber.  The tube the spring is in is metal.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on November 19, 2012, 02:23:11 pm
yea i can reply...... think how it works... gotta be metal... ive never seen one with rubber/plastic... oil pumps work metal on metal... all it does is restrict flow till dies..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 19, 2012, 02:42:02 pm
Quote from: CRSMP5 on November 19, 2012, 02:23:11 pm
yea i can reply...... think how it works... gotta be metal... ive never seen one with rubber/plastic... oil pumps work metal on metal... all it does is restrict flow till dies..

Lol well it is most certainly rubber!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on November 19, 2012, 04:08:53 pm
LOL!  Anyone doubting the rubber-ness needs to pull their stop solenoid plunger, scratch the end of it with a utility blade and post up a pic of the shiny metal...  ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on November 19, 2012, 11:01:30 pm
Quote from: libbydiesel on November 19, 2012, 04:08:53 pm
LOL!  Anyone doubting the rubber-ness needs to pull their stop solenoid plunger, scratch the end of it with a utility blade and post up a pic of the shiny metal...  ;)

It's shiny rubber not metal duh
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 28, 2012, 06:54:02 pm
Yeah it took me ten days.. But I have since replaced my plunger yet again with a good used OEM. So here is what I bring from my findings..

The second one has been destroyed in the same fashion as the first. Upon replacing the plunger i took a good strong light and took a peek in to the distributor head. No burs sharp edges or anything that is chewimg these up.. I also cleaned out my OUT bolt with shop air, but it was already free of debris. I have not since rechecked my case pressures, but I know I did when i installed it and I had normal pressures then. Another thing I thought that maybe the actual solenoid is at fault not pulling the plunger in enough and it getting sucked down.. So i put in a known good spare.

With a new solenoid, plunger and clean mating surface as well as out bolt.. I dunno what else it could be if it happens a third time.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on November 28, 2012, 09:03:32 pm
If you are just replacing the plunger each time, then it is the stop seliniod itself. Change the entire thing if it happens again.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 28, 2012, 09:04:14 pm
This time I have replaced the solenoid, plunger and spring with a different good unit.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: TylerDurden on November 28, 2012, 10:08:53 pm
As bizarre at it may sound, it looks like the stopper is being chewed off by the HP plunger. That would mean the bore/seat is bigger than normal, letting the end drop all the way into the plunger barrel. I'd pull it and measure the seat & bore vs. the stopper.

I'm surprised the ground up junk isn't plugging the injectors.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on November 29, 2012, 12:20:40 am
Tyler, don't you know that will be his next thread.  How do I get embedded rubber gunk outta my nozzles.  Maybe it hasn't run long enough for him to notice it. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on November 29, 2012, 12:33:31 pm
Haha. Dunno where the crap is going. Lol not entirely worried about it either.

The bore is identical to every other bosch head ive seen (75+??) and shows no sign of being enlarged. The first plunger that got chewed was the original Land Rover one. The second from a vw pump And the third also from vw. But that doesnt mean anything as it is a bosch part and all three were the same in everyway to one another.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 02, 2012, 08:19:21 pm
Well so far so good. The plunger has not been chewed off yet, fingers crossed.

It must have been a solenoid issue. Life experience gained next time I'll replace the whole thing and not just the plunger lol.

ALSO on a side note.. I am going to get pneumonia this winter. It was -5C out Friday morning and on my 80 km/h drive for 40 minutes had my car barely sustaining 160F whilst cruising... Christ
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on December 02, 2012, 08:24:27 pm
Time to block the radiator and save all that engine heat that is just dumping out the bottom.  And a new thermostat.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on December 02, 2012, 08:43:05 pm
A problem that's easily solved....   I know I post this picture alot, I really entertain myselff


(http://img.photobucket.com/albums/v306/Trev0rbr/DSCN0479.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on December 02, 2012, 09:02:51 pm
Ahh, the solution to not having those 5 MPH crash bumpers.  Reminds me of the 50's and 60's cars with the massive bumpers with the tits on them.  Must have been an engineer with a fetish that designed them and a CEO of the same mind that let them through the QA QC  process.  

Oh, they didn't bother in them days about the PC stuff now did they?


TADAH  I found one.  
http://images.craigslist.org/3k93Lb3Ha5Ia5L15Eecbqa4f85631451a174a.jpg
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on December 02, 2012, 09:09:13 pm
Jeremy, I can't believe that you're still not getting any heat.  Especially since you flushed out your heater core, checked the thermostat and powered up those coolant glowplugs. ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on December 02, 2012, 10:31:41 pm
Who was it that was going to ceramic coat all their engine parts to keep the heat in the cylinder?  I think when you figure your problem out you will have found that same solution.   Time for heated seats.  Leave the engine alone.  They do better cold. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: burn_your_money on December 02, 2012, 10:34:14 pm
Do you have all the foam around the blower motor and the heater core? Are your dash vents blocked off?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 02, 2012, 10:44:26 pm
The air is not escaping in to the cabin via that side port, it is foam sealed. The side cold air vents seal perfectly, and their respective tubes and joints also do not leak. As far as I know all air is passing through the heater core, both of the two tubes that go through the fire-wall are close enough to the same temp. And that is about the same temp as the front coolant neck as well.

I have not had the heater core out, but two winters ago when it was a 1.7 EN it had glass melting heat.

Thermostat works as it should. It is a 180F thermo and you can see it open ;) I have a mechanical coolant gauge, and WHEN it gets to operating temp it will sit at 180F all day.. Unless I am hauling ass up a hill.. I could push ~220f in the summer.

JEAN, I want to wire up the glow plugs in the coolant neck.. but I cannot get a stable idle to do so. Alternator load takes the idle down so that it either hunts hard for an idle, or chugs like 400rpm. (Never dies though)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on December 02, 2012, 11:39:08 pm
Quote from: 8v-of-fury on December 02, 2012, 10:44:26 pm
The air is not escaping in to the cabin via that side port, it is foam sealed. The side cold air vents seal perfectly, and their respective tubes and joints also do not leak. As far as I know all air is passing through the heater core, both of the two tubes that go through the fire-wall are close enough to the same temp. And that is about the same temp as the front coolant neck as well.

I have not had the heater core out, but two winters ago when it was a 1.7 EN it had glass melting heat.

Thermostat works as it should. It is a 180F thermo and you can see it open ;) I have a mechanical coolant gauge, and WHEN it gets to operating temp it will sit at 180F all day.. Unless I am hauling ass up a hill.. I could push ~220f in the summer.

JEAN, I want to wire up the glow plugs in the coolant neck.. but I cannot get a stable idle to do so. Alternator load takes the idle down so that it either hunts hard for an idle, or chugs like 400rpm. (Never dies though)
Have you tried backing out the max fuel screw a full turn or two and then readjusting the idle?  I would also go to a 195 thermostat. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 81 vw pu on December 03, 2012, 12:02:08 am
I believe I read that you deleted the egr and cooler. From what I have read these two help quite a bit with the initial warm up.
The egr dumps warm/hot air into the intake, and the egr cooler transfers  heat to the coolant.

I have an 03 alh that I just deleted the egr on and it takes about 5-6 miles to reach operating temp and its not even below 30 degrees yet.
Here's a link where Malone explains it a little better.

http://forums.tdiclub.com/showthread.php?t=305248
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 03, 2012, 12:44:58 am
Quote from: 410 on December 02, 2012, 11:39:08 pm
Have you tried backing out the max fuel screw a full turn or two and then readjusting the idle?  I would also go to a 195 thermostat.  

I have tried backing out the max fuel and turning in the idle set screw.. but I do not think I went two turns out, so I will try that tomorrow. The 195* stat will only help me if I can get the engine up to 195F lmao. I think I might take a stab and borrow my mothers sewing machine and go buy some black leather.. make a full frontal bra for it. lol Also have been looking in to easy ways to make a belly pan. It looks like it would be fairly simple with a very thin sheet metal.. cuts, bends and moulds would be a cake walk. Purely to direct air, not as a skid plate ;). ALSO! I have a hood blanket from my old diesel parts car I am going to install.

Quote from: 81 vw pu on December 03, 2012, 12:02:08 am
I believe I read that you deleted the egr and cooler. From what I have read these two help quite a bit with the initial warm up.
The egr dumps warm/hot air into the intake, and the egr cooler transfers  heat to the coolant.

Here's a link where Malone explains it a little better.

http://forums.tdiclub.com/showthread.php?t=305248

I did just very recently dump the EGR.. but only because it broke. The mounting screws backed out so it was swinging loose I guess and eventually stress cracked the accordion pipes. It didn't help make any substantially noticeable heat from what I remember last year when I did the swap in early February. Might just need to get a grid heater setup like the Cummins, amazing what just heating the intake air does though eh? Reading Malone's I had no idea it played that big a part in everything.. Crap now I am pissed it broke.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 81 vw pu on December 03, 2012, 01:15:52 am
Quote from: 8v-of-fury on December 03, 2012, 12:44:58 am
Reading Malone's I had no idea it played that big a part in everything.. Crap now I am pissed it broke.
I wish I had read that as well before I deleted my egr, but I'm going to reinstall mine as I plan to get a tune from him along with the dynamic egr.

Since you went m-tdi would you even have any egr function?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 03, 2012, 01:17:34 am
Quote from: 81 vw pu on December 03, 2012, 01:15:52 am
Since you went m-tdi would you even have any egr function?

You raise a good point, may not have been any actual exhaust gas going through to the intake.. but the cooler was still attached the manifold that sees 1000* ? lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: steveG on December 03, 2012, 09:46:54 pm
Wouldn't having the 195 deg thermostats alow the motor to heat to 195 deg befor allowing water to cool?

And isn't the major advantage of removing the egr the you don't get sout build up in the intake and keep the motor cleaner by not burning spent fuel?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on December 03, 2012, 10:06:24 pm
The 195 thermo would help if his car was reaching the lower temp to even open the T stat...fwiw though they start to open a little before the rating usually and are fully open by the rating. I don't think the 195 stat would hurt, but if the car only gets up to 160 it won't fully open the stat anyway.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on December 03, 2012, 10:49:04 pm
You'r right Lucas, the thermostats do start opening before the rated temp.  I think it's worth trying.  An easy test for the thermostat is checking how warm the rad hoses and rad are when Jeremy is at 160'.  If the rad and hoses are even a little warm, changing the thermostat will make a difference.  At 160, the rad should be cold with even the 185 thermostat.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 03, 2012, 11:32:39 pm
Yes the 195* thermostat would allow the coolant to raise to a temperature of 195F before the thermostat would open and allowing the water to flow through the radiator. HOWEVER, I have a 180* thermostat in there right now and the engine can barely sustain 160* F whilst cruising. So a warmer thermostat ain't gonna do diddly squat for me, unless I can stop airflow from blowing over my engine.

Yes that was the major point behind removing the EGR cooler, however with the introduction of ULSD there is not much left in the fuel to make much soot anymore so it is essentially a non issue. I have plans of running a top mounted T3 on this engine next year so it had to come off anyway.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on December 04, 2012, 08:56:42 am
I would put the 195 in there anyway 8v. The TDI could benefit from the heat all year. If your 180 is opening fully a shade early like say 177 then I could see it start to open at 160 and never let your car get any warmer. Cover that front end as even if the coolant isn't flowing through the rad it will help as the engine won't be getting all that cold air surrounding it.

I know what you are dealing with though, the TDI just doesn't make much heat.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 12, 2012, 06:36:30 pm
Guess what happened again guys? Turning the key off does not shut my car off.. That is three plungers that have been murdered and eaten by my pump..

What the hell is going on in there!?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on December 12, 2012, 06:59:01 pm
put a flap in the inlet manafold so you just cut the air when you want to stop your engine , then you can get rid of the guts off the stop solenoid and stop the crapy bits geting stuck in your pump and not stoping your engine/  link to solenoids http://www.thetoolboxshop.com/diesel-stop-and-advance-stop-solenoids-313-c.asp
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 12, 2012, 07:01:56 pm
Not a bad idea, it would be interesting to set up for sure. Have to hope you have good seals in the engine when it wants to suck in air ;) I would think. lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 18, 2012, 11:15:05 pm
Almost blew the o'l girl up tonight!! Showing off for some Cavalier's and lifted trucks at the local Timmies lol.

Lets just say I clearly had the best burnout and subsequent launch ;)

HOWEVER! When I let off there was popping and the exhaust sounded like I was missing on a cylinder or two..  :o ??? sounded like she was gonna stall. However a feather of the throttle and two more seconds of running and it smoothed right out and ran fine.

Scared me let me tell you, thought I popped the k03 for sure! lmao
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on December 19, 2012, 08:32:12 am
Quote from: 8v-of-fury on December 18, 2012, 11:15:05 pm
Almost blew the o'l girl up tonight!! Showing off for some Cavalier's and lifted trucks at the local Timmies lol.

Lets just say I clearly had the best burnout and subsequent launch ;)

HOWEVER! When I let off there was popping and the exhaust sounded like I was missing on a cylinder or two..  :o ??? sounded like she was gonna stall. However a feather of the throttle and two more seconds of running and it smoothed right out and ran fine.

Scared me let me tell you, thought I popped the k03 for sure! lmao
thats how my other MTDI goes when i give it to much gass ,pulls down on 2 , i still have not got to the bottom of this yet
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: srgtlord on December 19, 2012, 10:23:44 am
Maybe more fuel than the vehicle can successfully combust? Fuel/Air mixture Waaaaay too rich ?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on December 19, 2012, 11:45:47 am
mine pulls till it no longer revs... never got a miss with it... but i got double valve springs.... vs stock single... floating a valve would do that... lifter over pumps.. then gotta pump back down.. holds the valve off the seat...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 19, 2012, 02:53:20 pm
Quote from: snakemaster on December 19, 2012, 08:32:12 am
thats how my other MTDI goes when i give it to much gass ,pulls down on 2 , i still have not got to the bottom of this yet

Quote from: srgtlord on December 19, 2012, 10:23:44 am
Maybe more fuel than the vehicle can successfully combust? Fuel/Air mixture Waaaaay too rich ?

First time I have ever gotten this to happen, but not the first time I have done what I did in the parking lot ??? It was weird, and smoothed right out.

Quote from: CRSMP5 on December 19, 2012, 11:45:47 am
mine pulls till it no longer revs... never got a miss with it... but i got double valve springs.... vs stock single... floating a valve would do that... lifter over pumps.. then gotta pump back down.. holds the valve off the seat...

Seeing as how we have similar pumps, and turbo's.. the valve springs must be the only difference as to what happened. However.. our pumps are slightly different. You have done the Gov Mod, whereas mine is stock Rover governor. So there is noway the stock Rover governor would allow the 2.5 it came off of to over rev, so chances are it didn't over rev mine either. She was screaming though! lmao
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on December 19, 2012, 02:57:35 pm
Quote from: CRSMP5 on December 19, 2012, 11:45:47 am
mine pulls till it no longer revs... never got a miss with it... but i got double valve springs.... vs stock single... floating a valve would do that... lifter over pumps.. then gotta pump back down.. holds the valve off the seat...

I can testify the kubvan is a wildebeast.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on December 19, 2012, 04:47:18 pm
 ;D
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on December 19, 2012, 08:48:26 pm
I too have ridden in the toaster, 3rd is the best for the long pull.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: burn_your_money on December 20, 2012, 08:46:36 am
I'll take a stab in the dark and say partially clogged fuel filter.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 20, 2012, 05:07:04 pm
Hmm, yes. I've got the three different style of filter here that eventually needs to make its way on to the car ;) I had a few mornings where it would start and then die and no fuel would be comin through the filter.. so I had to run back in to the house and get some boiling water.

So yes, a clogged filter is probably what caused my stumble the other day.. and is probably robbing me of power!! How RUDE.

I will be using the rabbit spin on type when I redo my fuel lines, the car was a CIS gas car so the fuel lines come up on the drivers side. That is where my filter is now, behind the battery on the tower.

So I'll be looking for a 2 micron setup when I go that route as well, and run them in line with each other. Having my electric fuel pump on the pump side of both filters.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: burn_your_money on December 20, 2012, 05:26:52 pm
Wouldn't you be better off putting the pump before the filters? They push better than they pull don't they? Even if you stick a 10 micron or something infront of the pump to keep it "safe"... I don't see dual 2 micron filters being easy to pull cold fuel through.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 20, 2012, 07:23:57 pm
Sorry a 2 micron pump side of the stock filter. Not dual 2 micron. Stock filters are somewhere between 10 and 15 right?

I dunno if it matters on push over pull, either way they are moving the same fuel no? lol Pushing fuel out one side will cause it to suck fuel in to fill that void, assuming there is no air in the suction side.

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on December 20, 2012, 09:09:36 pm
no it matters. It will always try to make that 4-7psi, but if you put a filter before the pump it may not ever get there. I put my inline pump right before the filter and feed the filter with it. Works like a champ. Closer you have it to the tank to pull the better the pump will work. I found that out on my bronco years ago.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 20, 2012, 09:28:28 pm
OH, well I have had it right up before the filter, like 3 inches of line before filter.

My electrical pump sucks all the way from the tank. Its just a $15 ebay pump too. runs when ignition on, since April 2011.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: burn_your_money on December 20, 2012, 09:33:22 pm
Quote from: 8v-of-fury on December 20, 2012, 07:23:57 pm
Stock filters are somewhere between 10 and 15 right?

I thought 5-10 but I'm not sure.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on December 20, 2012, 09:51:00 pm
I think you are both correct. Something like 10-15 absolute 5-10 nominal
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 29, 2012, 08:58:17 pm
Well I blew through another plunger! This one happened a while back.. and I thought I was out of usable plungers.. but I found a few pump heads laying around that had good plungers still in them.

I checked the pumps idle pressures, as I was advised maybe excessive pressures could be sucking the plunger down through the bore on shut down. The idle pressure was around 45psi, on the low side even.

So not the issue.. but then I thought hey wait.. my pressure tester out bolt is not the one used while destroying plungers. So I looked inside my OUT bolt and found all of this;

(http://i299.photobucket.com/albums/mm307/J_holubek/20121229_135331.jpg)

All of the previous' plungers SNARF. LOL, so I have a new plunger in there with a surgically clean OUT bolt and so far a dozen or so shut-offs without issue.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on December 29, 2012, 11:26:17 pm
Nice!  Does it run any different now aside from shutting off like its supposed to?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 29, 2012, 11:27:55 pm
JF! Hard to tell, roads are hard packed snow.. I gots no tractions! Can't go above 1500 rpm without spinning my tires in every gear. Very hard to get the car to warm up ;)

Still having very odd idle issues. Cannot get it to act well cold AND hot.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 30, 2012, 02:12:40 am
On a side note, I serviced most of the electrical switches in my car. Door jamb light switches, cabin light, defrost, headlight, and 4-way. Cleaned up and slathered with die-electric. Everything works perfectly again! :)

New dash lights all around as well, I have never seen them all light up with the ignition on but lights off before. Now thats awesome.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on December 31, 2012, 09:00:50 am
woot
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: TylerDurden on December 31, 2012, 09:29:16 am
Quote from: 8v-of-fury on December 29, 2012, 08:58:17 pm
...hey wait.. my pressure tester out bolt is not the one used while destroying plungers....

So do you think the OUT bolt was plugged enough to cause the problem due to excessive internal pressure? I would think seals would be leaking before that point.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: TylerDurden on December 31, 2012, 10:31:55 am
Also, perhaps periodic inspection (weekly?) to see if any damage occurs incrementally, or if it is one catastrophic event.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on December 31, 2012, 11:54:10 am
Seals have less than an oil change amount of km's on them. New ones are super resilient to leaking.

I once messed around with a fresh reseal and a stuck pressure regulator. Maxed out my 200psi gauge no problem and physically slowed my drill.. no leaks
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on December 31, 2012, 02:43:18 pm
my out bolt full of black crap to , the only way i found out was poor starting from cold, the only fuel that was returning was from the injectors to the tank , it never advanced the pump with extra PSI that you could hear , cleened and refitted two weeks back to starting poor so will pull bolt tomorow .
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 02, 2013, 09:40:45 am
Didya find more crud up in the OUT bolt?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 02, 2013, 12:20:16 pm
Quote from: 8v-of-fury on December 30, 2012, 02:12:40 am
On a side note, I serviced most of the electrical switches in my car. Door jamb light switches, cabin light, defrost, headlight, and 4-way. Cleaned up and slathered with die-electric. All electrical components in working order.

On top of this I used some Molybdenum Dry Lubricant and I serviced all four door handles and lock mechanisms. The door handles and latches work superb, and feel better than a brand new car!  I also used some graphite spray to lube the insides of my locks (doors and trunk), I used to be a Lock Smith and we swore by graphite.

I highly recommend this as a every-winter maintenance item.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on January 02, 2013, 01:58:20 pm
I used to be a rodeo clown and we also swear by the stuff
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on January 02, 2013, 02:57:29 pm
Clowns with Spray Graphite?  So that's how they get so many it those little cars at the circus. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 03, 2013, 11:25:35 am
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130101_115221.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 05, 2013, 01:03:37 am
BTW, that picture is a 14km Hydro Electric Dam road twisting through some of the roughest terrain in Eastern-Canada. ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 25, 2013, 01:17:30 am
Car is shutting off as it is supposed to.. Such an odd problem. No one knew of the issue that I talked to, and I couldn't find any literature on it either. Car also received a 1000CCA with a 160min reserve capacity, and nearly a whole tube of die-electric ;). Mind the electrical nightmare, function>fashion with me lol.

Ghetto front air blocker! low beam to low beam.. Doesn't do much... and a new 195 stat as well.


(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130121_155134.jpg)


OEM hood blanket as well! Cut down hugely on the engine noise.


(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130121_155130.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 27, 2013, 12:40:51 am
See my air filter in this picture???

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130121_155134.jpg)

Look at it in this picture when it was new........!

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2012-02-21163707.jpg)


We went and resurrected the 90 Gasser today (http://youtu.be/_R7sDxmSGb4) (<< LINK), it has been sitting since mid August when we got the 88 Diesel to replace it. I noticed the accordion intake pipe I have physically contracting when I revved it up for the cranking while boosting the 90..  I have had the hood open literally every day since I put this TDI and that filter in, so I have really not noticed it getting darker and darker.. haha woooooa.

However, on a side not that cardboard I put in up front from low-beam to low-beam really did its job today! The car was parked 40 minutes from me, and it was a two lane highway drive at about 95km/h. It was blocking enough air to allow the engine to obtain and hold 205* F and blow some nice heat, even with the ambient being near -10C.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 29, 2013, 10:03:46 pm
Quote from: R.O.R-2.0 on February 20, 2012, 05:19:22 pm
now that it runs, start looking for replacement 020 trannies.. that TDI will kill one in short order.. guarantee it.

maybe not.. idk.. we will see whos right by next year this time!

Its this time this year KEV ;) I routinely tow 13-1500lbs with this combination.. Still holding up just the same.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on January 30, 2013, 04:01:50 pm
your radiator is tiny.  whats the deal with that?  be a man and get a real turbo, and be a man eat american bacon.

heres a real radiator

(http://img.photobucket.com/albums/v306/Trev0rbr/DSCN0032.jpg)

and heres a real cold air intake

(http://img.photobucket.com/albums/v306/Trev0rbr/P9210272.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 30, 2013, 06:30:47 pm
LMFAO TRAV! I SAW THAT LOWER PICTURE LIKE 6 years ago!!!!!!! (maybe not actually.. but you catch my drift eh?)

I was like.. look at this POS LMAO!. Awesome. So awesome.

How about be a real man and have more than 1.6L of displacement..... haha

I do believe our rads are the same size, mine is more towards the driver side to clear my 120A alternator.

YOU KNOW WHERE I STAND ON TURBO'S. SMALLER THE BETTER :) haha.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: tyb525 on January 30, 2013, 07:21:19 pm
So the cardboard is really necessary then??
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 30, 2013, 09:45:34 pm
Yes. These things make NO heat... Its brutal. lol. They do, but hauling around town with no air flow, cruising? forget about it. 160f is all it can muster without the blocker. Now I can cruise 200f no problem
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on January 31, 2013, 06:30:40 am
My mk2 just the same makes very little heat , i run a big bit of carboard in front of the rad and if i am towing i take it out (was 1.3 gasser), but my mk3 tdi golf ,that is a MTDI same engine spec as my mk2 golf , heaters are good and it dont have any heater plugs in the water systom , but my 98 A4 tdi dose , its strange , but had a nother mk2 gti with a MTDI in her and a 16v rad and the heaters are good same stats pipe work water pump good ? maby heater matrax is a bit gumed up , i never got to the bottom of it , hears a pic of my mk2 16v gti MTDI with rad etc . its a shager
(http://i12.photobucket.com/albums/a235/snakemaster1/102_5452-1.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: tyb525 on January 31, 2013, 01:47:37 pm
mine really has no problem keeping the needle in the middle or slightly above while driving on the highway. But idling and stop and go makes it fall a notch or two. I was thinking covering the rad with cardboard might cause it to overheat
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 31, 2013, 02:14:05 pm
It will overheat if ambient rises and you are relying on the stock gauge. They lie like 15* in either direction. I have done more than just cover the rad.. I have covered the whole front of my car haha.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 31, 2013, 02:15:38 pm
Also it is worth noting snakemaster and myself have DI engines, which are roughly 15% more efficient than your 1.6. Thus 15% less waste heat in to the coolant.. And less heat in the cabin.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: tyb525 on January 31, 2013, 03:14:05 pm
Good to know...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on January 31, 2013, 05:43:51 pm
This is my operating temperature... mind the groti-coffee stains! haha

-10c ambient, -18c with windchill.. cruising around town for an hour! With that full blocker up front, it blocks ALL air flow from blowing across the engine.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-01-31131739_zpsc73affe0.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on February 01, 2013, 12:04:05 am
Time for and under belly pan.  And you have the high temp thermostat in this beast right? 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: TylerDurden on February 01, 2013, 12:07:19 am
Quote from: tyb525 on January 31, 2013, 01:47:37 pm
I was thinking covering the rad with cardboard might cause it to overheat

Putting an air-blocker an inch (or more) forward of the core will block the ram air, but still  let the fans draw air through the core if it gets hot enough.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 01, 2013, 12:10:32 am
I have the high temp thermostat on the bench awaiting installation.. But I am thinking against it.. as I think it will allow things to get too toasty too quickly come 35C summer weather. Yes, I understand the thermo will still open the rad to circulation, but that will happen on average 15-20* later.. and the coolant could be well over 210f in the head by the time the thermo starts to open.. see where I am going with this? lol.

Brutal, under belly pan I am thinking about. One sheet of thin thin sheet metal with some braces (think your hood ;)) should do the trick.

Tyler, I am not sure how I would secure it there.. lol Turn the heat on high.. you'd be surprised how quickly/much my heater sucks the heat out.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: TylerDurden on February 01, 2013, 12:12:23 am
I block the grille. Same effect.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 01, 2013, 12:15:45 am
With, like a BRA? I dunno, I was cruising on the highway the other day at a fair clip and RPM and it was only going as high as 205 (96C). And it was around -5C ambient.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: TylerDurden on February 01, 2013, 12:21:31 am
On a rabbit, I'd shoot some cardboard with black paint and zip tie it to the back of the grille. I could still block the bottom half the radiator and be confident the fan could prevent an overheat.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 01, 2013, 12:23:20 am
I have an idea. I will disable the rear shroud rubber flaps for the winter/block time. That will allow the fan to pull air through those two holes from the bay, in case of an over heat.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on February 01, 2013, 12:38:05 am
Quote from: 8v-of-fury on January 31, 2013, 02:15:38 pm
Also it is worth noting snakemaster and myself have DI engines, which are roughly 15% more efficient than your 1.6. Thus 15% less waste heat in to the coolant.. And less heat in the cabin.

Actually, with that 15 % increase in efficiency, the reduction in heat loss is almost entirely to the cooling system (the heat turned into work and waste heat lost to exhaust are very similar between the two engine types).  Because of that, the heat loss to the cooling system is closer to 1/2 the heat of an IDI engine.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 01, 2013, 12:39:06 am
Wow, I knew it was less.. but not that much less.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 07, 2013, 01:42:20 am
I wish I had the time to tear my car down and do an overhaul... Guess I have to find a beater Mk 3-4-5 first eh?

UGH. Daily driving an MK1 and an MK2 has been quite the adventure. I bought this car when I was completely green to mechanics at 16.. I still have it, and have replaced every single thing, EVERY THING.

.. got big dreams .. got no time or money :( lol

Had my fuel filter plug up and leave me 135kms from home. Luckily I have CAA GOLD!!

Also it is running good GREAT on the 75/25 diesel/motor oil mixture.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on February 07, 2013, 10:23:51 am
i allwas carry a spair fuel filter in the car and tools and 5L of diesel , i ran a 1.6 td on 50% old engine oil turps and any thing it would run on , on that sucker i had 3 filters spaire , i would eat a filter every 3 days and still pull 125mph there was a rige reek from her to when you were to the max only, done this for a few weeks and then sold the engine ,back to the good old MTDI ,life dont get any beter than MTDI
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 07, 2013, 08:21:21 pm
M-TDI till I die. I think I will have this made as a decal.. Catchy lol.

SO! It has been a while since I have posted a real problem, or something I couldn't figure out with my brain tanking.. But this damn throttle has me stumped so I come to you people, lets see what you got.

Ok, it is a single external spring on the throttle lever like so;

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120916_182842.jpg)

And has the left governor setup; (Rover left, AAZ right) As can be seen, every spring appears stronger than the VW equivalent right beside.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120915_133626.jpg)


410 and I had speculated that because of the blueish smoke at idle that maybe my engine was not properly timed, and was in fact too retarded on the timing. So I referenced some other online photos and found another guy running a rover pump and he had used an AHU pulley as well. We both had our pullies referenced the same to the bracket (the pulley lock is useless when using a Rover pump and an AHU bracket and Pulley btw, rovers keyway is like 3* different than the AHU shaft) so it seemed proper. I could advance my timing all the way to the advanced position and get a good TDI sound going on but still had smoke. We assumed maybe I was a tooth off on the belt for the pump. So I moved that one forward today, and started off with the pump in its most retarded position.. as that should be close to max advance with the other belt position. Started and ran just the same, with heavy idle smoke.

I advanced it more while running, to only get MORE blueish smoke while running and no more noticeable clatter.. Why is this pump and engine combo not acting like any other diesel I have had my hands on? More blue smoke, as though I were retarding timing.. with a rougher idle. So I backed it down until I had what felt like the best sounding idle.

However! the issue does not really lie with my smoking issue as I am chalking it up to poor spray pattern on my 500k original injectors.. The issue lies with not being able to set a steady idle for the life of me.. Again, not reacting like any other Bosch Diesel I have worked on.. Like probably 20 different engines, all with varying pump setups.. no issues. Until this damned abomination lol.

No matter where the timing is, where the throttle stop screw is, where the max fuel screw is OR EVEN WHERE THE throttle arm to throttle shaft orientation is.... I cannot get a solid lower idle at all. The only idle that will hold solid when I turn on any electrical load sounds like it is well over 1100RPM and has my tiny k03 sounding like it is boosting a few lbs at idle for Christ's sake. I can set a lower idle where I cannot hear the turbo spooling over the engine noise, but then even using my windshield wipers will put enough load on the alt to bring the idle down to a chug-chug-chug of what sounds like 450RPMs.

What in the hell is going on?

(https://encrypted-tbn0.gstatic.com/images?q=tbn:ANd9GcQFXk03rnbh8ZQSfRLyFaWc-FdBEDDx1QO_5so4KPXB4jTriOOY)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on February 07, 2013, 08:44:06 pm
i took out one of the idle spring behind the cup thing and that helped me a tage, i had a shorter rod that holds the gov springs and it was a bit like the greef your geting at one point  , i say a M  i say a T i say D  i say a I , going to get some chear leaders round to shout it out the next time we get the vdubs to gether and a we dram of  Glenmorangie , cheers
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 07, 2013, 10:09:35 pm
Yes, but what of this??

Quote from: Jeremy
I advanced it more while running, to only get MORE blueish smoke while running and no more noticeable clatter.. Why is this pump and engine combo not acting like any other diesel I have had my hands on? More blue smoke, as though I were retarding timing.. with a rougher idle. So I backed it down until I had what felt like the best sounding idle.

What do you have yours timed to mate? And for clarification, you have the lowest most spring in my governor picture removed?? Would it be possible to get a video of one of your rigs running?? Just so I can hear another m-tdi for reference? Thanks a bunch.

It is just a sihtloaf of misery with this damn car lol. Shoulda went E-TDI..! GAH. \

Here is another thing.. the idle differs greatly from cold to warm.. Like, whatever idle setting that is good warm? Will not hold an idle when you first start it or until it warms up. If you set it to idle cold? Then it screams at hot idle.. I am at wits end, I have tried it all and nothing is reacting as it should.

#fedup

HAHA #hashtags #for #the #win (srsly tho, kiddddinglol.)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on February 07, 2013, 10:14:09 pm
The E tdi has the computer to adjust idle warm and cold. You may have to settle on a comprimise. The E tdi are supposed to be timed with the vag com when warm-final time not mechanical. Maybe you idle should be set the same.
I rode in the toaster and it went well, sounded a bit loud when cold but the idle was ok I thought.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 07, 2013, 10:23:54 pm
Yes, the computer changes the timing and the idle based on fuel temps, air temps, coolant temps and load.

If I set it where I want it warm, it will idle at 400rpm cold. It will never die out, but it won't hold a high idle.

If I set it where I want it warm, even using the window wipers will put enough load on the alternator to bring the idle down to chug-chug-chug of 400-450rpm.

Chris and I are using a different rover pump, his has a completely different style of governor assembly IIRC. I think like a Cummins, the one spring un-caged.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on February 08, 2013, 08:21:27 am
4 of my MTDIs will start from cold 650ish rpm and then warm 800 rpm
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 09, 2013, 01:04:18 am
650 might be more accurate as to what my idle is, so alright I guess that is something I will have to live with. Shakes an mk1 something horrible lol.

I could not set an idle of 800RPM and get it to hold that idle when I turned on anything electrical.. Dunno what is up.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on February 09, 2013, 12:45:58 pm
I set idle at 1k in mk1s. They just shake too much any lower.  I'm thinking since the governor is designed for a much larger engine, that once u turn the fueling down so that it keeps a much smaller engine at the correct idle ,  what used to take a small amount of adjust from the governor to compensate for small amounts of added load now takes much more since the fueling is turned down so much for idle.  Maybe u already no that and it's only theoretical from my understanding of these pumps, but perhaps u gotta swap over the weights and everything from an aaz or 1.6 if that's even possible.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on February 09, 2013, 02:02:19 pm
It would be possible to swap the weights/governor but I don't think that's the issue.  The mTDI pumps I build from Cummins base pumps have fairly solid idle speeds. 

I also have my idle raised a fair amount in my Rabbit to alleviate the vibration. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 09, 2013, 06:10:17 pm
Yes, and those 12mm pumps are from like 3.9L engines are they not? So it would seem the "larger governor weight" idea doesn't really seem to be the issue either.

So Andrew, if you have a solid and consistent idle can you take the idle screw and back it out to bring the idle way down consistently?? Or does it just get to a point and drop off?

The weird thing is this fellers..

I have another mk1 diesel with an AAZ and k03 combo just like mine but IDI in my driveway to compare with. I cannot get mine to idle consistently like I can the AAZ.. Or the 1.6 TD I also have to compare with. It can either be what I feel is too low and chugging, or what I feel is too high and screaming. One or the other... no in between. I also have a throttle hang between shifts.. Not so much that it hangs the idle, but takes a long time to come back down and I am usually already engaging the next gear..

I have set a bunch of these, Like I say I have two perfectly running other diesel in my driveway that will start and idle perfectly right away with out the use of the cold start.. they could even both have the fan and defrost on.. no issue.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 09, 2013, 06:12:44 pm
Quote from: libbydiesel on February 09, 2013, 02:02:19 pm
I also have my idle raised a fair amount in my Rabbit to alleviate the vibration. 

What turbo do you have? The k03 is screaming at anything over what feels like 900rpm..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on February 09, 2013, 07:34:32 pm
I had one used Cummins 4BTA pump that I built into an mTDI pump that had a difficult idle.  It would either idle high or very low.  If I set it at a reasonable idle it would idle low to start and then idle high.  I sounds much like your issue.  I figured that the idle spring was weak and that the low idle was when only the idle screw was engaged and the high idle was when the idle spring was fully compressed and the governor spring was starting to come into effect.  I solved it by stretching out the idle spring. 

The dual idle spring setup may be what is giving you fits.  You may want a single stronger spring instead. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 09, 2013, 09:26:31 pm
Alright. Thank-you.

I will be taking the pump lid off tomorrow and checking that out. Everything else about the governor is alright, so I guess it is just the idle spring.

Weird however, as engine size should not matter? I assume the 2.5L would have actually idled around the same RPM which means the springs and governor weights should still have the same effect to the throttle. Did your 4BTA have a dual idle spring? I will find my toughest idle spring, stretch it out and give it a go lol.

I like how it lopes at the lower idle I can set, and that the turbo is not spooling 23psi at idle lol.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on February 09, 2013, 11:31:12 pm
The mTDI pumps I build from new ones have a single idle spring and are solid on the idle.  I don't remember if the one that gave me trouble had an idle spring at the end of the governor spring and one in the control lever assembly or just one.

Oh, and my rabbit has a VNT15 on it but I haven't yet made the vane control for it so it is just wide open for minimal boost. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 09, 2013, 11:36:28 pm
Hmm, good point. I am not sure if my rover one has one in the control lever or not.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 10, 2013, 08:21:52 pm
I could not see if the control lever has a spring in it or not, the fuel was too dark. I did however swap in a 1.6 idle spring that I had stretched out quite a bit.

What happened?

I now have a perfectly acting idle.. Jesus, what a pain in my ass. I have the throttle lever to throttle arm orientation so that the governor cage is at its most relaxed position ie. fully rotated CW.

HOWEVER! Now I have a very weak pedal.. Let me try and explain. I now have to push the pedal way further down to achieve the same RPM for whatever gear. Not like there is useless throttle at the beginning either, it blips the throttle with a faint touch. But the throttle is less effective? It's weird for sure.

I can push the pedal down and get good amounts of black. The idle screw is bottomed, and I can't go another spline on the throttle arm.. backing out the fuel screw brings the idle down.

Its leaps and bounds better, just gonna have to frig around a bit more. lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on February 10, 2013, 08:32:23 pm
What is the normal position for the throttle arm?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 10, 2013, 09:03:19 pm
Varies for each pump I have seen. I have seen different length governor shafts so it would change based on that.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on February 10, 2013, 10:18:10 pm
Use an idle spring that is a bit less stretched out and shim behind it so the lever doesn't have to move as far to get to the intermediate and main springs.

Or just get used to driving it.   
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 10, 2013, 10:19:46 pm
Stretched it too far.. DAMN IT lol. I figured I might have, I don't think I have another a.6 idle spring around.. I'll have to look.

so you think the rovers springs were so soft that the control lever was bottoming them out and they weren't able to act properly?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on February 10, 2013, 10:24:46 pm
I'm not sure if it was a matter of both springs being too weak and bottoming out before you got a decent idle or if the weaker of the two was too weak and the stronger one too strong and the desired idle right between the two.

Do you have any room to shim the current spring before it starts being compressed when installed?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 10, 2013, 10:25:55 pm
Shim it how? like to make the idle spring take up a larger space?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on February 10, 2013, 10:29:09 pm
Pull the little clip off the end of the shaft and add a few washers to take up some space but only if there's space to eliminate without compressing the idle spring in the installed and relaxed position. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on February 10, 2013, 11:27:54 pm
we ever figure out what the goofy lever on throttle arm to side of pump does??

(http://www.crsmp5.com/2012_photos/1_16_12/6.jpg)


cause even though i added 4 washers to my gov spring.. had to back down the idle way far.. mine sounds like its got a cam for the 1st min or so depending how cold it is.. 30 sec 80*f  2 min at 40*f...

ive not had smoke issues, not screwed with soot screw yet, egt max 1250 under ~21psi even when the head heat soakes and starts to bring coolent and oil temps up.. mine set at 118 also where most say 130ish to start.. i wanted little more retarded when i was breaking it in.. but been happy so why mess with it..

(****disclaimer, headed west out of denver it hit 1450 and now uses qt oil in ~200ish miles, but i think it was due to altitude, assume cooked oil seal on exhaust side of turbo, no puddles/runaway/new oil spots on back, but thirsty it is)

but tripple digit down highways, 5k in 5th.. 1250 max is most ive seen..

so with that imo my mix must be pretty good.. towed car back, up down hills.. stayed away from denver west side.. no temp probs.. more then enough power.. idle great.. so can it be due to my silly lever thing?

sorry just had bowl.. so ignore stuff in middle..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 10, 2013, 11:35:18 pm
Were you doing like 150 mph?! 5000 in 5th on the CTN 02A ?!?! AWESOME and SCARY lol

I don't have an inter cooler yet, or the 02A yet.. SO I cannot say what is up. I am pretty sure I can slip my current new 210mm clutch no issue in 5th gear.

I was gonna gov mod it while I had it open, I'll prob do that tomorrow when I frig with the idle spring again and install my oil catch can.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 10, 2013, 11:56:43 pm
btw, Chris.. that was the most understandable post to date ;D lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on February 11, 2013, 12:07:23 am
Quote from: 8v-of-fury on February 10, 2013, 11:56:43 pm
btw, Chris.. that was the most understandable post to date ;D lol

After I started reading it I actually scrolled back up just to make sure who the post was from.   ;D
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on February 11, 2013, 12:51:36 am
no idea what 5k refers too to be honest, when my tach runs out, it starts back over at 4k.. and goes up again.. :P idle says 1800, 4k is 72ish mph in 5th.. 55ish in 4th.. its my referance point due to speedo innacuracy, hell no work at all now.. and i no own gps.. that belongs to legless..

but yes.. i know its been in tripple due to gps.. how fast.. no idea.. always do that silly stuff alone.. it was also 1st night breaking it in... after i backed it down from 28psi.. it really runs well and never saw past 1250 either.. but i backed it down.. one day ill buy my own gps for that and a go pro camera.. till then.. i know its been past gps tripple.. was not foot to floor when i did that.. and it was a pull in 5th from 75.. under 1 mile.. :D wind picked up and i backed off.. :P debate night was balls to wall maxed out in under 2 miles on freeway 3am... doors open... othh times..:D

too bad almost outta the 4bills a oz stuff... did not buy much to start with.. but so much smoother then the 1.25/oz stuff... i miss cali.. easy to mix it up there.. 4bill stuff hard to come by here.. and i gots a cookie and a cornbread muffin too.. like i was in cali or somethin.. but i paid for it.. in cali the stores tend to give up a cookie with purchase.. till other day not seen that here.. hell 1st time ever seen food here... but supply gone so will have to see if when i can get more.. back to cheap..

think of it like beer vs good booze.. one will get you a feel.. but your thoughts are different..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on February 11, 2013, 07:16:51 am
Quote from: 8v-of-fury on February 10, 2013, 11:56:43 pm
btw, Chris.. that was the most understandable post to date ;D lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 21, 2013, 01:21:10 am
I have a chirp at idle, that if I grab the serp belt tensioner arm with vice grips while running and remove the smallest amount of pressure.. it stops chirping? The tensioner pulley was replaced within the last year..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on February 23, 2013, 05:50:01 pm
Quote from: 8v-of-fury on February 21, 2013, 01:21:10 am
I have a chirp at idle, that if I grab the serp belt tensioner arm with vice grips while running and remove the smallest amount of pressure.. it stops chirping? The tensioner pulley was replaced within the last year..


mine did that, but then i put american bacon grease on the belt+tensioner and problem solved.  let me know if u cant get the american stuff up there.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on February 23, 2013, 05:55:24 pm
Quote from: Trev0rbr on February 23, 2013, 05:50:01 pm
Quote from: 8v-of-fury on February 21, 2013, 01:21:10 am
let me know if u cant get the american stuff up there.

 :D
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 24, 2013, 08:45:26 pm
Quote from: Trev0rbr on February 23, 2013, 05:50:01 pm
Quote from: 8v-of-fury on February 21, 2013, 01:21:10 am
I have a chirp at idle, that if I grab the serp belt tensioner arm with vice grips while running and remove the smallest amount of pressure.. it stops chirping? The tensioner pulley was replaced within the last year..


mine did that, but then i put american bacon grease on the belt+tensioner and problem solved.  let me know if u cant get the american stuff up there.

You put grease on the belt too??? INTERESTING.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on February 25, 2013, 01:00:02 am
Wait till the rats find it.  Or a raccoon. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: srgtlord on February 25, 2013, 02:40:10 pm
I had the same chirp, until I put in new bushing and seals , and replaced the tensioner in the serp tensioner. I had to replace the arm as well because mine was well worn... That chirp is the tensioner arm grinding away at the bushing..... You can find all the parts on idparts.com
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on February 26, 2013, 01:26:05 pm
***e. Well it is intermittent, weird.

Should I just replace everything, like the arm as well? or take chances and say its gonna be 'arrrry
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 15, 2013, 12:50:45 am
I gots plans ;)

I think the 11mm and .216's will spool this no problem.

GT2056 180hp @ 22psi

Dots from left to right are as follows, 1000, 1100, 2300, 3500, 3750, 4000, 5000, 6000.

(http://www.squirrelpf.com/turbocalc/graph.php?version=4&pr0=1&pr1=1.07&pr2=1.8&pr3=2.53&pr4=2.53&pr5=2.53&pr6=2.53&pr7=2.53&airflow0=2.1&airflow1=2.5&airflow2=8.5&airflow3=17.5&airflow4=18.6&airflow5=19.4&airflow6=24.4&airflow7=29&product_id=24)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: vanbcguy on March 15, 2013, 09:09:44 am
Everybody's new favourite turbo!! ;)

Considering the price for a brand new one (they go for about $850 everywhere I've seen) is only juuust over double a rebuild for an old K24/T3 it's a damn good deal.  They're a bit smaller than the K24/T3 too so faster spool times.

Decided on a manifold yet?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on March 15, 2013, 11:49:20 am
jeremy u shold sell me your 88 for 850$ to fund your new turbo.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 15, 2013, 01:04:13 pm
Quote from: vanbcguy on March 15, 2013, 09:09:44 am
Decided on a manifold yet?

Not yet, still in the planning stages. I have a T3 here that will makes it way on to the engine to replace the k03 first..

Quote from: RabbitJockey on March 15, 2013, 11:49:20 am
jeremy u shold sell me your 88 for 850$ to fund your new turbo.

It's the woman's car mate ;) She's got the two silver mk2's ;D. My 84 in the middle :)

(http://i299.photobucket.com/albums/mm307/J_holubek/88%20Jetta/20120819_185702.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on March 15, 2013, 02:16:22 pm
what about the coupe.  and whats she need 2 of the same thing for haha.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: the4ork on March 15, 2013, 07:24:15 pm
great thread, had fun reading it. I was a little dissapointed you didnt go full electric, as it would have been a more helpful read for me as that is what i am in the middle of.

where did you learn all the pump stuff? i came across this thread searching for pump DIY's on how to upgrade my 10mm pump.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 15, 2013, 09:33:24 pm
Quote from: RabbitJockey on March 15, 2013, 02:16:22 pm
what about the coupe.  and whats she need 2 of the same thing for haha.

Coupe is my bro's daily AAZ.

Quote from: the4ork on March 15, 2013, 07:24:15 pm
great thread, had fun reading it. I was a little dissapointed you didnt go full electric, as it would have been a more helpful read for me as that is what i am in the middle of.

where did you learn all the pump stuff? i came across this thread searching for pump DIY's on how to upgrade my 10mm pump.

I was gonna go full electric.. Looking at buying several full running TDI's for $600 a piece in the near future.. So the coupe and the 88 might get some LOVING. The coupe will probably go MTDI, but the 88 will more than likely keep the hydro clutch and go full electric. Depending on whether I find more Rover pumps or not ;).

The pump stuff? All self taught and some very appreciated help from 410 within the last 1.75 years ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 16, 2013, 02:12:23 am
Been doing some brain-tanking..

(http://www.squirrelpf.com/turbocalc/graph.php?version=4&pr0=1&pr1=1.07&pr2=1.55&pr3=2.03&pr4=2.03&pr5=2.03&pr6=2.03&pr7=2.03&airflow0=0.014&airflow1=0.021&airflow2=0.035&airflow3=0.053&airflow4=0.076&airflow5=0.097&airflow6=0.123&airflow7=0.146&product_id=107)

My k03 right now with the 13-15psi I have the manual boost controller set too (according to the squirrel performance turbo calculator) should be producing about 125hp right now.. non-intercooled with no smoke too.. It shouldn't be over spooling the turbine until about 4900-5000RPM. Which I don't think this engine has seen close too in the year it has been in my engine bay.. lol! Working it out on the Gearup.com, the engine has likely never seen above 4300. I have a tach and speedo eventually planned, have had neither for the year its been in! Go by seat of the pants lol.

My updated Squirrell Performance settings (http://www.squirrelpf.com/turbocalc/index.php?version=4&target_peak_power=200&pr_ref=14.45&engine_disp=1.9&engine_disp_factor=0&target_af=18&bfsc=.36&max_ic_loss=.5&rpm_redline=5750&rpm_peak_power=4750&rpm_max_boost=2400&rpm_min_boost=1100&vol_1=89&vol_2=93&vol_3=90&vol_4=87&vol_1=89&vol_2=93&vol_3=90&vol_4=87&intake_temp_1=70&intake_temp_2=100&intake_temp_3=110&intake_temp_4=120&turbo_n=1&map_sel0=76&map_sel1=77) spread across the Garrett GT2056, and the Volvo Garrett T3 50 trim.

Similar power points I picked, and some backup on why I did ;) An ALH making that power with mods listed..

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/19TDI200hp320TQ_zps66dba3df.png)

Same settings 200hp @ 17.8psi;

GT2056

(http://www.squirrelpf.com/turbocalc/graph.php?version=4&pr0=1&pr1=1.07&pr2=1.65&pr3=2.23&pr4=2.23&pr5=2.23&pr6=2.23&pr7=2.23&airflow0=2.2&airflow1=2.6&airflow2=6.3&airflow3=11.7&airflow4=16.9&airflow5=21.6&airflow6=23.6&airflow7=25.2&product_id=24)


Volvo T3 50 Trim

(http://www.squirrelpf.com/turbocalc/graph.php?version=4&pr0=1&pr1=1.07&pr2=1.65&pr3=2.23&pr4=2.23&pr5=2.23&pr6=2.23&pr7=2.23&airflow0=2.2&airflow1=2.6&airflow2=6.3&airflow3=11.7&airflow4=16.9&airflow5=21.6&airflow6=23.6&airflow7=25.2&product_id=77)


As can be seen, they can support 200hp on my setup. The T3 50 Trim does it well, and the GT2056 better than that again. But they are both gonna cost me upwards of $750 :(..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on March 16, 2013, 03:44:18 pm
let me pop ur bubble: vw is 35 trim.  hahaha

(http://i40.photobucket.com/albums/e208/schmeldenhoffer/car%20pics/T3map7.gif)


here is the thread that pictures is from, also it is a good thread to see the difference between k24 and t3

http://www.vwdiesel.net/forum/index.php?topic=19545.5; (http://www.vwdiesel.net/forum/index.php?topic=19545.5;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 16, 2013, 04:33:30 pm
That is not what I found through my research.. ?

I found alot of people reference it as a 45? And some a 40.. never a 35 though.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on March 16, 2013, 05:21:04 pm
Easy solution, measure.  I just did and came up with 36 trim for the VW T3...  How does your T3 compressor measure, 8v? 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 16, 2013, 05:26:14 pm
Ahh goood point Andrew.. I'll look in to it tonight. It's hanging off the back of the 1.6TD parts engine haha.

35 Trim 175 @ 14psi.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/35trim175hp_zpsdff182f3.png)

The line is not supposed to go down as it goes right.. I am just really jittery right now!

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/T3map7_zps55f59cfa.gif)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on March 16, 2013, 05:57:28 pm
My post didn't work but yeah I have measured 3 of them they are 35 trim or close enough to be called 35 trim haha.  That's why I like the idea of the hybrids cause they're cheap to build and should e good. the part I think is the most antiquity and kills efficiency is the turbine and wheel and housing.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on March 16, 2013, 05:59:29 pm
See people can be wrong but Rabbitjockey cannot.  I think alot of people get confused because it comes in a .42 at compressor housing, which is the same as saabs and Mercedes and alot of other cars that come with a 45 trim wheel.  But actually u can get any trim t3 in that housing my friend even has a 60 trim in a .42ar

This is vw compressor wheel next to a 45 trim Mercedes wheel which is actually going to be installed on Lucas car

(http://img.photobucket.com/albums/v306/Trev0rbr/Photo0291.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 22, 2013, 12:30:11 am
Seems a 50 trim T3 is going to be the most economical bet, for my budget build-up.

6000 is an extreme red line but apparently Chris pulls 6k in his Toaster Oven ;). Just goes to show it will still be like 67.5% at 6000 rpms pushing a mere SUPER COLD 20psi with the help of the AWIC I will be getting :)

50 Trim 175hp @ 20.7psi

.42 AR Compressor
.48 AR Turbine

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/19175hp207psi_zps659d49e1.png)

(http://www.squirrelpf.com/turbocalc/graph.php?version=4&pr0=1&pr1=1.07&pr2=1.75&pr3=2.44&pr4=2.44&pr5=2.44&pr6=2.44&pr7=2.44&airflow0=2.1&airflow1=2.2&airflow2=6.9&airflow3=13.8&airflow4=16.8&airflow5=19.4&airflow6=23.2&airflow7=26.6&product_id=77)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on March 22, 2013, 08:01:30 am
Copy cat
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 22, 2013, 02:08:26 pm
Quote from: RabbitJockey on March 22, 2013, 08:01:30 am
Copy cat

You're the one that put my mind on it.. lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on March 22, 2013, 04:23:59 pm
It looks like you're over the surge line, no? 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 22, 2013, 05:04:37 pm
Its right on it, i dunno.. It seems like it could be alright no?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: the4ork on March 22, 2013, 07:14:55 pm
you can order some of the t3/t4's with a .36a/r turbine as well, and maybe with a stage 3-5 wheel you could still flow enough.

IIRC the .48 hotsides dont start to restrict high HP 16v's until the high rpm range. back from my turbo gasser days, a .63 was a must to break 450whp.

Ive often toyed with the idea of a 45 or 50 trim t3/t4 .36ar and internal wastegate.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: the4ork on March 22, 2013, 07:25:27 pm
can you order all the GT turbo's without ball bearing?

a 2871 would be cool, provided you can get a turbine a/r small enough?

(http://www.theboombopshop.com/v/vspfiles/photos/garrett/GT2871R-743347-1-C.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 22, 2013, 09:48:39 pm
This is the one I am looking at;

Internal waste gate
.42 AR Compressor, wheel: exducer: 60.41mm/ inducer: 43.20mm
.48 AR Turbine, wheel: inducer: 62.86mm/ exducer: 45.74mm

(how is that a 50 trim? LOL)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on March 22, 2013, 10:21:41 pm
[(43.2^2)/(60.41^2)]*100
[1866.24/3649.37]*100
51.14 trim

I wouldn't want any realistic points on the map over the surge line. 

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 22, 2013, 10:39:30 pm
Ahh I did not know this mathematical equation lol.

Well in all honesty, I do not know any realistic RPM points for my engine I guess lol. I suppose max boost could probably come on later than 2900.. but that would be fueling dependent wouldn't it?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on March 22, 2013, 11:05:59 pm
I wouldn't sweat being that close to the surge line. All te lines are fuzzy on te map depending on environmental changes there is wiggle room.    If half of the full boost rpm range was in it then yeah I'd be worried
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 22, 2013, 11:18:34 pm
I did both tie-rod ends last week, they were dangerously close to letting go! LOL. I also found I need new bushings in both sides of the rack.. no biggie though, cars only 230K.. 65k were me and I am sure they haven't been done which mean I just push new ones in :). Friggan these are year old axles.. already rips in the boot and I have had to replace both of them in a year. Good thing I spent the coin and went with lifetime warranty! lol. They almost didn't warranty this one because it is older than a year, and the boot was ripped. I am like clearly there is no dirt that could have gotten in this hole to cause the clicking I hear...

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-18154545_zps457b310b.jpg)

The bullsiht I am dealing with in my trunk at the moment... Is there supposed to be a drain down in the fender wells ?? That is rust converter not water right now.. lol But there is a lot of dirt accumulated down in there isn't there!?

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-22143133_zpsf775e96c.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-22143138_zps267e1ac5.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-22143145_zps7dc0a01c.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: Rock3tman on March 24, 2013, 03:48:04 am
My 1983 Jetta trunk looks almost identical...I'd check your body sheetmetal at top of left and right taillight housings (midway around side corners) for little cracks.   My water came in either there and/or at the failed trunk lock gasket/escutcheon.   My trunk gaskets are fine.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 30, 2013, 01:32:11 am
Sorry I missed this reply Rock3tman! I am planning on a full exterior body work and paint this summer, so I am sure it will be addressed then. Seems it has been leaking a damn long time to rust it out like that.

Replaced my other lifetime axle today and went on a 4 hour road trip to make sure everything was tickledeboo. Dusty out! Got like three friggan oil leaks going on too.. Two oil and one tranny.. Like FML. Where the hell is the oil on the passenger side coming from? Doesn't look like valve cover, cam seal? Only other thing up top right.. The tranny leak pisses me off as all those seals are only a year in service.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-29135545_zps1803992a.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-29124235_zps72ad1e41.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-29124240_zps6e8032cd.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-29124253_zps7bcbc759.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-10170755_zpse17a3d64.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-09114245_zpsd7c9dab5.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 30, 2013, 01:42:52 am
I then, while I was under there.. I adjusted my.. well attempted to adjust my shifter.. why is this so bent at the relay lever and selector lever? Seems like its a little bit too far over. I got it mostly adjusted, all super lubed.. omg its amazing. Need a few new bushings, and to finish adjustment tomorrow (ran out of lightsss) and this thing will be Ferarri shifter status lol.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-29165024_zpseb692ab0.jpg)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-29164914_zpsbff31ec6.jpg)

Like my exhaust?? ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on March 30, 2013, 02:09:17 am
It is bent like that because somewhere along the line someone dropped it off a jack or ran over a large rock or stump.  Take it off front and back and straighten it out you will have even greater shifter goodness when you do.  Be assured, I have done it and it makes a world of difference for 1st and 2nd lining up correctly. 

Hey stuff happens.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 30, 2013, 02:17:25 am
Straighten the rod? Or is it just the Selector Lever that is bent on the rod? I gave it a go while still in the car, but until I get new bushings if I go that route.. it will wait lol.

I may upgrade to the 02A before too long if everything plays out, so bye bye rod shifter.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on March 30, 2013, 02:33:07 am
I think the rod is bent behind the bracket.  Trying to rebend it in place is just going to mess up the bushings.  You really need to take it out and look down it or lay it flat on something very straight.  Got a 6 foot level?  That is what I used to see the bump. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 31, 2013, 04:19:35 am
I did not remove the rod to re bend, it is perfect where it is now. No guess that every gear is exactly where it should be ecery time. PERFECTION.

Lathered some Teflon based lubricant on all the joints, stuff is designed to be submerged in water on marine stern drive lower ends.. so its not coming off till I wipe it off.

Its literally a brand new car right now. New struts/shocks springs and mounts, new tie-rods, got it aligned, new brakes at all corners, got my summer wheels on and balanced, shifting aligned..

Gonna do an oil change, and at the same time pull the pan and check things out in there, Probably pull all the crap off the passenger side of the engine and stop one of two oil leaks.. I will then maybe think of addressing the tranny leak, wth why is that flange seal leaking? I put a new green sleeve in and everything. What a piss-off lol. So if I do that, I'll probably fill it back up with syncromesh :) and enjoy the extra shifty feels from that too.

Regarding the oil change.. I run a 0w40.. its expensive haha, if I cannot nip this damn oil leak.. I may consider thicker oils or DINO :o Engine calls for a 505 right? But the same turbo on my brothers AAZ can run a 15-40 DINO, so why can the AHU not?

Quote from: TDIclub
Specifications - The oil specified for use in the Volkswagen TDi for current models meets the "API Service CG-4" rating. This mark means that the oil has been tested for use in Diesel (C = compression ignition) engines to meet the requirements of a test level called "G" in a 4-stroke engine. The oil may also have been tested for use engines fueled by gasoline, methanol, propane, or other fuels ignited by a spark plug (S = spark ignition). The "S" ratings (SG, SH, SJ, etc.) have no bearing on the suitability of the oil to protect a Diesel fueled engine from the special demands imposed by the higher compression ratios and the tendency for all diesel engines to place soot in the oil.

Since there is little difference internally between the earlier and later engines, it is only prudent to use oil meeting the latest standards, even in the earlier models. The latest standard is CH-4, and the one previous to that is CG-4. Many oils which have CG-4 printed on the packaging actually meet CH-4, but due to the time taken to use up old packaging, it is only the labeling which is not up to date.

Quote from: TDIclub
The information in this section refers to API service classes which are North American standards.  Different standards for engine oils are used in Europe and elsewhere. It should be noted that since this vehicle was developed in Europe, it is much easier to determine whether a European engine oil is suitable. Any synthetic oil meeting the specification VW 505.00 is suitable for use with this engine with the full recommended oil change interval.  The VW 505.00 is the manufacturer's own specification, but in North America this specification is rarely seen, so we must rely on the API grades.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 31, 2013, 04:22:03 am
EDIT:

Quote from: TDIclub
Oils which are suitable for the full recommended oil change interval in all climates include, but aren't limited to:
Mobil Delvac 1, 5w40 (full synthetic, a reformulated version of Mobil 1 which is intended for diesel engines)
Chevron Delo 400, 5w40 (full synthetic version)
Shell Rotella T (full synthetic version, not to be confused with Rotella SB synthetic blend or regular Rotella T non-synthetic)
Amsoil Series 3000, 5w30 (full synthetic, CH-4 rated)
Amsoil High Performance, 10w40 (full synthetic, CH-4 rated)
Amsoil semi-synthetic 15w40 (CH-4 rated and high quality, but almost as expensive as the full synthetic, and higher viscosity at low temperatures)
Redline, synthetic version (make sure you get the type meant for diesel engines, with the CG-4 or CH-4 rating)

In warm weather, a good-quality non-synthetic oil meant for diesel engines with CG-4 or CH-4 ratings may be used. They're not suitable in cold weather due to reduced cold-pumping properties, and it's prudent to shorten the oil change interval because non-synthetic oils may not resist breakdown at high temperatures as well as the synthetic oils (remember that turbocharger). These oils are much easier to find. These include:
Mobil Delvac 1300, 15w40
Shell Rotella T, 15w40
Chevron Delo 400, 15w40

WOOHOO, Friggan right! I am getting me a $13 bottle of oil Monday morning! I'll switch back to probably a 5w40 for next winter.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on March 31, 2013, 07:44:18 am
Quote from: 8v-of-fury on March 30, 2013, 02:17:25 am
Straighten the rod? Or is it just the Selector Lever that is bent on the rod? I gave it a go while still in the car, but until I get new bushings if I go that route.. it will wait lol.

I may upgrade to the 02A before too long if everything plays out, so bye bye rod shifter.

if you do...  use an 02j shift tower, tt short shifter and I hear a 99 beetle shifter boxs bolts nicely into a mk1.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on March 31, 2013, 06:22:04 pm
looks like your camshaft seal is leaking , what i do is take the camshaft cap off take the seal out and run a craft nife round the back outer part of the seal , so when you refit the seal it sits 1.5 mm further in to the head and no more leak , if you look at the camshaft it has a were mark on it .53mm where the seal runs
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 31, 2013, 07:41:07 pm
Can I fill and grind down that groove?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on March 31, 2013, 09:50:45 pm
I think his method of moving the seal to an unworn part of the shaft is the easier fix.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on March 31, 2013, 09:59:09 pm
I reread his post, seems way easier now lol. I dunno how I read it before but it seemed.. I don't know, harder than just shaving the seal lol. But yes that works well. I will be doing that then come tomorrow :)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on April 01, 2013, 09:05:23 am
You could also install a sleeve.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on April 02, 2013, 07:01:58 am
yea seal sits further back on the camshaft , so the lip of the seal sits on a fresh bit of the cam , when you get her out you will see the camshaft has a bit of a grove in it , you would think the seal would only were , dont take to long to do and a cheep fix .
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 03, 2013, 12:01:58 am
oohh ahhh, POWAHHH (http://youtu.be/aVq6MdQ9Czc)  ;D
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: burn_your_money on April 03, 2013, 04:15:51 pm
Nearly double the posted limit in a residential area? Do you not like driving? ;D
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 03, 2013, 05:49:11 pm
Quote from: burn_your_money on April 03, 2013, 04:15:51 pm
Nearly double the posted limit in a residential area? Do you not like driving? ;D

Not residential, I am in a factory area after hours. Yes double the limit, that is why I did it there! haha.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 08, 2013, 11:23:26 pm
Look what I got coming :)!!

(http://img.tapatalk.com/d/13/03/22/etapuher.jpg)
(http://www.siliconeintakes.com/images/product/water_air_kit_3_picture.jpg)(http://www.siliconeintakes.com/images/product/aluminum_smallkit_picture.jpg)(http://www.siliconeintakes.com/images/product/reducer_black_picture.jpg)(http://cdn.shopify.com/s/files/1/0182/1073/products/med-4cyloilcoolers_large.jpg?3138)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on April 09, 2013, 05:31:18 am
you need a flange or a race pipe for that intake.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 09, 2013, 07:29:47 pm
Quote from: bbob203 on April 09, 2013, 05:31:18 am
you need a flange or a race pipe for that intake.

No, I was just gonna run it that way. lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on April 09, 2013, 07:51:19 pm
dude just run it non turbo with a cone filter taped to.  :D
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 10, 2013, 06:34:24 pm
Chill, I got this. lol

http://www.summitracing.com/parts/hda-205/media/images

(http://static.summitracing.com/global/images/prod/large/hda-205_w.jpg)

I don't care what you say sign, Im BA.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-04-08113755_zps8baf4c7a.jpg)

What is your work vehicle? lol

(http://i299.photobucket.com/albums/mm307/J_holubek/Random/2013-04-09141138_zps4c6f9824.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CdnVWJunkie on April 11, 2013, 07:50:10 am
Quote from: 8v-of-fury on April 10, 2013, 06:34:24 pm

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-04-08113755_zps8baf4c7a.jpg)



Is that Lake Simcoe in the back ground?  How far down is it?  Here we're on Lake Huron and the St.Clair River.  They're down substantially.  Some say we're the lowest ever but I think we're still 6" or from that record.  People with docks are wondering if boating will be feasible for them this year.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on April 11, 2013, 08:07:40 am
nice MF  no cab could be a bit chilly , will your oil filter hit your front crosmember when you fit that oil cooler sanwich plate .
hears my work horse/ donkey it gets a hard life , some times we go camping and tow this
(http://i12.photobucket.com/albums/a235/snakemaster1/2012-11-25151747_zps3f79353e.jpg)

(http://i12.photobucket.com/albums/a235/snakemaster1/100_6051.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on April 11, 2013, 08:21:19 am
Quote from: CdnVWJunkie on April 11, 2013, 07:50:10 am

Is that Lake Simcoe in the back ground?  How far down is it?  Here we're on Lake Huron and the St.Clair River.  They're down substantially.  Some say we're the lowest ever but I think we're still 6" or from that record.  People with docks are wondering if boating will be feasible for them this year.

That is Georgian Bay. We are probably down at least 5-6 of surface level from this time last year.. and that equates to about 12 feet out on most shorelines. WHICH MEANS!!!!! There is uncharted islands now and low spots that now no one knows about..

Quote from: snakemaster on April 11, 2013, 08:07:40 am
nice MF  no cab could be a bit chilly , will your oil filter hit your front crosmember when you fit that oil cooler sanwich plate .
hears my work horse/ donkey it gets a hard life.

Nice caravan ya Pikey lol. Cool Rover though haha. The oil filter shouldn't hit the cross member.. as there is the stock AHU oil cooler on there now and it is pretty large, the oil filter is tight but it fits no issue. If she no work.. I'll put in a remote filter too :) That'd be greatttttt. Marine uses oil suckers down the dipstick to suck it dry, and then the filters are up top and upside down so they drain back when you pop a hole in them. A 100% no mess oil change nearly every time lol.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 08, 2013, 10:37:07 pm
Went down to my buddies for the weekend and I traded his dad a day of back breaking labour on their chicken farm (x2 350ft X 50ft barns which are two levels..) for this ;) !!!!! NICE Full stainless, even the flex, and yes that is a cherry bomb.. also stainless. 2.25" mandrel bent and fully welded. 

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130505_134004_zps924ca4c6.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130505_134004_zps924ca4c6.jpg.html)


And of course, shes running great and sounding even better.. think Peterbuilt style haha. so I had to tear back in to it again haha!

Got EGT, Boost, PD150 intake, .216's, and hopefully an AWIC if I can swing the cash ;).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 09, 2013, 08:28:44 am
So u got a an exhaust for spending time with a bunch of chicks?  Doesn't sound like a baddeal
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on May 09, 2013, 03:15:27 pm
More likely the feathers and poop they leave behind. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 09, 2013, 11:29:19 pm
Well originally I was just gonna pay him $200 total for materials and his time.. but instead I traded my body. haha. I worked with no chicks, just his crazy farmer cousins. Super farmer family.. His dad has 14 other siblings.. He has like 49 first cousins!!!!!

It is a fully beast exhaust though, he even polished the part that sticks out from under the car.. so it looks like a tip.. but wont rust ;). I will most certainly have to update the exhaust note thread when I get it all back together. I've got the engine bay torn right back down now and am doing a WHOLE TON of reorganizing. I wanna put the battery in the trunk and then run a fuse block up in the bay to power all of what I power directly from the battery currently.

Here is something I wanted to run by you guys as I am curious as to why it is this way.. Me and my brother both have mk1's (you all probably know this anyway hah), they are both powered by 1.9's. Mine being the M-TDI and his being an AAZ. I have a turned down 11mm pump and stock injectors, and he has a maxed out 9mm and stock injectors (albeit the IDI injectors are plenty oversize). Both have new bearings, and no drag on the brakes. We have similar transmissions so we cruise within 50 RPMS of each other as well. I know I have a 180 stat, and I am sure his is similar.. They both also have non inter-cooled k03's

Now what I want to know is why my cruising temps are 180-190 and his are 165-175, I will pull a hill and my temps (on a hot sunny day) could easily rise to 205.. his barely touches 180. We even have the same short non-ac mk1 radiators.

I thought the DI was supposed to use less fuel for a given RPM over their IDI 1.9 counterpart?? Thus less heat from combustion.. not to mention less actually lost in to the cooling system via thermal transfer. SO what the hell is going on here lol.

I have a theory, the injectors seem like they are RETARDED dirty as it s
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on May 09, 2013, 11:57:57 pm
My guess is that your overall timing at your cruising speed is too advanced.  Had a similar issue with my toyota pickup with a mtdi.  If the timing was right, the rad fan would never come on.  If I advanced it too much it would run hot on the hills and the rad fan would come on regularly.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 10, 2013, 07:26:41 am
they are 2 different ko3s from i know too.  but still i'd think its something timing or fuel related before anything else. and maybe his thermostat is stuck open some too.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 10, 2013, 10:23:50 am
Are you running the same max boost?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 10, 2013, 12:46:13 pm
did they serve you lunch?

(http://www.robotsforhire.com/wp-content/uploads/2012/03/NapoleonDynamite.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 10, 2013, 02:56:46 pm
The AAZ and 1Z/AHU K03 turbos are functionally the same.  The center sections and compressor scrolls are identical.  The turbine housing is oriented differently with a different flange but I believe the AR is still the same.  The wategates are different. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 10, 2013, 07:13:53 pm
Quote from: libbydiesel on May 10, 2013, 10:23:50 am
Are you running the same max boost?

No, but I was not considering WOT or high boost pulls, merely at cruising speed. The two engines, albeit different injection are nearly identical so I assumed mine would cruise cooler being that it is DI. How do the waste-gates differ? I want to assume the AHU ones are maybe larger or more efficient at diverting the airflow?

Quote from: RabbitJockey on May 10, 2013, 07:26:41 am
maybe his thermostat is stuck open some too.

His gets up to temps super quick, so I do not figure a stuck open thermostat.

Quote from: RabbitJockey on May 10, 2013, 12:46:13 pm
did they serve you lunch?

Haha, not that kinda lunch.. but yes I was provided lodging, food and too much beer ;).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 10, 2013, 07:21:37 pm
The AAZ wastegate pushes closed and pulls open on boost.  The TDI one pulls closed and pushes open on boost.  I prefer the TDI one as boost is on the sealed diaphragm side.  The AAZ version has boost on the shaft side with a seal around the shaft and so it seems they all leak blowby oil. 

You should take both cars to the top of a long hill and coast down.  See which one gets going faster and coasts further.    Do you have similar tires and tire pressure?  Wheel bearing components and CV joints are similarly fresh?  What I'm getting at is that your mTDI may have greater rolling resistance and the added load could easily account for the added temps.

All said and done tho, I think you have a timing or injector issue. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 10, 2013, 07:29:06 pm
I for sure know that I have dirty injectors in there currently, I get a good "retarded timing" style smoke with any amount of advance especially when cold.

I like your idea of the hill, a good test. If anything mine SHOULD have less resistance. I have brand new bearings all around, no brake drag, two new axles and a fresh alignment and also run a 45psi tire pressure. His is out of alignment, has however old axles (probably stock), ballooner tires and more conservative 32psi. I don't know, I too think it is fueling.. gotta be.

I noticed with the DI the injection sound did not really change with any amount of timing advancement.. Like I even went a tooth further on the pulley and it didn't change anything.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 12, 2013, 09:15:56 pm
So yeah, get it running good.. TEAR BACK IN TO IT! haha

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-11201631_zps44d90750.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-11201631_zps44d90750.jpg.html)

All four look like this one, have not had any more build up or anything since I cleaned it out a few years back. Drove around for a while with the EGR still hooked up. Could use another slight cleaning it would seem haha.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130507_180024_zpsfd8c8f74.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130507_180024_zpsfd8c8f74.jpg.html)

Ohh they are dirty.. and I can get number three out.. will not budge! I was gonna hit the head with a torch.. but its a blizzard here..

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-11201433_zps1280b75e.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-11201433_zps1280b75e.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12155814_zpsa188f82a.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12155814_zpsa188f82a.jpg.html)

Also check this siht out... I opened the pump today to do a little modification and this is what I found. The clip was floating around the pump, and the missing piece was no where to be found.. ? It left a good gouge in the bottom of the case, and looks like it got logged for a bit because it sheared the rubbers in the gear that spins the governor assembly! WHOA.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12175046_zps35f553bb.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12175046_zps35f553bb.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12175229_zpsfcc6a58a.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12175229_zpsfcc6a58a.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12175405_zpscaf3c004.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12175405_zpscaf3c004.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12174815_zpsb17250da.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12174815_zpsb17250da.jpg.html)

Here is one of the reasons I pulled the pump apart for, I have a good wear mark in the pumps main shaft.. That I was either thinking of getting welded and filed down, or just cutting the seal back to ride a different part of the shaft.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12180523_zps59883a36.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12180523_zps59883a36.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12180528_zpsb163304c.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12180528_zpsb163304c.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12180531_zpsbf4fec53.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12180531_zpsbf4fec53.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-05-12180539_zps179a6e5a.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-05-12180539_zps179a6e5a.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 12, 2013, 10:41:37 pm
Also, I will be needing new coolant lines for two reasons.. Stock oil cooler delete and because they were damn near rotten through! I have no idea how they haven't blown yet. Wow, they were sooo soft and crap. I will be needing a different bypass hose as well as a different water pump to the metal hard line to delete the stock oil cooler from the cooling system.

I was thinking I could easily use a 1.8's hoses and probably lengthen the bypass hose to account for the taller block.. but the 1.8's upper flange goes in to the side where as the AHU's is on the bottom ish.. So get stock AHU stuff and cap the un needed ports??

Anyone got good cheap sources for me? :)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 13, 2013, 08:00:30 am
go to your local parts store and ask if you can go in the back and check out their hose.   :o

they'll usually let u look through their inventory and then maybe you can find one that will work.  also maybe non turbo 1.6 stuff will work?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 13, 2013, 10:11:29 pm
I was thinking non turbo 1.6 stuff.. that should actually work well except for the taller block between front flange and the water pump.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 4wheeler on May 13, 2013, 10:12:40 pm
How did this water to air cooler work out for you ? I m looking at the same thing for my 4x4.

Quote from: 8v-of-fury on April 08, 2013, 11:23:26 pm
Look what I got coming :)!!

(http://www.siliconeintakes.com/images/product/water_air_kit_3_picture.jpg)(http://www.siliconeintakes.com/images/product/aluminum_smallkit_picture.jpg)(http://www.siliconeintakes.com/images/product/reducer_black_picture.jpg)(http://cdn.shopify.com/s/files/1/0182/1073/products/med-4cyloilcoolers_large.jpg?3138)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 13, 2013, 10:15:53 pm
Some funds fell through so the AWIC was not ordered just yet.. but there have been tons of reviews on this exact kit. It is incredible and worth every penny!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 13, 2013, 10:22:26 pm
Quote from: 8v-of-fury on May 13, 2013, 10:11:29 pm
I was thinking non turbo 1.6 stuff.. that should actually work well except for the taller block between front flange and the water pump.

My local parts guy can get me the MK1 radiator with the filler neck for like $190 his cost, I need one as my 1981 radiator has finally rotted the plastic hose flanges :(.. Do you think its an alright price to pay? Gahh, I hate spending monies haha.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on May 13, 2013, 10:41:48 pm
No, I have one outside that was off the GTI, worked then when I took it off. I would let you have it for 10.00 plus shipping.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 14, 2013, 07:44:31 am
thats too much, i can get the stock one brand new for under 100, and the one with a filler neck for 90-120.  also lucas your radiator might be a little bit different most westmoreland rabbits had the bolt in style radiator jettas and cabbys had the pin mount.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 14, 2013, 09:10:43 pm
Yeah well... You guys are in Murricah where you pay diddly-squat for everything.

I pay triple for the same thing made side by side in the same factory.. But hey, we have Health Care haha.

Lucas I appreciate it, but going used will be the same as mine.. likely rotted plastic. I may try and jerry-rig this one back in to action to save coin.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on May 14, 2013, 09:47:58 pm
pin vs bolt in is year of core support.. 82 german, 83 westy..

keep overflow bottle... the tank rad bad for air pockets..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 14, 2013, 10:11:13 pm
Overflow is so ungodly lol.

I have no issue with my bro's rad with the filler neck. I see no other area for air to go there as opposed to the rads without the filler neck lol.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 15, 2013, 07:52:58 am
Quote from: 8v-of-fury on May 14, 2013, 10:11:13 pm
Overflow is so ungodly lol.

I have no issue with my bro's rad with the filler neck. I see no other area for air to go there as opposed to the rads without the filler neck lol.

i have the the filler neck rad in my rabbit and i love it, honestly i've never had a problem with air trapping on any of my diesels.  my 2.0 takes a bit of wrestling to get all the air of the system tho.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 15, 2013, 07:56:06 am
Quote from: CRSMP5 on May 14, 2013, 09:47:58 pm
pin vs bolt in is year of core support.. 82 german, 83 westy..

keep overflow bottle... the tank rad bad for air pockets..

??? really  my 81 jetta is pin mount, my 81 rabbit is bolt mount
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CrazyAndy on May 15, 2013, 11:08:56 pm
Quote from: RabbitJockey on May 15, 2013, 07:56:06 am
Quote from: CRSMP5 on May 14, 2013, 09:47:58 pm
pin vs bolt in is year of core support.. 82 german, 83 westy..

keep overflow bottle... the tank rad bad for air pockets..

??? really  my 81 jetta is pin mount, my 81 rabbit is bolt mount

My '81 Rabbit is pin mount; weird.  Maybe gassers go bolt mount later?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 15, 2013, 11:12:58 pm
I have two 84 (original gas engine) pin mounts.

But alas, they are both German Jetta's lol. I do not care for rabbits of any generation.. LOL
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 15, 2013, 11:35:56 pm
Quote from: CrazyAndy on May 15, 2013, 11:08:56 pm
Quote from: RabbitJockey on May 15, 2013, 07:56:06 am
Quote from: CRSMP5 on May 14, 2013, 09:47:58 pm
pin vs bolt in is year of core support.. 82 german, 83 westy..

keep overflow bottle... the tank rad bad for air pockets..

??? really  my 81 jetta is pin mount, my 81 rabbit is bolt mount

My '81 Rabbit is pin mount; weird.  Maybe gassers go bolt mount later?

Ok riddle me this what is the build date of the car??  And was the original engine 11 or 12mm?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CrazyAndy on May 16, 2013, 06:07:15 pm
Quote from: RabbitJockey on May 15, 2013, 11:35:56 pm
Quote from: CrazyAndy on May 15, 2013, 11:08:56 pm
Quote from: RabbitJockey on May 15, 2013, 07:56:06 am
Quote from: CRSMP5 on May 14, 2013, 09:47:58 pm
pin vs bolt in is year of core support.. 82 german, 83 westy..

keep overflow bottle... the tank rad bad for air pockets..

??? really  my 81 jetta is pin mount, my 81 rabbit is bolt mount

My '81 Rabbit is pin mount; weird.  Maybe gassers go bolt mount later?

Ok riddle me this what is the build date of the car??  And was the original engine 11 or 12mm?

11mm, and build date of dec 1980 IIRC.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 17, 2013, 01:04:48 pm
intradesting!!!!  mine is a later build date i believe it is around august 1981,  i'm not sure if it is 12mm or 11mm tho, but it definitely has the older 1.5 style crank nose, ill check soon when i get a chance.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 17, 2013, 01:52:05 pm
I thought the older crank sprocket/nose and the 11mm head bolts always went together.  I've never seen the older crank with the 12mm or newer crank with 11mm.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on May 17, 2013, 03:54:35 pm
Quote from: libbydiesel on May 17, 2013, 01:52:05 pm
I thought the older crank sprocket/nose and the 11mm head bolts always went together.  I've never seen the older crank with the 12mm or newer crank with 11mm.

i thought the same thing and had been saying that on here and someone told me it wasn't true that some were a mix.  but who knows they may have thought that because they had a newer block with the older crank swapped in.  i never actually looked at my head bolts before even tho i have had the vc off many times
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 19, 2013, 12:10:23 am
Updates,

I am sticking with the overflow bottle style rad, as I can get new in Canada for $55 and coupled with the other crap I need.. free shipping too. Score. I have found that 1.6 NA coolant lines work perfectly to delete the stock oil cooler from the coolant system. I will be using the stock 1.6 NA hardline, hardline to overflow, and the water pump to the front coolant neck as well. Its all on order !

I re&re'd my injectors today, got the bodies prepped for paint.. and the new nozzles installed. Gotta clean the bores in the head and they will likely be installed Monday. Also got the pump fully back together and ready to go back in, complete with a higher lift AAZ cam plate and hefty governor shimming. Now that I got the injectors to move the fuel.. I need more of it ;).

Likely be another week minimum before she see's the road again. Almost at a stand still until the parts show up. I need the parts so I can get it running to drill the exhaust manifold for the EGT probe.. and right now its drained of oil and has no filter flange on it haha. Does anybody have an old non-oil cooler filter flange kicking around? I could really use the threaded union in there if I cannot find one at Home Hardware tomorrow.. That will button up my external oil cooler as well. Now to save the funds for the AWIC :) My most favorite part! I'll be doing a trunk battery relocation with the help of long thick gauge jumper wires, I think they will work perfectly.

I currently use a 20ft 4g jumper cable set with lugs on the ends for my amplifier and people look at me like !@#@#%#!@$%!%!~!$@ You are using Jumper cables!? THAT IS SO GHETTO, HAHA WTF durr de durrrr durr. I'm like yeah, what did you pay for amplifier "wiring" kit?? $200+? Riiighttt, my $75 seems a WAY better choice, DICKS lol. Plus I actually have both cables run to the battery and not just ground in the trunk relying on the stock battery to body ground to carry my current.. Another spot where all the haters fail, 2g power wire, and the 10g ground to the trunk floor.. Then you got the 12g stock wiring harness for the body ground.. RETARDS.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on May 19, 2013, 09:05:20 am
Why didn't you use the camplate from the ahu pump you had?  It has a much better profile for direct injection compared to the aaz one.  A lot of the older Fords have the oil filter threaded peice you're looking for, like maybe an old cougar. ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on May 19, 2013, 02:27:19 pm
Isn't the threaded pipe you are looking for just a 3/4 inch by 16 thread per inch nipple?  Seems to me that is what I ended up with on my flange, oil heater, filter setup. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 19, 2013, 09:13:56 pm
The AAZ compared to the Rover one is significantly better by itself.. And the AHU one is still inside a pump on the shelf haha. I am not so sure the AHU and AAZ differed much if any from what I recall.. but you are probably right. Next time its apart, Ill throw that one in and see.

Yes it is 3/4-16 UNF, my hardware store didn't have one.. so I was thinking of just threading this one I have just a little further. Its close to fitting as is.. so I will likely go that route.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130516_191215_zps4dcb64a4.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130516_191215_zps4dcb64a4.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130518_132754_zps7707fd2a.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130518_132754_zps7707fd2a.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/inj1_zps263eef69.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/inj1_zps263eef69.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130516_192317_zps330c29e6.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130516_192317_zps330c29e6.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130519_175921_zpsb23e3db5.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130519_175921_zpsb23e3db5.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130519_175914_zpsef1735c7.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130519_175914_zpsef1735c7.jpg.html)


These sunsabisshes will be getting anti-seized gobbed all over them before they go back in their holes.. That is for sure! It was a week long battle everyday after work to get #3 out. Stripped, cleaned, primed and painted. Complete with .216's Veg Injection nozzles.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 19, 2013, 10:52:28 pm
I have a slide hammer pilot bearing puller.  I removed the puller parts (rarely used) and bought a coupling nut that fit the threads and then welded onto it a nut that is the threads of the injector union.  That tool works INCREDIBLY well on pulling stuck TDI injectors.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 19, 2013, 11:05:32 pm
Yeah that is a good idea, I don't expect these to be out again anytime soon.. so maybe next time I'll build a puller haha.

More or less at a stop now until parts arrive. Small things.. routing fuel lines and cleaning up the electrical is what I'll chip away at after work this week.. or maybe get it all done tomorrow? Who knows lol.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on May 19, 2013, 11:37:48 pm
Hey Jeremy, do you have a picture of the landy camplate profile? 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 19, 2013, 11:39:58 pm
I can get you one no problem JF, the piece is on my bench. One minute.

Also I measured the lift, around 2.5mm, compared to 2.25mm of the 1.6's and 3mm of the AAZ.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 19, 2013, 11:55:52 pm
Looks like a 1.6 idi camplate to me lol.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130519_234351_zps8489b16c.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130519_234351_zps8489b16c.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130519_234135_zps75b2a3ba.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130519_234135_zps75b2a3ba.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on May 20, 2013, 12:08:18 am
Wow, that is a lame camplate!  I highly recommend using the ahu camplate over the aaz camplate.  The total lift is almost the same between the two but the up ramp is way steeper on the ahu camplate.  The steeper up ramp suits the tdi injectors better and allows the same amount of fuel to be injected quicker compared to the aaz.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 20, 2013, 12:10:57 am
So you're telling me.. I should rip the two pumps apart and get the ahu cam plate in to it? Gah haha. I guess I should have  asked before just going ahead and doing eh lol.

True-say, I don't think I took any pictures when I had the AHU cam-plate out last..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 20, 2013, 12:17:11 am
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20120730_131956.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20120730_131956.jpg.html)

The only picture I have of the AHU one, from when it was hitting my governor assembly.... hah.

Looks pretty similar, I'll pull them apart tomorrow I guess and check it out ;).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 20, 2013, 12:17:52 am
I just pulled a camplate out of a LR 300 pump and it has a much less symmetrical profile that the one pictured.  The UP ramp is much more steep.  I replaced it with a Cummins plate because it had a few rust pits in it.  
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 20, 2013, 12:19:15 am
Interesting, what year is your 300TDI pump?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on May 20, 2013, 12:20:00 am
Quote from: libbydiesel on May 20, 2013, 12:17:52 am
I just pulled a camplate out of a LR 300 pump and it has a much less symmetrical profile that the one pictured.  The UP ramp is much more steep.  I replaced it with a Cummins plate because it had a few rust pits in it.  
Interesting!  The steepness of the up ramp is the most important part of the camplate after total lift. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 20, 2013, 08:41:16 am
I have no idea what year the pump is.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on May 20, 2013, 09:25:17 am
What does a steeper or shallower cam plate do?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on May 20, 2013, 09:38:09 am
It would inject the fuel faster or slower in the same time span.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: camboscams on May 26, 2013, 12:05:02 pm
Well after reading all 45 pages of this thread, it would seem that any more effort i put into my idi would be futile.... Considering how easy it looked like the swap was this would be the absolute Cadillac of an engine swap. I have an 81 rabbit and have never been super satisfied with the engine, it does do well considering that its over 30 year old technology, but the cool factor of a MTDI would be the cats ass....

So thanks to Jeremy's graciousness of sharing his learning curve it would seem that the biggest hurdle of this swap is getting an injection pump that acts like it should.

Andrew, i remember you saying you would sell MTDI pumps that you have built in $1000 range, is that without a core? And do they act like a properly tuned idi when installed as far as idling cold and hot? Because as much as i love my Giles pump i have now, i can only imagine what it would cost for him to build me one without a core....

Over the last few years i have been a bit fed up with the ol idi (couldn't be because i'm asking 120% more out if it then it was designed for 30+ yeas ago??) but i feel like this would modernize the car enough that it would make it much more enjoyable to drive and own. 

Thanks for the awesome read and the inspiration to spend even more money that i don't have!!!!   
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on May 26, 2013, 12:24:43 pm
bbob has a libby pump on his b3... there is a thread on to m tdi or not from this week.. i did a "sort of review" of b3 and tdi e vs tdi compairson in it..

if i had 3k to blow on each of mine they all would be m powered.. the issue you may overlook though.. depending on year used parts.. head, injector lines, stuff like that are hard to get vs say a 1.6idi...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 26, 2013, 01:27:39 pm
I do not require a core with the pumps I sell and the idle is as solid as any stock mechanical vw diesel.  
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: rallydiesel on May 26, 2013, 10:25:17 pm
If you can use a mig welder, "Hey"'s posts in the FAQ are pretty much a step by step on building a mtdi pump.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 26, 2013, 11:02:28 pm
Quote from: rallydiesel on May 26, 2013, 10:25:17 pm
If you can use a mig welder, "Hey"'s posts in the FAQ are pretty much a step by step on building a mtdi pump.

I had a pump with those modified internals, it was nowhere near the pump that the Land Rover pump was in stock unmolested form. In my eyes, retrofitting and modifying a 1.6/1.9 IDI pump to make an M-tdi pump is a complete waste of your time. Yes it ran, and yeah it had more power than a 1.6.. but it was hardly more power than a 1.9L AAZ...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on May 27, 2013, 12:05:41 am
th eused rover pump cannot be beat.. took months of geting him to give up on his modded stuff vs the rover he finally put on his... and for all the others i see who have noise/unhappy m experiance the rover pump used from ebay uk is a gamble.. libby = newish and support.. for 2x as much.. but if your ebay find bad you saved nothing by time it fixed...

but in no way will i "mod a pump" when the rover pumps are out there.. no need to canabilize 2 pumps you could resell to fund the rover pump... then with libby option.. you got aa chance.. :D
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 27, 2013, 12:11:56 am
Quote from: CRSMP5 on May 27, 2013, 12:05:41 am
libby = newish and support.. for 2x as much..

Andrew's are brand new zero-mile units.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 27, 2013, 12:17:15 am
I wish I took a picture of tonight's progress, I got a lot done out there. Still a lot left to go though!

Got the coolant system wrapped up with pretty much everything new. New rad, out flanges, thermostat, hoses, and coolant bottle with the level sensor to be wired in to an LED in the future. Box of goodies! All of it for $160 shipped to my door, nice. On top of the coolant stuff previously listed there was a dipstick tube, intake manifold gasket, valve cover gasket, cam shaft seal, exhaust hangers, and three Bosch oil filters for the future.. I have three cars that run this filter, so its all good.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130522_180237_zps2d6a0f8f.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130522_180237_zps2d6a0f8f.jpg.html)

The oil system is pretty much done as well with the addition of the EuroSport external oil cooler, which looks like the oil cooler rad will fit perfectly in front of my coolant rad. Of course, the big 'ol dirtyawesome fan favourite Mann filter ;). I ended up adding about 4 more threads to my original long oil filter mount and using a thick washer to take up slack to mount the thinner sandwich plate to the oil filter mount. Success!

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130523_183228_zps26c6a20d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130523_183228_zps26c6a20d.jpg.html)

The fuel system is well underway as well.. being that this was originally a CIS gas engine car, the metal fuel lines ran along the firewall with the brake lines and then up in behind the battery where they hooked in the fuel filter and CIS mechanical fuel distributor. So I then originally when swapping to diesel ran my fuel filter off the drivers tower and had the soft lines cross the engine bay to the pump. I have cut the metal lines back, re-bent them up towards the passenger tower and flared the ends. I didn't snap a picture as it got dark too fast, but I am now running the fuel filter over on the passenger fender. I am running the Mk1 spin on type, which I hope to upgrade in the near future with an additional filter after this one. Preferably a 2-micron Racor unit with water separator and a sight bowl. Does anyone know the thread off hand of the mk1 fuel filters?? The filter will be pressure fed with a 5-7psi electrical pump in the engine bay and clear lines used for all of it, so I can keep a close eye one all the air that shouldn't be there lol.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 27, 2013, 12:24:29 am
The fuel filters are 3/4-16 (or the metric equivalent) just like the oil filters.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on May 27, 2013, 04:23:18 pm
i have had 3 land rover pumps on my 1.9 tdi some moded some std , and i have build 2 1.9 aaz pumps converted to mtdi pumps that are maxed with nice bits , and thay will toast the landrover pumps in std and mild tune
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 27, 2013, 10:24:28 pm
What all did you have done to the 1.9 pumps to make power on the DI engine?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: snakemaster on May 28, 2013, 11:26:33 am
mod gov , and more travel lever one from difrant pump , transit or welded control lever , 11mm head , lda mod top and bottom for more travel , some times no guts in it depends on what control lever i use , index thotle , max fuel screw  , thay would hang on the revs a little but way beter torque than a std LR pump , i run most of my stuff with 110 hp injectors and a gt15 turbo , big down pipe , blanked egr , no wast gate pipe , but gage over taking 32psi 50seconds or no more than 17psi on load for longer times
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 28, 2013, 11:20:57 pm
Not too shabby, You have WAY more parts over there to experiment with than we do on this side of the pond ;). For us, a complete unit such as the Land Rover pump does well. I never did have an 11mm in my 1.9 pump.. only the 10mm.

Got a ton of work done this evening, but was held up from finishing.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130527_074326_zpsd601b4c8.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130527_074326_zpsd601b4c8.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130527_200319_zpsf07fadd5.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130527_200319_zpsf07fadd5.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130528_213412_zpsc494c7c7.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130528_213412_zpsc494c7c7.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130527_074436_zps0ebef4e3.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130527_074436_zps0ebef4e3.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130528_213439_zpsb46511e1.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130528_213439_zpsb46511e1.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130528_213508_zpsd521cab3.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130528_213508_zpsd521cab3.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130527_074359_zps03918d6d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130527_074359_zps03918d6d.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130528_214919_zps6216883d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130528_214919_zps6216883d.jpg.html)


Coolant and Oil systems buttoned up and ready to JAM! BUT THE FUEL SYSTEM IS HOLDING ME UP. As can be seen in my last two pictures the mk1 fuel filter uses a 19mm headed banjo bolt.. and I only have one of them. I figured this out as I was buttoning the fuel system up. GAH, I need the car on the road for the weekend BTW haha. Does anyone have any idea if the dealer can get me these older larger banjo bolts? OR where I can get one aftermarket stylez?

For reference sake, I ended up having to use the mk3 TDI hardline and the mk3 TDI hardline to waterpump lines with the one hose that goes to the stock oil cooler blocked off. I used a 1.6 NA diesel by-pass hose behind the injection pump. I also used an mk2 NA or TD hardline to over flow bottle as it fit my setup better. I used the mk3 style rad to overflow small hose, where it goes from the front rad neck instead of the rad.. slightly cleaner look.

Seriously though peeps, I really need a larger banjo bolt hose end! ;) ASAP.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on May 28, 2013, 11:30:45 pm
You could tap it to the closest NPT and install a brass barb. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 28, 2013, 11:34:05 pm
Quote from: libbydiesel on May 28, 2013, 11:30:45 pm
You could tap it to the closest NPT and install a brass barb. 

I love you. srsly.  :-*

LMFAO. Genius, thank-you. I have been wracking brain over the whole thing the past little while so I am scattered. This was literally the only hiccup though :).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on May 29, 2013, 12:51:56 am
tap nipple on rad?? your nuts.. get a cap for it... you break that nipple you buying rad...

id rethink hoseclamps on them oil cooler hoses dude.. 150psi oil cold in am = oil mess real fast.. if your going to use clamps get german/swiss screw style like oe vw ones the mk1s had..

dude also rethink lower hose.. it cannot rest on the alt like that.. it will chaif and when accel will lift on that hose pulling on the lower nipple... its going to break something...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 29, 2013, 07:38:42 am
Not the rad nipple Chris, for the mk1 style fuel filter. It was a used cooler setup and came with those hose clamps, so I assume they worked with the guy using 10w30 ;) I use a 0w40 Synthetic I should be golden eh? lol.

The oil cooler hoses just lightly touch the alt, but they will have a piece of hose put around them to stop the chafing. The picture may look like a tight fit, but there is plenty of play in those hoses.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CrazyAndy on May 29, 2013, 10:08:57 pm
Do you mind telling me the length of those oil cooler hoses?  I'm getting some lines made up for my own setup and could use a ballpark figure to go around.  I'd add an inch or two to what those are, since I'm getting a local NAPA to make them, and the stuff they use is usually for trucks and farm equipment so you know it's gonna be tough to bend. 

Off-topic, come to think of it, they'd probably help me splice my 1.6/1.9 turbo drain hoses!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on May 29, 2013, 10:19:15 pm
Quote from: CrazyAndy on May 29, 2013, 10:08:57 pm
Do you mind telling me the length of those oil cooler hoses?  I'm getting some lines made up for my own setup and could use a ballpark figure to go around.  I'd add an inch or two to what those are, since I'm getting a local NAPA to make them, and the stuff they use is usually for trucks and farm equipment so you know it's gonna be tough to bend. 

Off-topic, come to think of it, they'd probably help me splice my 1.6/1.9 turbo drain hoses!


(http://img.photobucket.com/albums/v406/CRSMP5/mo%20bs/kneelsuckers.gif)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on May 30, 2013, 01:20:22 am
Crazy Andy.  I put a second oil filter on my 81 and it is under the drivers side behind the bumper.  I used some power steering hose as it was the only thing I could trust to take the 130 PSI when cold and be oil compatible.  Ended up buying 6 ft but I bet I could have done 5.  It was 3 bucks a foot at Auto Ozone.  Might have found it cheaper elsewhere but the guy cut it then told me the price.  Then he triple checked it and saw that was for a foot not all 6 feet.  Dang almost had a bargain. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on May 30, 2013, 10:52:45 pm
My car is being a total gong show with trying to get it going..

I've got an electric pump, and clear lines.. so I know my pump is full of fuel. I have fuel at three of the four injectors, so they are pretty much fully bled. I am getting a small amount of fuel whisps from the exhaust.. but not one hint of wanting to fire off. Why does it hate me when I show it love?

I tore the pump down and put in a new main shaft seal and I tore the injectors down and did new nozzles. The pump is moving fuel (via the clear lines and bled injectors), and the injectors were put back together in a tub of diesel fuel so they are clean too. Pump-Cam-Crank timing is perfect, no questions there. It was a long hot day, so I used the locks this time ;).

The pump timing may be a little off, but that has never hindered a start before even when it was cold out.. and today I was dealing with like 80f ambient temps while attempting lift-off. What gives?

Fuel, Air, Heat.. I've got all three lol. Oh for reference, the pump settings didn't change from when it ran two weeks ago.. really only the nozzles...............................

As I just wrote that out... Because of the now larger injector nozzles, does the pump need re-setup? ie. more fuel screw? SunuvaBISH!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 01, 2013, 06:16:51 pm
Quote from: libbydiesel on May 28, 2013, 11:30:45 pm
You could tap it to the closest NPT and install a brass barb. 

The 1/4 pipe thread brass nipple threaded right in and I sealed it with JB weld ;) haha. It is guaranteed sealed for the life of the vehicle.

UPDATE

Got it running. Brain was a mushy platter of, well.. mush. I turned the fuel screw way out because it is easier to get the lids on the pumps without them protruding in to the pumps internals.. SO It was about 8 full turns to far out to even fuel an idle with the pedal on the floor lol!

I turned it in pretty much until it bottomed out, and then got it to start and only stay running with pedal. Perfect, I am close. The  throttle arm was one spline out. Move it one spline and I got a screamer upon hitting the key. No problem, back the fuel screw out 1 full turn and retry. Still too high, but close. One half turn more totaling 1.5 full turns out, and the car was holding a perfect idle and no hanging upon revs. It would also keep that solid idle when accessories were turned on, and I mean turned on. I turned on my rad fan, defroster, headlights and the cabin fan on high. The idle only just barely came down. Some of you may recall that I had a battle with a rocky idle since doing the swap, I want to place nearly full blame on the CRUSTY old stock injectors with over 500k on them!

The pump is now a modified 300 TDI Land Rover unit, with 1.6TD delivery valves, an AAZ cam disk/plate, roughly 4.5mm of governor shimming and a 1.6 NA/TD idle spring in the governor cage.

Running like a mint, don't ask where I have my timing set.. I didn't use a gauge or check it lol.

http://www.youtube.com/watch?v=SOtE0mA3KGs
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 01, 2013, 07:42:39 pm
Quote from: CRSMP5 on May 29, 2013, 12:51:56 am
id rethink hoseclamps on them oil cooler hoses dude.. 150psi oil cold in am = oil mess real fast..

dude also rethink lower hose.. it cannot rest on the alt like that.. it will chaif and when accel will lift on that hose pulling on the lower nipple... its going to break something...

I thought more in to this, and the cold oil pressure shouldn't have an effect on the oil cooler.. because it is thermostatically controlled flow there will be no oil flowing through there when under 180f.

I got it running Friday after work at about 730pm and left for a 200km road trip at 8pm haha. Mind the air filter, its temporary.. going in the rain tray, as well as the washer reservoir !

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130601_154831_zpsc8f6f312.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130601_154831_zpsc8f6f312.jpg.html)


This is the new Operating Temperature :) PHewww, cool. Idle Hot Oil pressure too.


(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130531_204010_zpscb6c2a1d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130531_204010_zpscb6c2a1d.jpg.html)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130601_160758_zps70bd6219.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130601_160758_zps70bd6219.jpg.html)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/FB_IMG_13701175636490305_zpsda945123.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/FB_IMG_13701175636490305_zpsda945123.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on June 01, 2013, 08:24:16 pm
Quote from: 8v-of-fury on June 01, 2013, 07:42:39 pm
I thought more in to this, and the cold oil pressure shouldn't have an effect on the oil cooler.. because it is thermostatically controlled flow there will be no oil flowing through there when under 180f.

Flow and pressure are two different things and you can certainly have pressure without flow.  Most likely that thermostatic control opens a bypass channel so the oil can bypass the cooler but one leg of the cooler will still be open to the gallery.  In that situation the cooler will still be pressurized to the same pressure as the oil gallery. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on June 01, 2013, 09:17:47 pm
 ;D

what he said... imo the other side still got pressure of some manner... else the thermostat would allow a air pocket of oil move when it did open.. id goto a highpressure store like napa does now.. else place deals with hydrolic lines for big earth equipment... they can crimp and give line made for high pressure...

that stuff looks like rad hose... those screw clamps have ate into the rubber... its going to be like blown turbo oil lines...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on June 01, 2013, 09:27:33 pm
It looks like multi-purpose hose.  Rated to 300 psi.  Should be fine for an oil cooler. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on June 01, 2013, 10:45:04 pm
Yep.  Working Pressure rated to 300 PSI  AND  Made in the good ole US of A.

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 02, 2013, 09:51:49 am
Quote from: CRSMP5 on June 01, 2013, 09:17:47 pm
that stuff looks like rad hose... those screw clamps have ate into the rubber... its going to be like blown turbo oil lines...

Quote from: libbydiesel on June 01, 2013, 09:27:33 pm
It looks like multi-purpose hose.  Rated to 300 psi.  Should be fine for an oil cooler. 

Quote from: ORCoaster on June 01, 2013, 10:45:04 pm
Yep.  Working Pressure rated to 300 PSI  AND  Made in the good ole US of A.

If my engine produces 300+ psi on a cold start, I think I have bigger issues haah. I bout the kit used, so the hoses had ratty ends  but luckily I could chop off all the torn parts from the ends and still have enough hose to reach for me in a clean fashion.

Crimped hydro lines Chris!? What am I just throwing cash away now? haha. Noway sir, I will always be budget minded lol!

NEXT UP!!! EGT, BOOST, and AWIC!!

Blue for boost;

(http://www.auberins.com/images/1813ba.jpg)

Red for EGT;

(http://www.auberins.com/images/1812%20web.jpg)

AND THE AWIC TO RULE THEM ALL;

(http://www.siliconeintakes.com/images/product/water_air_kit_3_picture.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on June 03, 2013, 04:47:39 pm
How much did you pay for awic setup?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: camboscams on June 03, 2013, 08:10:37 pm
Dude, Auber gauges are the sh**. I have one for egt and if you let it idle for awhile and let the temp stabilize then turn the headlights on and you can see the temp go up a few degrees from alternator load! Very awesome! I would love to have one for boost as well
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 03, 2013, 10:57:26 pm
Quote from: bbob203 on June 03, 2013, 04:47:39 pm
How much did you pay for awic setup?

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/tits_zps03375459.png) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/tits_zps03375459.png.html)

Quote from: camboscams on June 03, 2013, 08:10:37 pm
Dude, Auber gauges are the sh**. I have one for egt and if you let it idle for awhile and let the temp stabilize then turn the headlights on and you can see the temp go up a few degrees from alternator load! Very awesome! I would love to have one for boost as well

They are pricey.. But I am thinking of doing a full set of them for everything!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: vanbcguy on June 04, 2013, 06:10:56 pm
I have a pair of Auber gauges but I still haven't found a round tooit. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 07, 2013, 11:06:46 pm
Well check this out homeboy's.

Because I am not running an Inter cooler and like ~15psi from the k03 I keep blowing the runner coupler between the intake and the pipe from the turbo. It is not silicone, it really should be. So I took the MBC out and it is back to opening the waste gate at the stock 9-10psi?? Ughhhhhhh, no balllls! Haha, That extra 5 or so psi.. made a world difference. When I get that IC on there it will be INTENSE! I have enough fuel for 1 k03 per exhaust runner ;).. How awesome would that be!?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: damac on June 08, 2013, 01:02:56 am
Quote from: camboscams on June 03, 2013, 08:10:37 pm
Dude, Auber gauges are the sh**. I have one for egt and if you let it idle for awhile and let the temp stabilize then turn the headlights on and you can see the temp go up a few degrees from alternator load! Very awesome! I would love to have one for boost as well

I use these on my personal cars now ever since my sister in law blew up a turbo engine in 85 jetta :(  She didn't pay attention to low coolant light or temp gage and drove until it locked up.

I got an aircraft alarm off ebay that I also use as an alarm trigger :)

They sell cases to contain the units so only the wires will run through it through a grommet which I haven't finally installed yet.  Also suggest mounting them somewhere out of direct light, or you won't see them in the daytime.  When doing my final dash install I am going to make some kind of overhang on the top to try and keep the screens in the shade.

I also use their senders.  I never had a problem with their stuff until a couple weeks ago when my egt gage just turned off.  Yanked it and checked it and its dead, no display.  Contacted them to find out the warranty is only like 90 days and they will see if repair cost is less than a new unit :(  I am hoping that is a fluke.  I checked my wiring and all connections still tight and intact with the shrink still on each wire.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 08, 2013, 10:31:06 pm
I just recently had the need to have more than water temp, voltage and oil pressure.. lmao. Never had the need on any engine before.. as they were nearly stock or I just didn't care, plus I am brokestatus as I have way too many projects on the go all the time.

I did not see their cases! DAMNIT! That is a buzzkill, I would definitely like to run them pretty much directly above the stereo on the top of the dash for direct viewing as they will be the big important gauges. Aww hell, I think I am about 30 seconds from pushing the clicker to order the AWIC...... oh no interwebs and alcohol do not mix! haha.

Because I keep blowing the rubber coupler I have between my turbo cold side outlet and the intake manifold andI have removed my manual boost controller.. I am really noticing the stock boost pressure. Turbo spools up, and then you just don't hear it anymore (because the waste gate is nearly the same size as the turbine wheel haha) its no good. I think I will see if the 98's SMIC will fit in there for the time being and just rock it under the battery until the AWIC gets here..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on June 08, 2013, 11:13:31 pm
Do you have boost connections that aren't beaded?  I didn't think the K03 had the ability to blow of connections that were beaded.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 08, 2013, 11:39:31 pm
No I mean the rubber is being blown apart. LOL. Not slipping off the connections. Yes they are beaded. Kinda a pain when it happens because it is usually only when I am on the highway hauling ass.. ie. Big boost, lotta intake heat.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on June 09, 2013, 08:35:18 am
wrap it thin sheet metal?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: libbydiesel on June 09, 2013, 08:51:42 am
What are you using for the connector?  When you install the AWIC actual silicone couplers made for intercooler installs. 
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 09, 2013, 09:09:11 am
Quote from: bbob203 on June 09, 2013, 08:35:18 am
wrap it thin sheet metal?

That is not a bad idea for the time being!

Quote from: libbydiesel on June 09, 2013, 08:51:42 am
What are you using for the connector?  When you install the AWIC actual silicone couplers made for intercooler installs. 

Rubber. Which is perfectly fine for stock boost ;) Yes I will be using silicone.. its just not readily available locally to me is all.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 09, 2013, 09:56:24 am
Look at what my bro picked up yesterday at an automotive flea market! $175!!! Coupe's gonna look beast!

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/0820001827_zps03940f5d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/0820001827_zps03940f5d.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130608_201956_zps51d848ee.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130608_201956_zps51d848ee.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130608_201951_zps1174e1cb.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130608_201951_zps1174e1cb.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 20, 2013, 08:14:33 pm
NICEEEEEEE, Buddy who did the exhaust also cut that flange and machined the lip on the pipe. SCORE. PD150 with race pipe for $115!!

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130615_191847_zpsa38f9493.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130615_191847_zpsa38f9493.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 25, 2013, 09:43:34 pm
So 410! The AAZ Cam disk/plate is working pretty damn well, and the VEG-Injection .216's are also a very nice nozzle. Nothing odd became of their install, which I was fully expecting.. lol. I think the .216's ability to inject more, quicker coupled with the much steeper ramp'd and higher profiled AAZ Cam disk/plate it is a damn good combination for a 195-220bar DI injector.

The thing is literally nuts.. and I don't even have it dialed in yet! Awaiting my AWIC to come to me! Ordering it this week! WHAT-UP. Been holding off because their site is so full of great things, I didn't wanna pull the trigger and then need something extra.. eh?

I am definitely going to be purchasing their Water/Meth kit in the future.. It has computer controlled injection! Sensing boost input and EGT levels.. Frigging awesome
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: vanbcguy on June 26, 2013, 01:23:59 pm
I hadn't seen their Water/Meth kit before, that's pretty rad.  If you do end up doing a stand-alone VNT controller like I'm building it would be pretty easy to add water/meth control too, no reason to have another whole controller.  The Arduino has extra PWM pins and it already knows about throttle position and boost levels.  All you'd need is the reservoir, pump, nozzle and another FET for the controller... :)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 26, 2013, 10:57:59 pm
I need to do the suspension again.. at the very least the springs and mounts really..

I have Monroe Sensa-Tracs and mounts all around, (Chris before you pipe up) they are a good strut/shock but I have a horrible spring kit on them.. Like a $55 RACELAND spring kit.. haha! They aren't bad for normal driving, but for me they don't do a good enough job dampening/rebounding.

I do not really enjoy the lowered business, as it REALLY diminishes what you can do with the car in terms of driving style. I am like 1.5-1.75" lowered from stock right now, and it doesn't have too much travel before the front end plows in to the strut tower and bottoms the struts out. Maybe I just need a good set of springs on these struts to make it all kosher?

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-03-30152402_zps6831c3e5.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-03-30152402_zps6831c3e5.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on June 26, 2013, 11:17:10 pm
untill you drive say a monroe, beside a good german gas shock set up... you will never see how the valving in those is so far off.. they too strong.. you can think wht you want.. im telling you that insert is 90% of the issue....

hell maybe its too long for short springs so bottoms out?? the differance on the kubvan with its original build kofaps (only used as they were new and free) vs the koni in that aspect alone was impressive.. just ask mike.. he rode in it in philly before koni.. then madness after... same springs.. bump stops.. wheels/tires...

you really need to try a real set up.. once you do you will never buy that crap for vw again..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 27, 2013, 10:00:03 pm
Quote from: CRSMP5 on June 26, 2013, 11:17:10 pm
untill you drive say a monroe, beside a good german gas shock set up... you will never see how the valving in those is so far off.. they too strong.. you can think wht you want.. im telling you that insert is 90% of the issue....

I have an identical 84 in the drive way with Bilstein HD's on it, doesn't ride any better...

Stock top, Bilstein (obviously) lower;

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/IMG01279-20120114-1511.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/IMG01279-20120114-1511.jpg.html)

The cofaps rode like *** because they were ***.. those aren't even a gas strut! Cannot compare them to a monotube gas charged strut. I am convinced it is the springs and a bad mount..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on June 27, 2013, 10:42:53 pm
I will be ordering these to start..

(http://i.ebayimg.com/t/Vw-Rabbit-Cabriolet-Complete-HD-Front-Strut-Mount-Kit-/00/$(KGrHqN,!iEE2JCwCo7(BNrmID3+Bg~~0_12.JPG)

This set comes with the later style bump stops made of higher durometer rubber then earlier mk1 to accomadate the heavier Cabriolet and Scirocco II

Each Kit Includes:

2 Meyle Germany Strut Mount Bearings

2 Kolb Germany Strut Mount Bushing Spacers

2 Meyle Germany Heavy Duty Bump Stops

2 Meyle Germany Dust Boots
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on June 27, 2013, 10:47:16 pm
no i can compair them to the many i changed between 86 and 96... back when they had good german suspention parts... bilstines i have felt went poo poo long ago.. boge non existant... sachs = junk.. hell id worry abt new koni with what ive seen... but 1 thing certain.. monroe/kyb so on from local parts stores always rode like poo.. but you may be right.. not been in a mk1 with the local store stuff in over 15 years..

their gas pressure has always been obserdly high.. too stiff to compress.. so they tend to balloon shock towers.. rip shock towers out of caddies with less rust then german ones.. hell they always tended to give a lift to the front ends of a stock mk1 too...

what you describe on how it hits...

junk over gassed shocks...

tire pressure more then 28psi... hell my 15s run 25... yes 25... that number on side wall is max.. not reccomended tire pressure.. factory is 28 for a reason... and when low profile tires.. gotta drop lower.. but yes tires wear more.. but the arss feel better..

over sprung springs...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 01, 2013, 06:48:11 pm
The springs are defo the crappiest set of drops I could buy.. I paid $58 for the set of four haha! They have no rebound properties at all lol.

Monroe did not have the Sensa-Trac 15+ years ago I do not think.. Have you ever read up on them? They are way more than what you pay for.. a really good strut..

Quote from: Monroe
Sensa-Trac products have a proven margin of safety:
Sensa-Trac shocks and struts adjust rapidly to changing road and weight conditions, delivering enhanced control with uncompromised ride comfort.
Sensa-Trac ride control products automatically adjust to changing conditions. They offer superior comfort for normal driving and deliver extra control when operating conditions get more demanding.

The Monroe® Sensa-Trac® strut with PSD (position sensitive damping) and the Safe Tech™ system combines our exclusive precision tapered grooves in the pressure tube with application engineered valving and Fluon banded piston to improve the ride, handling, and safety characteristics of the vehicle.

These features allow the Monroe Sensa-Trac strut to adjust more rapidly to changing road and weight conditions than any other available shock absorber.

The result: enhanced control with uncompromised ride comfort.

I was web surfing today, and I am definite I will be buying these in the VERY near future :) Do you think I should get the Cabby/Scirocco II style?

(http://cdn.shopify.com/s/files/1/0182/1073/products/SportSprings_medium_stockphoto_8_1024x1024.jpg?3822)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 02, 2013, 11:08:00 pm
Pulled the front brakes apart to service them (routine maintenance, and it is why I get 5+ years to my rotors and pads ;) 2.5 years to date on hardware pictured)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-07-02200126_zps6dcdf414.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-07-02200126_zps6dcdf414.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-07-02201552_zps66e483b3.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-07-02201552_zps66e483b3.jpg.html)

ughhh.... I found that the hard hitting right strut may have been blown, at the very least it blew my bump stop to pieces. It is a gas strut.. so I don't see where this oily fluid came from?

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-07-02201317_zpscd8431f1.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-07-02201317_zpscd8431f1.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-07-02201535_zps54877a83.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-07-02201535_zps54877a83.jpg.html)

I also found out that I have cracked my exhaust at a weld from this past long weekends camping trip, and subsequent off road trail to get to the destination.. :( Sadness. With all this extra BS I gotta do, the AWIC has been back burner-ed for an even longer period of time :( which is totally non-heinous! On top of that I need to pull my passenger tie-rod and put in a new steering rack bushing, as I can hear the rack flopping around in there.. move it by hand too.

-Mk1Autohaus strut mount kit $100 shipped
-H&R sport/drops (set of 4) $277 shipped
-Steering rack bushing $31 shipped
-AWIC + full install kit and everything needed $580 shipped

Priorities are needed, but what is important? ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on July 02, 2013, 11:31:27 pm
Oily fluid came from the strut case.  There is a bit around them all.  My guess is that it was hammering away and it just came out the top of the nut area where the strut shaft goes up.

And I just threw my old bump stops away last week.  They were the best but not as bad as yours. 

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on July 02, 2013, 11:55:20 pm
A gas strut also has oil in it.  The gas is added to prevent foaming of the oil.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on July 03, 2013, 01:02:26 pm
what do you do to your brakes?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on July 03, 2013, 03:39:41 pm
looks like an orbital polisher has been run on them.  Little circles no?  Cleans the pads with brake clean and wipes the rotors too?  Must have very fancy wheels that he can't clean easily.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 03, 2013, 10:04:52 pm
Quote from: 410 on July 02, 2013, 11:55:20 pm
A gas strut also has oil in it.  The gas is added to prevent foaming of the oil.

No shizz eh? I was unaware, thank-you for the fill in. So, I dunno though because the struts still seem to be doing their job well.. so I don't think it was their oil that came out.

Quote from: RabbitJockey on July 03, 2013, 01:02:26 pm
what do you do to your brakes?

I service them, regularly. lol

Quote from: ORCoaster on July 03, 2013, 03:39:41 pm
looks like an orbital polisher has been run on them.  Little circles no?  Cleans the pads with brake clean and wipes the rotors too?  Must have very fancy wheels that he can't clean easily.


40 grit by hand on the pads and rotors. Also took the loose rust off and ground down the small ridge on the edge. Snowflakes, super rare and highly sought after lol.


Any opinions on the H&R spring kits? Rabbit/Jetta/Scirocco I or the Cabriolet/Scirocco II springs?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on July 03, 2013, 11:05:16 pm
Can't say anything on those springs.  No Knowledge whatsoever.  But not Totally Clueless.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on July 04, 2013, 08:41:59 am
I have used cabby h&r springs on my rabbit.  They seem good haha bi hve bilstein sports with them and theyre some type of sport spring themself.  The ride is firm but forgiving handling is great
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 04, 2013, 09:43:17 pm
With a Rabbit..... why not use the Rabbit springs? You never cease to cause wonder Trev0rbr lol. I only wonder on the Cabby springs because they are designed for a heavier weight on the rear axle, like a Jetta would also have. I just feel that any kit that puts the Jetta/Rabbit/SciroccoI in the same category for rear springs... is gonna be a horrible rear spring for the Jetta.

Well I guess I will get the cabby set, and put them on my monroe's (because I truly feel they are a great strut.. just the springs I have on them right now suck.) along with the mount kit pictured. Should be a damn solid setup when I am done with it.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 18, 2013, 09:01:40 pm
So I have just gotten my parts in, YAY.

HD strut mount kit via mk1autohaus, as well as his SS brake lines which are amazing quality! The strut mount kit comes with bump stops and dust boots as well as proper sized strut mount bushings. I also got a delrin bushing for my steering rack as well because it has been clunking since day 1 of ownership lol.

On the way is a Peloquins 80% "LSD diff" kit, as well as the H&R sport springs. Coupled with my mono-tube gas struts... its gonna handle like a BEAST. I ordered two spring sets, one for my brothers 84 as well. He has Bilstein HD's, so I'll give you a true review of how well the Monroe Sensa-Tracs actually stand-up to the "big guys". We will also have the 88 1.6TD strutting a set of H&R on Bilstein's as well.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 18, 2013, 09:03:38 pm
Pics for clicks :)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-07-01192300_zps8d28849d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-07-01192300_zps8d28849d.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on July 19, 2013, 02:15:05 pm
Quote from: 8v-of-fury on July 04, 2013, 09:43:17 pm
With a Rabbit..... why not use the Rabbit springs? You never cease to cause wonder Trev0rbr lol. I only wonder on the Cabby springs because they are designed for a heavier weight on the rear axle, like a Jetta would also have. I just feel that any kit that puts the Jetta/Rabbit/SciroccoI in the same category for rear springs... is gonna be a horrible rear spring for the Jetta.

Well I guess I will get the cabby set, and put them on my monroe's (because I truly feel they are a great strut.. just the springs I have on them right now suck.) along with the mount kit pictured. Should be a damn solid setup when I am done with it.

i got the cabby springs used for cheap, i thought id be ok since my car is diesel with ac and a slightly heavier interior, for the most part i was right how ever it did sit high up front, but then i installed jom lowering spring caps, it game .25-.5 inches and made things pretty level.  still a hair higher up front. the best riding vw i have been in was definitely my brother 88 16v after he installed new boge gas turbo shocks/struts.  it was amazing like riding on a cloud that was on rails and really handled as well.  but as chris said, all those parts have gone to *** and the shocks were back to being *** in probably less than a year on stock springs.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: Smoker on July 20, 2013, 10:09:45 pm
Quote from: 8v-of-fury on May 19, 2013, 12:10:23 am
THAT IS SO GHETTO, HAHA WTF durr de durrrr durr. I'm like yeah,  .. RETARDS.

This has been the highlight of my evening so far.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 21, 2013, 09:45:58 pm
You are very welcome. haha!

Springs and Peloquin kit should be here early this week.. NEXT WEEKEND will be time do Du Werke.
Title: Re: Re: Re: 1998 TDI/02A --> 1981 Jetta
Post by: One_punchmachinegun on July 30, 2013, 04:27:19 pm
Quote from: theman53 on August 23, 2010, 10:10:54 pm

Wheel hop usually sounds like a bang, bang, bang, BOOM CRUNCH METAL LIFE SUCKS RIGHT NOW as opposed to a screetch or squeel of peeling them off

I was just going through this thread and this ia SO true... Hahah
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on July 31, 2013, 12:01:22 am
So this beast is beastly. I cannot keep my damn boost pipes on! Granted it is not inter cooler yet and the charge air is outstandingly hot.. the one pipe between turbo and intake cannot handle the heat and pressure and slides off its flange when it has been running a while and I get on it good.

4th gear on the ACN is amazing in town! It is a 1.03 ratio, and it keeps me near 2000-2500 for maximum power deliverance. When I punch it while turning in the least bit I loose traction all together. It is pretty good, because the in town little " my cars better than yours" races are usually a roll on type, or the m come screaming up from behind to prove to me they are better.. The pickup in 4th gear is incredible. 60-110 (2000-3800 Rpm) like nothing.

Been looking at used 020's in my local area with Peloquin or Quaife differentials already installed in them for the $400-600 range.. DAMN GOOD DEAL considering the diff is $900-1300 by itself. If I find one next week (pay week) I am getting one for sure lol. hands down. May even take a look at the performance style clutches for the 020 if I deicide to rock that route for a while. Why not? The stock 020 is doing just damn fine. No odd noises or anything and the gear oil is still in ok shape with 1.5 years of heavy abusive driving on it.

I have received my latest over hauling of parts barrage;

-German strut mount kit
-Stainless steel brake lines both from Mk1AutoHaus
-Mk1 Scirocco 16v calipers and brackets to do 10.1" vented cross drilled front setup
-I have the larger 200x40 backing plates and hardware off of my old 98 TDI donor, I just need the drums and bearings now to do that too :) Gonna stop on a dime.
-H&R sport springs which look incredible quality, via EuroSport accesories
-The 80% Peloquin LSD kit, needed the flange seals anyway.. and this kit not only came with the additional LSD stuff it had the flange tool too.. so I was only a few more dollars in to it to do the LSD kit.
-Delrin steering rack bushing for the passenger side of the Mk1 rack which is a very common failure due to rack design. The only spot in my steering/suspension with any play left... BOUT TIME!
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on August 06, 2013, 12:42:19 pm
i think as long as you take it easy when you shift the 020 should survive, banging gears obviously isn't good on a transmission thats known for failing.  tho honestly, i beat the *** out of a few of them and they seem to have always held up.  but i know the mk3 020's were basically trash, not to mention they were in a car that weighted 1000lbs more than the rabbit they were initially intended for, and also had probably twice the hp of the original gas engines, 1.6 had what 70hp at most?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on August 06, 2013, 04:56:44 pm
1.5 = 49 hp
1.6 = 52hp
1.6td = 59 hp supposedly... ive seen stock ones with more and less though.. back when stock td was not the norm and conversions were not common..

gassers 65-90hp..

my biggest worry for him is it needs gone thru.. the added torque on 5th gear does bad things in a unopened 020 and i doubt his has been..

then take off in wet the diff can work pretty hard...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 10, 2013, 07:02:08 pm
I tow 1500lbs with this car man lol. If anything, this trans has seen more abuse in the last 1.5 years than yours did in its lifetime behind your built engine. Through all gears, I get on the power so it is really torquing that gear box.

They came installed behind the stock 90-100hp MK1 GLI-GTI's too.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 11, 2013, 09:34:13 pm
On top of all the other crap I got, I also ordered some 1987 Scirocco calipers and brackets. I have vented discs and pads already from my 1998 Jetta that I got my AHU from. I could have used the calipers too.. but these ones were German remans and came with brackets for nearly the same price as getting brackets by themselves. $78 a piece ! :) Yes. I have driven the big beast, with its 55ft trailer in tow.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-09164012_zps88d391f0.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-08-09164012_zps88d391f0.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-09100117_zps3796ff09.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-08-09100117_zps3796ff09.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 22, 2013, 10:45:52 pm
So a deal fell through for the Scirocco spindles.. and my 10.1 brake idea was scrapped. Returned those calipers, and for less money (!!!) Bought new calipers, discs and pads for a vented 9.4 setup. I also took this time to bleed the system completely with DOT4 and put my SS brake lines in.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-20174423_zps7907f7da.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-08-20174423_zps7907f7da.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-20181324_zpsfce766f1.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-08-20181324_zpsfce766f1.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-20181345_zps854f2c82.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-08-20181345_zps854f2c82.jpg.html)

I also tried on some 20" rims, just to see what it'd look like..

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-18150451_zpse32274a2.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-08-18150451_zpse32274a2.jpg.html)

Look at my poor compressor wheel :( :( She ate something somewhere..

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-16153452_zps33d54be2.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-08-16153452_zps33d54be2.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on August 22, 2013, 11:19:30 pm
That turbo damage sucks!  I bet it still boosts okay though.  Lots of k03's out there but might be an opportunity to try something different.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 23, 2013, 07:07:30 am
Been that way since I got it.. Catlins got a VNT-15 coming my way ;)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on August 23, 2013, 08:43:21 pm
Lol@thatturbo.

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 23, 2013, 09:34:02 pm
Quote from: RabbitJockey on August 23, 2013, 08:43:21 pm
Lol@thatturbo.

She makes great power despite its size.. really. Especially non-cooled where it is a super short intake tract. I needs an IC in there though.

Going to mount the battery in the trunk, and do the stock mk3 SMIC where the battery was. Maybe do a hood scoop, or something.. I dunno.

Everyone hates, because EVERYONE looks for peak power ability ;).
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 23, 2013, 09:41:17 pm
Here is the price list, and part numbers for that brake setup if you are interested. Altrom was the supplier me thinks. I paid less money for pads, rotors and calipers!! then those 10.1 calipers lol.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-23213502_zpsccc9637d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-08-23213502_zpsccc9637d.jpg.html)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ToddA1 on August 24, 2013, 01:26:22 am
Why didn't you use those 16v carriers and calipers?  They bolt onto your stock steering knuckles. All you would have needed were 10.1" discs and pads.

-Todd
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on August 24, 2013, 07:39:33 am
I used to have 10.1s on my jetta but i took them off to run 13d. I just think its funny how screwed up that compressor wheel is.  Ko3 is a great little turbo
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 24, 2013, 07:41:02 am
Yeah no. Those calipers werent fitting stock knuckles. 3/4" difference on the carrier bolt pattern.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ToddA1 on August 24, 2013, 09:44:05 am
You didn't have the correct carriers.  S2 16v carriers are a direct swap; I've been doing it for years.  You may have had A2/A3 carriers.

-Todd
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 24, 2013, 12:32:42 pm
Those were 1987 scirocco brakes. Identical to the mk3 stuff i have.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on August 24, 2013, 02:42:21 pm
scirocco 16v stuff bolts straight up just uses different carriers.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 24, 2013, 06:02:29 pm
The knuckle needs to be changed to cabriolet or rocco.

My stock is the smaller bolt pattern.

(http://i299.photobucket.com/albums/mm307/J_holubek/20130816_175825_zpsdbedb6b5.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ToddA1 on August 24, 2013, 09:15:36 pm
You got sent the wrong stuff. All Sciroccos from the 70s and 80s are based on the A1 chassis. The entire suspension, power plants and driveline is interchangeable with Rabbits and Jettas from the same era. 

I just sold a set of S2 16v carriers to someone a few weeks back and I haven't heard a complaint of ill fitment.  There are a few sets for sale in the vortex classifieds. 

I've been running 10.1" brakes on my A1s on A1 knuckles for 2 decades, with no issues.

-Todd
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 24, 2013, 09:20:30 pm
This invoice, for 1987 rocco calipers;

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-08-09164012_zps88d391f0.jpg)

Gave me identical brackets to the ones on the right, the ones on the right are from my 98 jetta parts car.

(http://i299.photobucket.com/albums/mm307/J_holubek/20130816_175825_zpsdbedb6b5.jpg)

No sending of wrong parts, my parts guy is a vw guru and i got exactly what I ordered. 16v rocco calipers. as can be seen on the invoice.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on August 24, 2013, 09:36:57 pm
the 16v, mk3, corrodo, 1st vr6 use same caliper... even audi 4000k quattro do... but 16v rocco, 4000q use same carrier where the others do not...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 24, 2013, 09:38:51 pm
Right, I know that.. Which is why I ordered 1987 16v rocco calipers w/brackets lol!

They were identical to the mk3 10.1 stuff I already had. SOOO all I need for a future upgrade is the carriers then.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 24, 2013, 09:44:47 pm
However.. This does still allow for the $34 snow tires on 13's..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ToddA1 on August 24, 2013, 09:45:24 pm
Correct... but wouldn't you want to take that up with your parts guy?  Have him get the carriers you were supposed to get from the start.  

The carriers are getting hard to find.  They're approaching $100.  After I sold my carriers a few weeks back, I started second guessing my decision.  

-Todd
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 24, 2013, 09:53:19 pm
Must have been too good to be true then lol. I did not take it up, because after some light reading it would appear people were swapping the whole knuckle from cabby/rocco to the mk1 Rabbit/Jetta.

I have complete 200x40 mk3 rear drums to go on yet.. and it already stops too good for the tires.. so lol Lock ups come with ease, and there is no fade on a good long and hard stomp.

I may entertain rear disks yet as well...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: CRSMP5 on August 24, 2013, 11:39:31 pm
skip the rear disks... run the big drumbs... i have 11" roddo fronts on my kub with big drumbs.... the 84 coupe.. i started with rear disks.. then 10.1" fronts... imo rear drumbs way less issues...

need 16v rocco prop valvs.. nla... to keep the rears from locking up first... then they stl a lttle off tl yoou add the 10.1 up front.. then balanced again...

need to upgrade to a 22mm master on paper.. so booster and dick with pedal rod...

big drumbs with 10.1/11 fronts.. stock master still works..

you saw me say audi 4000 quattro is same carrier as 16v rocco right?? 84-88 buddy.. tons of them vs 16v rocco... so no small supply.. just need right parts bin...
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on August 25, 2013, 08:13:26 am
Drumbs
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on August 25, 2013, 10:03:14 am
The advantage to running rear disks, means I can keep the 9.4 fronts and still run 13" wheels for el'cheapo winter tires and what not. Whilst still having the braking power I desire or towing.

If I were to do it, I'd probably get the self adjusting prop valves in the cabin between the front seats and run new lines back to the axle.

Are the German mk1 and German mk2 different for what master they accept? I put a 22mm master from my 98 parts car in to our 90 German mk2 with factory 9.4's and big drums. It originally had the 20mm like most others.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 08, 2013, 08:32:01 pm
So I am literally feeling like Lucas right now, where my car is being a real piss-off ;) lol. I would sell it, but I know I wouldn't get $500 for it.. and it was my first car, so I'd literally be sad beyond sadness the second it happened.

Now I guess I have to look at it this way, I daily this 29 year old car. A minimum of 450km a week.. so for such an old car to do like 20,000 a year is fairly impressive as it is.

But alas, I am finding I need to constantly "overhaul" it, for lack of a better word. It is too much to do all at once, and again it is my daily car.. so Monday morning it needs to be on the road.

Right now I have to do:

-front struts
-rear shocks
-strut mounts
-springs
-internal steering rack bushing
-a better intake tract and filter location, have a hot air ram setup right now lol
-I'd like to do the rear trailing arm bushings.. but that looks like a nightmarish job to do, as it has never been touched..

The big one. The car is most recently decided it wants to rust away to nothing. A bunch of seams are rotting from the inside out. That siht is above my level of what I can do.. and it is steadily getting worse.. I don't know what to do.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ToddA1 on September 08, 2013, 10:11:55 pm
What you need done mechanically, is mainly front suspension.  Not too bad. 

What I can't see is the extent of the rust. Sometimes it's easier to start fresh.

-Todd
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 08, 2013, 10:27:30 pm
picture most panel seams, rotting out. The trunk lid, the trunk floor to rear valence.. front valence, rear 1/4's..

nightmare. It needs stripped and done professionally.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: srgtlord on September 08, 2013, 11:05:30 pm
 I decided to park my red diesel beast and start fresh with a southern golf. Im hoping the rust will stay away for at least 6 years. If it lasts longer than that Ill be more than happy :) But seriously , take a roadtrip to the states and pick up a rust free car. I started digging intot hte rust spots on my red car and holy crap...where you can see the rust is the tip of the iceburg. Once you grind down to clean metal you will find there will not be much clean metal left ....
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on September 08, 2013, 11:39:14 pm
Are you still an advocate of munroe struts? I need some new ones on my passat and dont want to spend big..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 09, 2013, 09:56:57 pm
I am not convinced the struts were crappy.. I am pretty sure the horrible (read barely any) spring rate of the crappy springs I had ruined them by constantly pounding them in to submission. When I put them in they rode great, and were a very nice feeling strut. I wouldn't get anything but the Sensa-Tracs.. Lifetime warranty too.

The rust isn't inhibiting my use of the car, just I can see it getting worse.. and I want to strip it and paint it.. but its my daily. so it doesnt really work out lol. ugh :(

Well I just ordered a set of Koni STR.T, so these should do extremely well with the H&R blue sports.. Probably better than my brothers Bilstein HD's. I'll give you guys a product review lol, same cars, same springs, same engine weight.. it'd be a fair comparison.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 10, 2013, 09:04:27 pm
THESE!!

(http://sprinterstore.com/Koni%20Logo%202%2018%2008.jpg)(http://www.parts4vws.com/images/parts/KONISTRT.JPG)

PLUS THESE!!

(http://www.urotuning.com/v/vspfiles/photos/54724-55-2.jpg)

I need one of these NOW!!

(http://pgperformance.com/images/P/18035_300w.jpg)
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on September 10, 2013, 09:31:13 pm
Those Konis are pretty nice.  I've done a few sets and they're quite firm.  I put them in the wifes car and plan on ordering a set for my car as soon as I can justify it.  Apparently they are a stiffer ride then the koni reds but I can't verify that personally.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on September 10, 2013, 09:33:55 pm
From what I gather the 4 point brace is the biggest improvement you can do to an MK1. Now that you have ran those springs do you like them? I have always hated progressive springs on anything especially performance type suspensions, so let me know what you think.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 10, 2013, 09:38:06 pm
I haven't run these yet, but my bro has a set on his Bilstein HD's in his mk1 and they are the tits man.. HOLY COW do they handle.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on September 10, 2013, 10:18:28 pm
i have installed a front tie bar on all my mk1s it makes a very noticeable difference.  never had a 4 point bar piece tho.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 10, 2013, 10:21:51 pm
the 4-point is just as much improvement over a 2 point or a k-bar as those are over nothing. I read it is INTENSE stiffness with one.

Brother and I are gonna get the cars up on hoists side by side and make some up.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: theman53 on September 10, 2013, 10:29:37 pm
The springs could make it handle but I never liked the feel of progressive springs. All springs are progressive but the progressive rate change springs like those pictured I have always hated the feel and couldn't get used to them. The big name shock manufacturers put them on racing quads and then that was the craze, but I couldn't like them. I have less experience in autos, but that TJ jeep I have has them and it sucks to drive feel wise.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 10, 2013, 10:38:37 pm
The springs pictured are not what I actually got though, I do think they are still all 4 progressive.

Front:
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-07-24073945_zpsba269d0d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-07-24073945_zpsba269d0d.jpg.html)

Back:
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-07-24073952_zps9c7568c7.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-07-24073952_zps9c7568c7.jpg.html)

Installed rear: (he used KYB GR-2's and they rock with this spring)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-07-31184225_zpse2248e0f.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-07-31184225_zpse2248e0f.jpg.html)

Jeeps suck to drive anyway lol.. even the grand cherokee.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 14, 2013, 12:11:34 am
No truck? No problem.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130907_134905_zps896c9621.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130907_134905_zps896c9621.jpg.html)

Do you guys think there is something wrong with these struts?? There is nothing holding them in..

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130912_180632_zps56b44330.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130912_180632_zps56b44330.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/20130913_200128_zpsfb77fad6.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/20130913_200128_zpsfb77fad6.jpg.html)

The shop that installed the struts in to the housings (at the time i had no way of removing the old ones) did not back fill them with oil.. so they burnt out due to the HUGE pocket of air around them, insulating them to die lol. There has to a full 3/32" between strut and housing all the way around..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 15, 2013, 08:45:33 pm
Rear wheel wells are still in good shape, thank the lord.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-14120121_zps500142d6.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-14120121_zps500142d6.jpg.html)

Filled my mounts for better longevity. These are supposedly German "HD" mounts from Mk1AutoHaus, so that should help as well.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-15134310_zpsd3b9f63b.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-15134310_zpsd3b9f63b.jpg.html)

Prepped these for installation when Struts appear.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-15134340_zpsb4efc6a8.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-15134340_zpsb4efc6a8.jpg.html)

I also took the flanges off the transmission but did not take any pictures, drained the transmission and got it all cleaned and prepped for the replacement of the flange seals as well as the addition of the Peloquin %80 shim kit which will help EXTREMELY this coming winter. For this addition on 90mm axles it was recommended that I grind the stubs of my axles down to 1/16" of the circlips ridge. While I have everything apart, I am going to grind and rust check some of what is under there to keep it from getting too much worse. I will do a service on the rear drums while it is convenient too.

Anyone recommend a good synthetic trans oil to run??
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on September 15, 2013, 09:28:01 pm
I found the peloquin 80% kit caused the plastic diff housing to breakup and fill the trans with plastic bits and clog the pinion bearing feed hole leading to the bearing wearing faster.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 15, 2013, 09:45:04 pm
Interesting.. however, how many tests did you do to find that this happened precisely because you installed the %80 kit?

Not saying I do not believe it is possible.. Without knowing though, how could you know it caused it directly?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on September 15, 2013, 10:34:14 pm
Doesn't  the kit increase the pressure applied to the internals?  The plastic can't take it so it goes into explodo mode?  Seems bbob is saying I did this to my diff and then this happened.  Something comparable to:  I changed my oil filter and then the engine ran dry of oil.  Checked the filter and forgot to give it the extra 1/4 turn.

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on September 15, 2013, 10:57:59 pm
Ive heard other accounds and broke vw said he has seen it before. Correlation doesn't equal causation i know just some fwiw info. That being said that plastic thing really is useless especially if you plan on running one of these.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on September 15, 2013, 11:00:16 pm
Not that its really worth it to tear down the box to remove it. I think you probably risk exploding your trans from torque before you have any really issue with the plastic thing causing serious problems..
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on September 16, 2013, 12:49:24 pm
Vinni viddi vicci haha nerd
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 16, 2013, 04:34:27 pm
Veni Vidi Vici.

Close ;). So when I fist pump in the club, ***es know they about to be conquered.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: RabbitJockey on September 16, 2013, 04:38:48 pm
I seen it spelled a few ways so go suck a fart
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on September 16, 2013, 06:30:59 pm
Latin language can only be spelled one way, durr. lol

Travis devise a turbo for me to use.. lol
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury on October 27, 2013, 10:06:04 pm
I never updated after the suspension install! :o

When I got the struts, damn good price for the four of them too.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-17183352_zpse996c17b.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-17183352_zpse996c17b.jpg.html)

I added about 1.5" of spacer to the rear lower spring perch, in order to remain at a level ride height with a loaded trunk. the only issue was with these h&R's they didnt fit properly on the lower perch like the OE springs did. They are about 1/4" wider overall.. It hasn't affected anything though.

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-18211249_zps8c75835c.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-18211249_zps8c75835c.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-20212957_zps58e7aec8.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-20212957_zps58e7aec8.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-23193038_zpsf23b54b0.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-23193038_zpsf23b54b0.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-18202232_zps8a80e23c.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-18202232_zps8a80e23c.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-22182851_zps51ddd23d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-22182851_zps51ddd23d.jpg.html)

With my skeleton load in the trunk it rides about 1/2-3/4" higher in the rear, perfect!

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-24174906_zps8d829c35.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-24174906_zps8d829c35.jpg.html)

Had to work a Saturday, so I stripped the interior out and did a full on detail. Hellz yeah getting paid to work on my own shiz

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-28123620_zps91aac1f8.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-28123620_zps91aac1f8.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-28170403_zpsde620452.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-28170403_zpsde620452.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2013-09-28170348_zpsdefa81cc.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2013-09-28170348_zpsdefa81cc.jpg.html)

Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: bbob203 on October 27, 2013, 10:12:58 pm
That lift kit won't let you down mine is almost 3 years strong and lots of lbs hauled.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury! on March 31, 2014, 11:43:20 pm
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2014-03-21001653_zps9dd33442.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2014-03-21001653_zps9dd33442.jpg.html)

Welcome back to myself.

Check this one out guys! I had some wetness around the #1 injector.. so I decided after soap'n'watering it that I had a compression leak there of sorts. Didn't show on my compression test a month back, musn't be a huge issue. The compressions test yielded 410-420psi across the board. Not bad for a non-rebuilt AHU with over 500k on it eh? Anyway I pulled the #1 and this is what I found.. I then pulled the rest and tested

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2014-03-31163225_zpsf3134e83.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2014-03-31163225_zpsf3134e83.jpg.html)
(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2014-03-31163303_zps17b70e5d.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2014-03-31163303_zps17b70e5d.jpg.html)

So I rigged up a spray pattern tester ;)

(http://i299.photobucket.com/albums/mm307/J_holubek/84%20Jetta/2014-03-31172351_zpse252f887.jpg) (http://s299.photobucket.com/user/J_holubek/media/84%20Jetta/2014-03-31172351_zpse252f887.jpg.html)

Click this link for a video of what is pictured above! ;)

https://www.youtube.com/watch?v=DgFvy5sLcQ4

How do you guys feel about that spray pattern? All 4 sprayed this way.. but I feel like this was more than likely my issue with the bad bluing smoke at idle i've been having most of the winter.. Cylinder temps too cold causing severe carbon deposits? What causes this anyhow?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 410 on April 01, 2014, 10:58:19 am
Looks okay to me.  What don't you like about that spray pattern?  Don't forget that the injection pump puts out way more fuel while cranking then at idle.  The build up on the nozzles looks like oil to me.  Could be coming from several sources.  Valve stem seals, turbo, oil control rings, even excessive crankcase pressure.  I know you said your compression is good that doesn't rule out any of the issues I listed.  Excessive crankcase pressure can also be caused by a bad vacuum leak since the vacuum pump exhausts into the crankcase.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: 8v-of-fury! on April 01, 2014, 01:23:31 pm
Well that spraying was after I cleaned off a lot of snarf.. I meant like the holes were completely surrounded by carbon, so likely when installed they were not spraying properly.. thus my blue smoke at idle issue.

I do have a lot of oil in the CCV system and have a catch can I haven't installed yet. Guess now is the time! I will check my vacuum pump lead to the booster as well.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on April 01, 2014, 09:26:45 pm
I figured the spray was after cleaning but was really looking for the pre clean shot.  Must have been a straight stream off to one side I bet.  Issue is cold temps or low head temps?  Can't remember if you run a heater at night or not.  Like you say build up over time till one day she smokes like a sailor and cusses a blue streak like the same.

Only thought so far.
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: VWee on November 27, 2017, 09:10:54 pm
Good day. I noticed that you have upgraded the suspension of your vehicle but I can't view the photos you have uploaded from Photobucket. Can you suggest where to buy lift kits 4 less (http://4wheelonline.com/Suspension_Lift_Kits.24) or recommend where you bought yours?
Title: Re: 1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)
Post by: ORCoaster on November 27, 2017, 11:13:30 pm
I shopped and called around a bunch of places and finally settled on this kit.  For a Jeep Cherokee, it is the same sized axle as the VW pickup. 

Purchase details  Purchased from: SDTruckSprings.com

Lift Block Kit - 1987-2001 Jeep Cherokee 4wd (w/2.75 axle) - 3 inch Blocks [7863]    $50.95
Item #97086   http://www.sdtrucksprings.com/index.php?main_page=product_info&products_id=7863

I thought I wanted 3 inch blocks between the axle and the springs.  That was a bit aggressive, I should have gone 2 inches.  But the tailgate in now above my knee caps and I think I measured it at 21 or 22 inches off the ground.  I can check that in the light of day if you want a for sure height. If you want less than 3 inches you need to order the Ubolts in one place and the blocks on another.  They don't have a kit for that vehicle in 2 inches.   

The kit came with Ubolts that were about 2 inches longer than I needed so I cut 1.5 inches off when I was installing them.  I also had to enlarge the hold down plate holes just a tad as the diameter was tight too.  But they did fit.  I don't have to use a jack anymore to crawl under it and the rear end isn't dragging on the ground with the bed completely empty.  I can load the crap out of the pickup now except it lacks power not having a turbo on it.