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31
IDI Engine / Re: Booster full of brake fluid
« Last post by ORCoaster on March 08, 2024, 09:29:21 pm »
Today was a beautiful sunshiny day to work on the brakes again. 

Yesterday I got off work an hour early so I used that daylight to pull the MC and booster off the truck.  I found that the front seal on the booster was allowing air to sneak in next to the shaft that engages the MC.  So I found a way to seal it up without buying a new front seal.  I am not sure you can even do that.

I applied a vacuum on the booster and it held for a long time and was released when I pushed on the pedal shaft.  OK got that part fixed and I had already gone through a second MC I bought off a guy on CL.  So today I slapped it all back together and tested it out. 

HMM mushy brakes, but I had yet to bleed them so I did that and I have a low pedal but not bad brakes.  When I had the booster apart I tried to turn that little nut on the end and it just would not budge.  So rather than break it off I am just going to live with brakes that are a bit lower to the floor than I would like them to be.  Other than that they will send you rocking forward if you hit them with much force.

So, now to do something else with it.  We are in for another 5 days of rain so I will have plenty of time to think about what I want to do next.
32
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by RabbitJockey on March 08, 2024, 07:38:37 am »
33
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by ORCoaster on March 07, 2024, 10:58:51 pm »
Owning a VW is always a continuing adventure.  Keep us apprised and don't forget pictures.  We love pics.
34
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by fatmobile on March 07, 2024, 10:35:27 pm »
 They do make a rubber oil pan gasket,.. from a gasser 2.0 block maybe 93-99.
  valve cover gasket from the same engine too.

 Yep, you tried everything else I can think of. Might be time to pull the head.
 It'll be interesting to find out what's going on.
35
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by Mohatanous on March 07, 2024, 08:20:58 pm »
Update:

Pulling the pan yielded no results other than finding a very dirty oil pan, which appears to have been leaking quite a bit. My next step is to pull the head and see what's going on. Maybe it swallowed a valve that I can't see or something else going on in the cylinders that I can't see. I may end up doing a rebuild of it at this point, it would help me really learn about the motor and I think it could be an adventure.

To be continued!
36
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by ORCoaster on March 04, 2024, 09:19:38 pm »
Less of a problem to check the bottom side than to pull the head.  Loose crank caps perhaps. 

Odd that you didn't suck anything out of the cylinders but then maybe the mice didn't get very far with their chewing and stashing work. 

I'd pull the pan. 
37
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by fatmobile on March 03, 2024, 10:01:30 pm »
  Ahhh too bad some stuff didn't fly out and then it turns.

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

 Did you figure out what cylinder is stopping the piston?

 I wonder if the flywheel was put on wrong.
 Been a long time since I heard of someone changing the clutch and screwing that up.
 While the injectors are out see if you can confirm the TDC mark on the flywheel is at TDC.
 Maybe feel where the piston is as the valves are opening.
38
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by Mohatanous on March 03, 2024, 04:36:22 pm »
Also, when looking up parts for this, is this a reliable site?

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

I typically use Rock Auto for all my other things, but didn't know if this site would be decent for things Rock Auto may not have.
39
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by Mohatanous on March 03, 2024, 04:11:54 pm »
After pulling the intake manifold off I was able to see inside a bit with a camera I have for peeking into small places like that. I was able to see all the intake valves moving freely, and all of the exhaust valves also appear to move freely and without sticking from the top when I turn the camshaft by hand. I was able to see the pistons coming up to the top of their rotations on each cylinder, but it still does not turn a full rotation. Pulling the injectors and glow plugs out and a combination of blowing air with a vacuum on the intake valves has not helped the issue, (I made sure that the intake valve for each cylinder was open while I had the vacuum on it to make sure any small crap may have been sucked out). I did not see any debris in the cylinders from my viewpoints. At this point I suppose my next step would be removing the head, although now I wonder if it could be something in the bottom end?

The saga continues!
40
IDI Engine / Re: Booster full of brake fluid
« Last post by ORCoaster on March 02, 2024, 06:11:17 pm »
Yesterday I got to tearing into an MC and proportional valve I found on Craigslist.  MC looked pretty good and once I cleaned up the little bit of rust inside the bore I was able to bench bleed it and have it hold pressure with all ports sealed off.

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

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

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