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91
IDI Engine / Re: Sharing my 1.6td project
« Last post by ORCoaster on February 22, 2024, 10:37:37 pm »
on the tach, if you can find the same cluster you have but with a tachometer for a gas engine then you can run a Dakota digital converter.

But Why?  and that isn't stock, so I don't like to do that.  I prefer the long way around and convert the tach to use the alt wire which makes it difficult to do.  That is just me. 
92
IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting
« Last post by ORCoaster on February 22, 2024, 10:10:02 pm »
DO NOT TRY YOUR STARTER ON THIS YET!!!

Get it checked for timing, that means you need to pull the valve cover and align the cams if you can.  Lobes of the first or last cylinder, #s 1 and 4 should be in the horizontal position.  The IP plug should be able to get in the timing hole.  I use a 3/4 inch carriage bolt for that pin.  The plastic plug on the end of the engine needs to come off so you can see the timing mark for TDC. 

Watch some U Tube videos, and GET A BENTLEY MANUAL, it will be used well in the future.  But if this engine has jumped time and you hammered that valve with the piston it will be toast.  It may already be that.  IF not the clearance between the valve stem and the cam follower will be off.  Measure that if you can. 

Don't want to alarm you but you are wading in potential doo doo here.  So many times I have read or heard of valves kissing the piston because of a poor timing belt job and it just shouldn't happen.  If the timing is off you will need to loosen the cam nut and get the pulley to spin freely.  Tapping it with a punch from the back to the front is normally the best way to do that.  The shaft is beveled with no keyway to keep it in place. 

IF the pulley isn't free when you go to put the belt on if replacing it you can't line it up right and will fight forever trying to do so.  Moving the pulley with the IP solid and the crank at TDC is what makes it all go smoothly.  Then when tightening the belt with the tensioner you will see it move slightly as well. 

Best of luck,  Not a good beginner story but you can keep out of trouble by making sure it rotates freely by hand four times around.  You were mechanic-smart trying to see if it would roll over by hand instead of hitting the starter. 
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IDI Engine / 1.6IDI Not Fully Rotating/Not Starting
« Last post by Mohatanous on February 22, 2024, 09:21:05 pm »
Hello all!

I am new to the VW Diesel world and just picked up a 1983 Rabbit. The individual I got if from said that it had been running about a year ago but tried to crank it and it wouldn't start. Upon having it looked at they saw that the air filter had been chewed on by mice and didn't even try to start it afterward in fear of damaging things. I bought it and got it home and before cranking it I put a socket on the crank pulley to make sure the motor would rotate freely before trying to start it. It makes it nearly one whole rotation then stops and will not budge. It does this in both directions and stops in the same spot. I am not familiar with these engines yet, and am curious as to what I may be getting myself into and what the best course of action may be. Any advice would be great!

The person before me had been running it on vegetable oil at one point, and then apparently a fuel valve had went bad resulting in diesel pumping back into the vegetable oil tank, so I believe that's why they originally parked it. It seems to me that perhaps somebody tried to start it with ether or something and it skipped time, causing catastrophe. I'm not sure though, so i am asking the professionals. Thank you in advance!
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FAQ/Tech Tips/Please Read First / Re: MK3 AFN ECU remove immobilizer
« Last post by fatmobile on February 20, 2024, 04:08:26 am »
I don't know about all MK3s but on the American ones with the AHU engine.
 The immobilizer is a separate relay. Like the seatbelt interlock relay.
 It can just be bypassed.
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I always have a hard time finding the link to the write-up/DIY.
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I was looking for a writeup on it. I'd think there ought to be several but maybe they're buried way back. I had to shim my waterpump pulley about 1/8" out from the engine and that put it dead nuts on. Then I used the deep alternator pulley and machined off about 1/4" of the big spacer in between the pulley and alternator. That put it very close but could use probably a 1/64" shave. I'd like to have the factory gear from a non-AC vehicle so there's no confusion when ordering parts. I'd figure it could be taken from a Rabbit diesel or any other non-ac diesel but I don't know for sure.
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 I think there is a writeup in the FAQs.
 Just rotate the AC alternator down, grind a little so it will go down farther.
 Use a ford double pully and the same AC belt.
 Along with some creative adjuster bar stuff.

I put this non-AC, MK2 stuff on all my MK1s.
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Parts for Sale/Wanted / WTB Parts Car 1986 Jetta diesel in PA
« Last post by Sawbones on February 17, 2024, 01:03:32 pm »
Looking for a CE1 car, non-ac, NA diesel, 5 speed, 4 door. Body isn't really a concern. It can be rotten to crap but I'd like it to be pretty much complete and non-molested. Trying to find within 100 miles of PA 18655

Thanks!
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MK2 Golf/Jetta and Audi 5k / 1986 Jetta Properly converting from AC to single V belt
« Last post by Sawbones on February 17, 2024, 12:59:12 pm »
I have a 1986 Jetta 1.6 NA diesel. It used to be an AC car. Previous owner stripped everything and it came to me with a waterpump and alternator that didn't line up with the crank pulley. I went through a bunch of nonsense and got everything in line but I'd like to have the proper single belt setup. If I were to walk into a part store I wouldn't be able to say what belt I need for my crank/waterpump/alternator nor would I be able to say what alternator I need. Can I get the parts from a Rabbit diesel or MK2 diesel and bolt it on, off to the races? My alternator is a long shaft motorola but it used to be a Bosch and I don't mind swapping it back if needs be.

What all do I need? I think crank pulley, waterpump pulley, alternator but if there's other things, I'm kind of at a loss.
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mTDI Mechanical TDI Conversions / Re: Thoughts on mTDI AHU head porting
« Last post by RabbitJockey on February 16, 2024, 02:48:23 pm »
hell yeah, please keep us updated on your project
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