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Engine Specific Info and Questions => IDI Engine => Topic started by: lovinthedeez on April 14, 2009, 11:11:59 pm
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long story short
1.6 n/a from 81 rabbit that i rescued
86 jetta gli. if you know the car, then......
i need a four door for my fast growing kid, so this is my build for him. seems pretty straight forward. i guess this is this official kickoff because i started building the glow plug harness, and the motor will be out of the rabbit and sitting in the jetta running by the weekend., hopefully. anyhow....Started soldering up the glow plug harness per vinces pimperglowplugs tonite to the tune of less than fifty dollars including heat shrink and plastic loom. home cheapot had the 4 guage wire for 89 cents a foot, and loom and shrink wrap for dirt cheap. solenoid was 13 dollars. a couple of pics of the donor and the jetta
86 pirelli 4door gli
(http://img142.imageshack.us/img142/219/img4672mk7.jpg)
(http://img216.imageshack.us/img216/597/img4675ki4.jpg)
finishing up her new shoes
(http://img21.imageshack.us/img21/9306/img4756ht6.jpg)
the poor rabbit giving up its little heart, and a few other things....
(http://img73.imageshack.us/img73/8161/img3303mw4.jpg)
pulling the motor on the rabbit on thursday; jetta is ready to receive.., who knows .....pics and more to come
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Bth those cars look pretty solid to me, must be nice to have clean old iron to work with!
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whatcha doin with the little donor rabbit? wanna get rid of it? i live in oregon on the coast.. i got a blue one basically the same as that one.
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because he wants to give that rabbit to me.. thats why. lol, i can only hope.
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i don't really want to ditch the rabbit, but it has come to that. i bought the jetta on a whim from some shady thought they were mechanics. I needed a four door bad, and that came up. it ran like a top when i picked it up, but the head grenaded on me 100 miles down I-5. after looking into it, the bottom end was shot, I found NUMEROUS things wrong/missing with their work. the car is really nice though on the inside, the rabbit sat for four years before I rescued it as a moldy mess, and my lady hates it. i have a nine month old gigantosaur boy who is too big to go in and out of a two door rabbit. shell has interest in it, so it won't be getting crushed. it is getting parted a little though before i'm done with it. thanks for looking at my project, tomorrow the motor switches homes. yahhhhh[/quote]
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so i'm just waiting around for my friend to wake up so i can pull the motor out of the rabbit as his house, so i took a couple of pics
THANK YOU VINCE FOR PIMPING MY GLOW PLUGS!!!!
i know its been done for awhile, but this is MY glow plug harness; and i was kinda blown away at the low cost of doing this
my fuse box, wired up with 4 guage, sealed with liquid tape, $8.50
(http://img139.imageshack.us/img139/1962/img5070.jpg)
my napa garden tractor solenoid 13 bucks
(http://img217.imageshack.us/img217/9634/img5069.jpg)
10 guage glow plug wires with soldered and heat shrunk modded lugs
(http://img231.imageshack.us/img231/2294/img5065.jpg)
Since Vince is the man, and likes using this stuff; for 3 bucks, why not
(http://img220.imageshack.us/img220/5076/img5071.jpg)
I found 4 guage wire at home depot for 89 cents a foot
the whole harness costs less than 30 dollars......amazing
thanks vince, and more to come tonite....big day today
one more pic....the whole reason i'm doing this....its for him
(http://img2.imageshack.us/img2/598/img4900.jpg)
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Good work!
Post photos of the swap if you can... :)
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Leather seats ? WOW ! I've never seen them in a Jetta from those days. Sweat !
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yeah, you'll see a set pop up in the classified every now and then for crazy amounts of money, right up there with trophy. the seats are soooo comfy. But on with the work, It was one of those days that whatever you did took twice as long. But this is how the day went. did it all by myself, with the exception of having help getting the motor loose.
here we go. sorry old friend, but I need that kidney you got there
(http://img25.imageshack.us/img25/5088/img5076d.jpg)
clean AND solid
(http://img21.imageshack.us/img21/1081/img5078b.jpg)
liquid tension ease
(http://img8.imageshack.us/img8/3080/img5085u.jpg)
its like a rat with no where to go...
(http://img206.imageshack.us/img206/2807/img5086.jpg)
my jacks just didn't cut it to get REALLY high
(http://img106.imageshack.us/img106/764/img5088.jpg)
so across the street to the tweakers house I go. they have a super sweet racing jack, took me two minutes to finish, and VOILA, the only thing that really went wrong is I bent the lip on the tensioner against the motor mount bracket trying to get it out. no biggy, replacing the belt and tensioner anyhow.
(http://img206.imageshack.us/img206/1565/img5090.jpg)
the black hole
(http://img113.imageshack.us/img113/4378/img5092.jpg)
big thanks to my buddy charles who let me use his garage to perform this swap. if your ever in ashland oregon, stop in to the creekside pizza bistro and get a drink. he's a bartender there and the food is great
hopefully we'll get the motor out of the jetta today, and maybe have the diesel bolted in at least. might have to wait until next week.
[/quote]
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so i've been busy with work and being able to get to work on this. I've had to tow the rabbit from where the works being done, and now tow the jetta there to finish the swap. I gathered some goodies in the meantime. I got a new timing belt and tensioner, and i'm gonna go back and get a new front seal, because that was where my oil leak was occurring. but i'm almost finished prepping the jetta to take the motor out. I also ordered a new acclerator cable, because its different from the gasser one, and a new cold start cable. i bet the old ones would have worked off of the rabbit, but i'm trying to make it look not hacked. put on the wheels from the rabbit for now. soon as i can get this thing towed.....the fun really begins. one question at the moment occupies my thoughts, anyone know the inner diameter size of the fuel line at the sending unit. waiting for mine to come in.....need to get viton.
(http://img14.imageshack.us/img14/284/img5103n.jpg)
(http://img11.imageshack.us/img11/724/img5105w.jpg)
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I want those nice low pros that was on the jetta :lol:
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I want those nice low pros that was on the jetta :lol:
why, you got a honda :lol: .ewuhhhhhh
i gave them away to put her og shoes back on. i made some honda kid's day.
but anyhow, I pulled the gasser out of the jetta tonite in 2 hours after working all day. forgot the camera, but it wasn't very eventful. first motor removal on a mk2....if only the rabbit had a removable core. hope to have this up and running by the end of the week. I'll make sure to get lots of pics. A couple of issues I've run into so far are minor. the first is the cold start cable. I broke the old one, and can't find an mk2 pull switch yet. not biggy, i can make it work. the power steering. still waiting on this loop kit deal that will kinda make it a lot easier to steer at low speeds. gonna use the accelerator cable from the rabbit, it looks like it'll work. the ends are different from the gas cable. now I gotta give the diesel a little freshen up with a new front seal, timing belt and tensioner.
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where i left off on the jetta. still gotta remove some random cis wires and such.
(http://img528.imageshack.us/img528/7398/img5106.jpg)
(http://img26.imageshack.us/img26/7342/img5114q.jpg)
still gotta take out the gasser fuel pumps, and sending unit, which came today. yahhhh
still to do:
install front seal, timing belt on the 1.6
get viton and run my own lines from the tank to the filter and pump to the tank
knock out the diesel nozzle restrictor
figure out which radiator setup to use (mk1 or mk2)
its getting close.. gonna split the motors from the trannies and let the diesel meet the ACN
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You're gonna use the exhaust manifold from the Jetta correct?
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You're gonna use the exhaust manifold from the Jetta correct?
yup, but I don't know how the rest of the exhaust will line up though. In the end I hope to just run a straight pipe to a cherry bomb. but thats later. lets get this thing running
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didn't much done tonight. introduced the diesel to a new friend. hello ms. ACN.
(http://img207.imageshack.us/img207/88/img5127.jpg)
checked to make sure that the rear motor mount lined up. Need to clean up those threads a little. what was the first vehicle to use those threaded holes as a mount? it just blows my mind that there are provisions for a motor mount that wasn't utilized until four years after the motor was built.
my buddy helping me out, reminding me to pick up dropped messes and such.
(http://img216.imageshack.us/img216/2913/img5113w.jpg)
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all i know, is that ive had a buncha OLD OLD 1.5 engines.. and they all have the provision. im pretty sure the engine in my car right now is from a 77 or 78
btw... that is a really good alt. mount.. i had just about every style i thought there was, then i came across one of those mounts. i havent bent or cracked it yet. the pressed steel ones are a joke.
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so I got a bunch of work done in the past couple of days. I got the motor in,and bearing its own weight. I had to cut the mk1 motor mount off to make clearance.
(http://img527.imageshack.us/img527/4954/img5152.jpg)
(http://img9.imageshack.us/img9/4608/img5153v.jpg)
put on the front core and subframe with new grade eight hardware, which the p/o was kinda enough to either not have or if it was it was finger tight; thanks.
then I got to work and back together the linkages and hoses, as well as the manifolds
(http://img527.imageshack.us/img527/4932/img5155.jpg)
got to the diesel nozzle restrictor and took care of that real quick with a chisel. came out in two big pieces.
(http://img6.imageshack.us/img6/311/img5159j.jpg)
I tore out the cis main pump, and will remove the gasser sending unit after I drain the tank. I still have to figure out how the rewire the three prong plug from the jetta to the two wire diesel sender. bought new fuel line to run new ones from the tank to the filter, and from the pump back to the tank.
(http://img402.imageshack.us/img402/2467/img5161.jpg)
still have to drain the tank, and put in the diesel sending unit and wire it
run new fuel lines
wire the alternator and starter
install new glow plug harness
intall cold start cable
connect diesel acc. cable end to the gasser one
make a home for the fuel filter under the hood
the list is getting shorter and shorter, and there and pretty much no more parts left on the floor
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so i'm stuck on the wiring on this thing. I know that I need the red/black wire that feeds into the coil to run to my injection pump. when I have the key on, that wire only reads 2 volts or so. Is it just because the motor isn't cranking. also, i can't seem to find the wire to energize the solenoid to the starter. this thing is an electrical nightmare, all the hack jobs. I think I want to make a box of switches to run everything. it would go something like.
wire a main power switch to the ignition (so you can't steal it)
then it would be like a helicopter
main power on
glow plugs ignited
turn on the 12v switched to the ip
then push button start
then vrooom....well more like putt putt put puttt
gonna tow it home tonite, because the motor is bolted in, and ready to roll. It will be much easier having it at the house to trouble shoot. It's so close i can smell the diesel. so excited
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I found my solenoid switched power inside by the fuse box....make sure it stays 12v while cranking too.
almost there...and looking good.
BTW I'm using the gasser "intank pump" and sending unit in mine...works great long as the gasser pump is running...if the pump is off the IP cant suck through it....then you dont have to rewire anything. :wink:
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got the car home tonight. now i can finish up the wiring, and this thing should be golden. my poor little bunny. won't someone come save him
$9.27 and a six pack.....how do ya go wrong......
(http://img514.imageshack.us/img514/446/img5201.jpg)
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still 9.27 and a six pack? and it still doesnt come with the front clip? or is that including the clip now too? only reason i havent gotten back to you on that thing is because i havent fixed my trailer yet, has bad brakes on one axle.
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i'm gonna put the late westy fenders back on it. all it will need is a grill and markers for late westy, or put on another set of round fenders and keep the early westy. i told everyone who wanted body pieces that i wasn't cutting it up. I don't have the heart to really start parting it out yet. the only thing thats missing from it so far is the motor, the headlights, and the k-bar. I thought it would be a problem for it to sit where it is at, but apparently not, so its just kinda sitting at the moment. why don't turbo diesels fall from the heavens in southern oregon like they do in ontario?
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needed to take a little break after i found the timing jumped, for reasons not to be said, and i heard a little clicking when trying to start it using the og starter wire. i feel so dumb not turning it before i tried to start it, but, oh well. I retimed it, rotated it three times by hand, with good compression it seemed all the way through. gonna finish the swap, and if worse comes to worst, a different head. i guess we'll see. in the downtime, I removed the rest of the gasser stuff, including the knock box, ecu, and its wiring harness, and coil.
(http://img6.imageshack.us/img6/3016/img5232m.jpg)
nice uncluttered rain tray......needs a good cleaning
(http://img14.imageshack.us/img14/6193/img5224j.jpg)
(http://img100.imageshack.us/img100/8998/img5223.jpg)
I'm left with my starter wire, my coil wire, my temp and oil plus a few other wires, and all my lights still work. i'm stuck at the water temp wires on the end of the head. i have to go through the bently and figure out what goes where.
(http://img10.imageshack.us/img10/1561/img5225w.jpg)
gotta cut the diesel end off of my rabbit cable and connect it to the old gasser one
(http://img7.imageshack.us/img7/3657/img5231k.jpg)
still gotta make a new lead for my the alternator plug. two B+ wired to a single lug to the starter solenoid. D+ to the exciter wire
(http://img2.imageshack.us/img2/848/img5233s.jpg)
still gotta:
install the fuel filter under the hood, run new lines
install new pimped out glow glug harness.
bleed system, its getting close.......
hopefully i didn't wreck the head
it kinda looks like it belongs there.....look at all that room
(http://img140.imageshack.us/img140/2163/img5222j.jpg)
the wire I believe I need to hook up to my stop solenoid; the red/black that went to the coil that is sitting just above the vacuum pump in the last pic, can anyone confirm?
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haven't gotten much done since its been raining the past few days. been wild goose chasing the coil feed that i think i cut when removing the cis. I think that the red/black wire I was looking at is the tach wire, which is why i was only seeing two volts. I'm kinda stumped on something so easy. Think I'm gonna run a 12v switch for the ip, I think. went and got a new tube flaring kit to use the old cis to/fro lines as much as I can, and use viton for whats left over. also got a siphon pump to get the rest of the gas out of the tank. Need to get this done, pronto......... :P
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thats the coil negative you got there.. i would just find some keyed power somewhere under the dash and just T off of that. the IP takes under an amp to energize the solenoid. and for some reason i think the coil positive wire is part of the CIS loom if i remember correctly. im pretty sure thats how my old 85 golf was.
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so i was able to put some time into the project today. plumbed up the fuel system, which involved changing out to the diesel sender, and installing new lines running from the sender to the old cis that run in front of the main pump. I still need to get some kind of clear inline filter in between the filter and pump so i can see any air bubbles in the line. went to wire up the ip when i found the p/os jimmy rigged something wired up in the 50 terminal of the ignition switch. i think its the fuel pumps, because i found the hot wire under the hood. here is that removed...its a relay for who knows what
(http://img223.imageshack.us/img223/2904/img5246.jpg)
looks much nicer now. and found my black wire to run my ip
(http://img23.imageshack.us/img23/4953/img5249o.jpg)
slowly chipping away. working on mounting the glow plug fuse box, and wiring it up to a switch in the cabin.
still have to
wire up the fuel level guage at the sender.
bleed it
check timing real quick
turn it by hand a couple times.
start
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come more pics from today
fuel filter needs to be lowered just a little, but has plenty of room for adjustment.
(http://img19.imageshack.us/img19/7528/img5251h.jpg)
took off the hard lines, and took off the the bus bar and starting wiring up the plugs with the 10 guage now you see it
(http://img15.imageshack.us/img15/5286/img5252e.jpg)
now you don't, that's where the fuse box and solenoid will be, where the wires come out of the loom against the driver side strut tower.
(http://img18.imageshack.us/img18/2028/img5255u.jpg)
got the cold start cable all hooked up while i was in there as well as the fuel cutoff solenoid, ran back into the cabin
(http://img8.imageshack.us/img8/5209/img5256b.jpg)
got all the hard lines back on it. left it for the night.
(http://img23.imageshack.us/img23/5104/img5258t.jpg)
this is taking so much longer than i thought. being back on a good weather schedule sucks....
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LOOOOOOKING GOOOOOOOOOD
I can't wait to start my own diesel swap! I've been waiting for good weather since October! :) I'm so excited, and I just can't fight it! lmao... :oops:
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well......lots has happened since. the car runs, drives, great; but has some serious electrical issues due to me removing lots of extraneous wiring. i have an uncut full harness on the way, so it shouldn't be too bad, I think. the p/o did some serious rewiring, and I figured the best thing was to remove and replace with the right stuff. so I got some pics to add. all in all, the swap itself was super easy. i've learned a bit, but not looking forward to rewiring the car, but anyhow.....some last pics and a couple of videos
installed the new glow fuse box and the solenoid. the lug missing the cable is going to the starter lug
(http://img25.imageshack.us/img25/4522/img5261u.jpg)
(http://img22.imageshack.us/img22/5058/img5262a.jpg)
the donor rabbit found a new home: my friend a co worker who has a post hurricane katrina diesel with a wrecked up shell, and all kinds of electrical problems. gonna swap out everything from his car into my shell. traded it for two cases of sierra nevada :P
(http://img27.imageshack.us/img27/6716/img5302.jpg)
a couple of videos of me trying to start it for the first time. i got so excited that it started right up, i expected it to idle by itself after only 15 seconds, so thats why i had to post the second video. the acn tranny is great for the motor, it just takes a little getting used to
http://www.youtube.com/watch?v=dgwDCUWgs3Y&eurl=http%3A%2F%2Fforums.vwvortex.com%2Fzerothread%3Fid%3D4387069&feature=player_embedded
http://www.youtube.com/watch?v=1Y0ntOKK5fE&eurl=http%3A%2F%2Fforums.vwvortex.com%2Fzerothread%3Fid%3D4387069&feature=player_embedded
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so after I got the motor running, I ran into serious electrical problems resulting from the po(s) bad attempt at wiring. luckily i got a smoking deal on all of the harnesses for an 86 diesel jetta for 45 bucks shipped to my door(thanks bunnylove). just got the harnesses today, and they look great; 99.9 percent uncut ;D. time for a date or two with my bentley. ::)
(http://img200.imageshack.us/img200/495/img5468.jpg)
been busy lately putting a motor on my daily, runs like a banshee on crack and sounds like an rm80
(http://img188.imageshack.us/img188/5224/img5469.jpg)
(http://img40.imageshack.us/img40/2695/img5470v.jpg)
don't think its gonna rain much until october, so this should be fun
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started the harness swapping. first one to do was the rear harness, since it seemed like the most pita to do. wasn't too bad since its pretty much a plug and play operation. got my fuel guage working again, just in time for a three hour drive into the middle of nowhere oregon coast for my friends wedding. hope to get a couple of dash harnesses swapped out today. I still have a short somewhere in my brake circuit, and my headlight circuit. ughhhh.....electrical.....all in time. ;D
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so i took my diesel conversion on its first real road test....a paved(if you can call it that) connecting road forty five miles long through oregons roughest stuff. the road is closed in the winter....so you can only imagine. I would love to organize a gtg drive on this stretch, but i guess it would be hard as it's not for the faint at heart or the too low group. went for a friends wedding in agness, oregon. the pics aren't meant to be artsy fartsy; just glad that she held up on some of oregons toughest terrain. rolled through the biscuit fire area from 2002; one of oregons worst wildfires in history (500,000+ acres). It burned hot, but not completely. but here it is......45 miles of singletrack through oregons finest.
(http://img189.imageshack.us/img189/2452/img5529p.jpg)
(http://img200.imageshack.us/img200/5361/img5530.jpg)
(http://img195.imageshack.us/img195/5237/img5531.jpg)
(http://img193.imageshack.us/img193/2733/img5535q.jpg)
(http://img192.imageshack.us/img192/9858/img5536.jpg)
sometimes, the road was just gone
(http://img132.imageshack.us/img132/656/img5541k.jpg)
biscuit fire damage...it burned so hot.....perfectly healthy trees only fifty yards either way
(http://img41.imageshack.us/img41/3470/img5539d.jpg)
the town welcome sign.....man i love oregon
(http://img23.imageshack.us/img23/4625/img5542p.jpg)
300 miles through some of oregons toughest terrain.....got roughly 48 mpg (http://media.firevortex.net/icons/custom/green/fv-green-banana.gif) (http://media.firevortex.net/icons/custom/green/fv-green-panic.gif) (http://media.firevortex.net/icons/custom/green/fv-green-yippie.gif)
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DUDE! that looks like a BEAUTY cruising road!
If i lived in Oregon i would cruise it with you ;D Glad to hear you got 48mpg!
Looooooooookinggggg gooooooodddd
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Great build!
My family and I are moving to Oregon next May. We were just out there for vacation last month. I really dont know if my little 1.5 diesel can handle. Any pointers or am I just over reacting. We have a auto trans rental car and it was push to the max trying to make it up to the Column is astoria...
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i live in southwestern oregon. very rugged down here. the highest point on I-5 separates oregon and california. siskiyou pass at 4000 something feet. it gets pretty burly in the wintertime. whatever ridge I went over yesterday was much burlier than even that, and my 1.6 na never even skipped a beat, and its got about 200K on it. bring it out here, and enjoy the sweet oregon life. just be ready for the tweakers ;D
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so I have three of the harnesses swapped in now. The rear harness and the two dash harnesses are now in, and that seemed to cure the shorting problem I was having with the brake lights. Now I have another issue. everything seems to work okay except when I have the key on, lights on. when i signal left or right, the rear lights and the license plate lights :o go off like the emergency flasher is on. i think its a grounding issue. now I have to go through the wiring again. anyone have any pointers to which grounds might be causing this whole headache. I think I'm just going to have to tear the dash apart again, open up the bentley, and figure out which ground didn't get hooked back up when I swapped the harnesses out.
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Hope I'm not going over old ground for you, by both my girls have huge braided copper grounding straps on the engine, starter and the tranny to the firewall; The starter strap was an obvious addition; not sure about the block and tranny one: my old 92 Golf NA had them too. Road salt is darn hard on them though, and they really need replacing. At the firewall mount, there is what looks to be a 10-guage black wire on the same eyelet that runs into the cab via the drain tray access on the driver's side. This is I re-route I did, as I removed one when I changed out the power rack for the manual one. I had to cut it to remove the bellows covering the steering knuckle.
Point is: there is a lot of PO grounding issues dealt with on both of these cars. I'm starting to think just running a 10 guage front to back for future convenience is looking damn good right about now.
Cheers,
Andy
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hey thanks for the info. i ran a wire real quick from the negative terminal to the ground screw in the trunk for the rear harness, and yeah, problem solved; mostly. still have no brake lights, but I bet once I put more grounds to the body in today or tomorrow, it will fix the problem. i'm pretty sure that the brake switch on the pedal is good, because I was getting a nasty short to the turn signals whenever i hit the brakes before. at least I have the turn signals under control now with the headlights on. my car is now officially no longer afraid of the dark. all I have left to figure out is these darn brake lights. looks like its voltmeter time.
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and i fixed my brake lights, too. turned out it was just a broken wire. replaced it with the wire from the harness i removed. Its kinda nice having two harnesses. got the same red black wire that was supposed to be there. car is now fully functional, with a few bells and whistles to be wrapped up. still have to put in the engine harnesses, but there is no rush on that, as not much will change.
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got so much "buttoning up" work done on this, its silly. still need to get the lower steering column cover on well, but whatever. cleaned her up a little bit, and doesn't have in it anymore any car pieces or anything. freshly cleaned, hastily, and took a few pics. put on the wheel a few days ago. glad I didn't screw up the car too bad during the swap. the wiring went from rats nest to pretty much og. only a have two harnesses left to go.
couple of side shots
(http://img229.imageshack.us/img229/6126/img5772l.jpg)
(http://img261.imageshack.us/img261/606/img5773.jpg)
interior shots
(http://img155.imageshack.us/img155/262/img5768.jpg)
(http://img222.imageshack.us/img222/3171/img5769.jpg)
(http://img522.imageshack.us/img522/8137/img5770.jpg)
(http://img512.imageshack.us/img512/6803/img5771.jpg)
she had some junk in her trunk. there were two of these rockford HE's in the back in some giant
ass box. sold one for $$$$$, and kept just one.
(http://img142.imageshack.us/img142/4393/img5775.jpg)
(http://img36.imageshack.us/img36/7359/img5774c.jpg)
hard to tell how much has bent spent on this really. all in all, i would say less than a grand still.... ;D
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playing with it tonight, still need a heater switch, and make my cold start cable stay in place at the dash so it will work right. what piece am i missing. is it just a c-clip that hooks it to the dash or what?
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well, I found the heater switch still attached to the dash harness that I pulled out. ;D. the set of harnesses i bought didn't have the switch or the socket, so that turned out nice. I even found the little key thing that makes it switch speeds :P. wired it up real quick, and I have a heater and defrost once again. sure glad its 101 degrees outside right now ;D. figured out that I need to get a nut to hold the cold start into place. I think I need to reroute the cable, because I can't get the threads past the dash where the locknut will go. I only need another inch or so, shouldn't be too much of a biggie. the list keeps getting shorter and shorter. boy, there were a lot of hacks to fix with this thing ::)
reverse lights.....just need to get a new switch
speedo cable.....just gotta order it
proper ce1 diesel cluster....anyone got one???????????
and I think thats it really. I'm kinda proud of myself at having done the swap as properly as I have. there really isn't much hackage anymore compared to when I started. its still got a long ways to go, but at least i have the po's work fixed.
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Don't you hate PO'S work!? I was lucky on my jetta.. Completely un-molested. My 67 mercury on the other hand.. omfg.. Wanted to burn it down because of the mess it was in.... lol
GREAT JOB DUDE
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i totally hear ya on that one. this car; before the swap, caused so much stress with me/my lady/me and my lady/my baby. i wanted to push this thing off a cliff after setting it on fire sooooooo many times. went from a bad car buy deal, to a big letdown gasser head rebuild, to this; six months later. but the wrenching is over (for now ;D), and now it's just down to making it nicer for the fam. now I need to get back to work on the p slots. :P
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Does your tach work with the diesel engine?
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Does your tach work with the diesel engine?
nope, not yet. been trying to find a ce1 diesel cluster first before I get on that project. I've been driving standard cars; diesel's lately, all my life, and I don't think there is any need for a tach anymore. If I can't find one, I'm putting a clock back in. ;D
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decided I was tired at looking at this brand new water pump for the old gasser that was in the car before, and put it in today. water was a nasty brownish color. needed a good flush. the temp was kinda all over the place before, but it seems like it is running a little hotter than before, staying in pretty much the same spot all the time. the thermostat already in the housing was for the gasser. I didn't have time to get a new thermostat before I needed the car, so I just used it as it was. gonna get the diesel thermostat tomorrow and see where she runs. pump definitely looked like the original one. :P need to pull the aluminum thermostat housing off of it, and replace my crappy plastic one. ;D
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Now you need a turbo and intercooler!
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Now you need a turbo and intercooler!
yup, someday. I just found out the "new" waterpump i just put in had a bad bearing, which burst my middle waterpump hose. found this out on my trip down to the sf bay to see a concert with the fam. 130 miles into the trip, that happened. spent all day trying to put a new pump on, when I found the housing was cracked pretty good. sad thing is I threw away my old pump, which had a perfect housing. jb welded the housing, and limped it back home 140 miles with the radiator cap off so I could keep refilling it. amazed I didn't blow the motor.
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dang... that really sucks.
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this overheating is KILLING me ::)(stolen from the troubleshooting section :-X)
so before I hear the usual, let me explain what I have, and what I know.
swapped 1.6 n/a from 81 rabbit into a 86 jetta
still have the gasser exhaust from the manifold back
still using the gasser radiator from the jetta
never had a problem until i put in a new ( which turned out to be bad) water pump
car runs fine, even when getting hot. no smoke or anything
seems to run a little cooler when I leave the exp tank cap off. this makes me think head gasket. but if it is, shouldn't it be smoking, or not running right. the thing is that it runs FINE. no noticeable difference other than the temp guage. I live in a small town, and have been taking it all over the valley without a single snafu. however lately, it seems at the guage level to be overheating. I guess what I'm asking here is, is a couple of things
what would be the symptoms of a clogged gasser cc?
if blown hg, why running fine and no smoke: esp the cap on/off thing.
radiator plugged?
just getting real frustated. gonna drop the oil in the next couple of days.
a link to what seems to be causing all my recent headaches.
http://www.vwdiesel.net/forum/index.php?topic=20720.0
I'm blown away by the fact it runs fine sometimes, and sometimes the temp guage will shoot straight to the top after only a couple of miles, but still run fine. ???
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mine ran great....and I mean really really great.....HG was blown in 4 spots :P....the longer I drove it the more I noticed it was dropping off on performance...I was really surprised that mine ran so good with a blown HG...mine did not even over heat really...just kept puking coolant out the expansion tank.
how does a bad water pump bearing blow a hose?
pulled this from your other post..
"made it home 109 miles back over the mountains home, and the engine running decently.....just freaking hot"
how hot is FREAKING HOT?
best way to check your HG is to take it to a emissions shop and have them sniff the coolant expansion tank for hydrocarbons..
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freaking hot meant the needle was just about pegged the entire trip home. kept stopping to put a little more water in it. I don't know if the water pump caused the hose to blow. It was just kinda funny to actually see it blow and pee all over my foot like that. I can kinda smell the HC through the expansion tank. It must be the HG. can't see it being anything else at this point. I am just amazed at how well it runs with a blown headgasket, that's all. Either that or my head is fubar. either way, I see my little motor coming apart in the near future anyhow. not a big deal, as I work five blocks from home, and I don't really need a car. The little lady has her own. now if someone has a td just sitting around, could I please has it, pleeeeeasssssssssse ;D.
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i have BUNCHES of stock TD parts i will never use.. you are close, so i could make you a smokin deal if you wanted some of the pieces. i dont have a turbo oil pan, return line or feed line, or the turbo. but i have all the manifolds and important stuff.
and about your headgasket, they run fine with blown gaskets. i blew a HG once, put a new one down, and it wouldnt seal. pulled it back apart, and voila, the driver side of the block was pretty much cracked off, but it still ran great!
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finally got the motivation to get going on this since my motorbike wrecked its clutch. ::) So went to pull the head today, and got as far are pretty much having everything unhooked minues the injector lines and plug wires. lots of room to work and everything went smooth on disassembly, as it should have.
(http://img245.imageshack.us/img245/8859/img6638z.jpg)
(http://img245.imageshack.us/img245/7237/img6639.jpg)
(http://img190.imageshack.us/img190/5317/img6640w.jpg)
more pics to come in when the head comes off.....hopefully nothing but a headgasket.
:D
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so I got the head off today, and was actually kinda happy at what I saw. from before, I was overheating very quickly with puking out the coolant reservoir after only a couple of miles of driving. After limping 140 miles over the mountains running as hot as it was, i still won't be surprised if I cracked the block or head. but all I found after tearing off the head was a blown headgasket between at the #1 cylinder, and some pretty gnarly almost blocked off coolant passages. pistons had only a thin layer of carbon which wiped off with just a rag. bores look 2XX,XXX miles old, but still really nice. from the look of the ridges, I doubt it has been bored at all, which might come in handy later. ordered all the parts today, so that will give me a couple of days to clean it up real nice. a couple of pics of what I found; my camera blows so go easy on me ;D
gasket still on the block. looks like the p/o wasn't too keen on coolant changes over the 13 years he had it ::)
(http://img43.imageshack.us/img43/8943/img6642t.jpg)
(http://img27.imageshack.us/img27/4571/img6643p.jpg)
so (I think) it looks like a failure between #1 and 2. didn't really know why the oil is at the upper #3 bolt hole, but I figured it was just because maybe the gasket blew near there too?
(http://img15.imageshack.us/img15/2542/img6644r.jpg)
head looks alright for the most part. cracks seem a little worse on 1 and 4. a better head is definitely on the shopping list now.
(http://img40.imageshack.us/img40/2203/img6645x.jpg)
pics make it look worse than it really is. I think its gonna clean up very nicely tomorrow.......
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sooooooo.......after looking at the pics once again, i'm getting a little scared, actually just paranoid. why is oil there on the bolt hole beneath the #3 cylinder on the block pic. If the block was cracked, it wasn't because of me, because
1. this motor hasn't been cracked open for at least 100K miles(when p/o did a re-ring)
2. I though the infamous cracked block came from re-installing the head
3. It ran great the last two years I've been dailying this motor in two different cars, up until the day the wp went.
4. its a 11mm head.......
paranoid yes; scared, no.....
we'll see what 50 bucks in parts is gonna do. more to come
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sooooooo.......after looking at the pics once again, i'm getting a little scared, actually just paranoid. why is oil there on the bolt hole beneath the #3 cylinder on the block pic. If the block was cracked, it wasn't because of me, because
1. this motor hasn't been cracked open for at least 100K miles(when p/o did a re-ring)
2. I though the infamous cracked block came from re-installing the head
3. It ran great the last two years I've been dailying this motor in two different cars, up until the day the wp went.
4. its a 11mm head.......
paranoid yes; scared, no.....
we'll see what 50 bucks in parts is gonna do. more to come
Can you see all 4 photos you posted yesterday? I can only see the 2nd and 4th. So, I can't see what you are asking about.
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I have a few days until my parts get here, and I have the next two days off. plenty of time to clean that dirty little puppy up. and with the head off, I think its time to put my shifter rebuild stuff in seeing there is sooooo much room to work down there now. good to hear that the oil around that bolt hole is no biggy. I kinda figured it was nothing at first, and then started second guessing myself :P. now to get off my butt and to the store to get some stuffs.
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the head bolt hole is where the oil enters the head dude. dont worry about it, nothing is wrong. its supposed to be like that.
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so thinking that parts would arrive by the weekend, I went thru my fav online parts place. for the price of local markup and free shipping, I got t a few extra little things for nothing :P. The price I paid though is time, but whatever. I have the block and the head all cleaned up for the most part, and didn't find any cracks in the vicinity of the head bolt holes. The block cleaned up real nice, but the head was kinda tougher because I didn't want to use my scraper. I'm using a pretty good gasket stripper aerosol, but the head had some caked on stuff around the coolant jackets. I don't wanna go through the hassle of plate glass or anything like that. just looking to clean up some gunk. What are people using out there to clean up the head surface?
but anyhoo, parts come tomorrow. I'll have it together by tuesday. fingers crossed ::)
also thinking at this point. if the thermostat reading is close to what is was before, the radiators are getting swapped to the rabbit rad
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What are people using out there to clean up the head surface?
With a cautious mind and steady hand you could dress the flats on that head with scotchbrite on a drill pad.
Or do it by hand with an SoS BriLLo pad.
And/or red scotchbrite.
Plug up all oil and prechamber holes and cover all significant adjacent areas. Duct tape over any opening/opened valves as needed.
Blow everything out good when its over.
Put 12v to each Gplug and see if the prechambers glow nice too.
I just walked into this and haven't read all the pages, but it would be a fine time right now to do a first class Gplug wiring revamp -
- if you haven't already done one.
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got it all put back tomorrow yesterday. install went without any problems. I pulled the thermostat to test it before I took it for a test drive, and it turned out to be bad (just bought it before the pump went ::)) So now the motor runs GREAT, just need to get a new thermostat. so yup, no more overheating, no more coolant puking, and no more leaking; at least for the most part. wish I took some pics before I slapped everything together, but the little lady had the camera. So after all, this was caused by a cracked wp housing and a bad thermostat. wish I could remember who sold me that stuff on the vortex so I could go choke em. :P But whatever, I got my rig back and runs better than it ever did in either car......very happy for 50 bucks and five hours of labor. it was also good to see the motor cracked open to know it might be a good idea to start shopping for a new head.
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you need an old style mech 12mm head right? ive probably got you covered.
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got it all put back tomorrow yesterday. ..........So after all, this was caused by a cracked wp housing and a bad thermostat. wish I could remember who sold me that stuff on the vortex so I could go choke em. :P
tomorrow yesterday? That's a new one on me. ;)
Did you buy a used thermostat and water pump from someone on vortex???
Anyway, good that it's back on the road.
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tomorrow yesterday? That's a new one on me. ;)
Did you buy a used thermostat and water pump from someone on vortex???
Anyway, good that it's back on the road.
I bought what I thought was a new in the box pump. I didn't give it a thorough lookover over when I first got it, so I don't know the housing was cracked or not before I put it on. I bought the thermostat new, but again, I didn't check it before I put it in.
and rabbitonroids, its a mech 11mm head, but I think i want one of your other 1.6's for my other jetta.
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My thermostat was stuck shut when I bought the car. It was heading to the graveyard in the sorry shape it was in. It had everything against it staying alive. The connectors on the 2 temp sensors were swapped so the temp gauge was not working. The fan relay and the other relays (except one) were laying on the floor because the fuse relay panel was not mounted and hanging by the wires and the left foot kicked all the relays off. I didn't know any better at the time, I thought they were extra relays. The connector to the radiator fan was not plugged in all the way and fell off, same thing with the radiator temp switch connector. My friend drove the car home that way and luckily didn't kill it. On the drive home, he stalled the engine (forgot it had a clutch and jerked the engine) and it wouldn't re-start because the connector to the starter motor solenoid fell off!!! .I really want to wring the neck of the last person who worked on my car. >:( When I put it a new thermostat, I made sure it tested good in boiling water before I installed it. I fixed things one by one and it's running pretty good now. :)
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tomorrow yesterday? That's a new one on me. ;)
Did you buy a used thermostat and water pump from someone on vortex???
Anyway, good that it's back on the road.
I bought what I thought was a new in the box pump. I didn't give it a thorough lookover over when I first got it, so I don't know the housing was cracked or not before I put it on. I bought the thermostat new, but again, I didn't check it before I put it in.
and rabbitonroids, its a mech 11mm head, but I think i want one of your other 1.6's for my other jetta.
other jetta? i didnt know you had multiple jettas.
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got this 84 gl kicked down to me from a guy who snagged the td out of it and was gonna scrap the shell (he does the bus/van thing)
(http://img406.imageshack.us/img406/7505/img5901.jpg)
fully complete except for the motor itself which the guy did a great job of taking it out with cutting anything. it just sits waiting for a motor....someday
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That rabbit was sweet. Nice Pirelli Jetta though. Good work all around!
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thanks......that rabbit was a moldy mess that I rescued from behind some tweaker's trailer that had sat for 3 plus years
(http://img263.imageshack.us/img263/6969/img2792gd4.jpg)
(http://img233.imageshack.us/img233/6450/img3082vm8.jpg)
the inside was just plain shatty. mismatched everything, spray bombed dash, no carpet or headliner. the only good thing about it was the body and the mileage it got. the shell will live again as my friend now has it.
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so I finally got around to putting in another thermostat, and got some interesting results. so I bought the 180 degree thermostat. after installing it and test driving it, the temp guage is right back where it was before, smack dab in the middle. it doesn't deviate though, so that makes me comfy. so like I thought originally, the pump water pump must have been crap when I installed it. Maybe the guage is just not reading correctly. I thought that gassers used the same 180 degree thermostat, so why would would the guage read differently as I've heard before. Still need to dial in my timing though. waiting on a new dial indicator as I wasn't real happy with my old one and got rid of it. need to get on this before the rainy season hits :P.
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a lot of time has passed and I just let the car sit for the most part. I just put in a new water pump and housing in from german auto parts and it runs great. Also put in new glow plugs, and she runs perfect right now. I love it. looking for turbo parts atm. got this guy to work for cheeeeeaapp.
(http://img341.imageshack.us/img341/9567/img7421z.jpg)
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thats really cool that your kid is under the hood every time you are. hes gonna be a big boy huh? and its obvious he already has grease & diesel running through his veins..
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installed the block heater last night, and now hard starts in the morning are a thing of the past. still need to time my pump though. all to come when I get my new tools. :D Thing runs amazing now. sooooo happy. best 25 bucks i ever spent
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been working on trying to tidy this thing up lately. removed the center console, and kinda like it better that way. trying to hide some wires and run a new power supply for my gps. Also got my glow plug switch carved into a dummy switch next to the defrost.
(http://img714.imageshack.us/img714/2200/img8049.jpg)
(http://img163.imageshack.us/img163/4383/img8050y.jpg)
Got some new duraterms for nine and change from parts geek, and finished my electrical upgrade. t6 after years of drooling over your guys', I finally shelled out the coin. local napa has em for 149 :P
(http://img709.imageshack.us/img709/1298/img8047.jpg)
sad to say though, that if i end up getting the mk1 i want next week, this thing is goin bye bye. :'(
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bought new fuel line to run new ones from the tank to the filter, and from the pump back to the tank.
(http://img402.imageshack.us/img402/2467/img5161.jpg)
still have to drain the tank, and put in the diesel sending unit and wire it
run new fuel lines
wire the alternator and starter
install new glow plug harness....
When did you purchase new fuel lines for send and return from the tank? My dealer has them for $40 each. Is there anywhere you can buy the bulk hard plastic tubing that is used in these cars? My return line has a block... :-\
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I only ran lines from the sender to just in front of the fuel pump that you quoted to the nylon lines that I think you are talking about. If you dont want to get the nylon, just run fuel hose all the way up. just make sure its secured real well.
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I only ran lines from the sender to just in front of the fuel pump that you quoted to the nylon lines that I think you are talking about. If you dont want to get the nylon, just run fuel hose all the way up. just make sure its secured real well.
I suppose its the stiffer nylon lines that I'm looking for; All the way from the engine bay back to the tank. EFI Nylon Fuel Line? Is that what it's called? Thanks for the help.
So you keeping the Jetta or going with the Mk1?
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any fuel line that is rated for use with diesel fuel, and can be used under vacuum (sucking of the ip).. should be good to go.
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So you keeping the Jetta or going with the Mk1?
keeping the mk1, and parting out this one.....im me for things :P
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So I sold my beloved little experiment yesterday, and am getting ready to deliver her to the new owner. It's a little saddening but its time has come. I don't have the time to tinker with the little bugs that come up with it now, and the new owner seems like a good person in a crappy situation who needs a car right now. He's never had a diesel but seems happy to learn. When on the test drive, he beat it like a gasser, which I kinda had to let him know about the world of diesel. ;D. Car was sold in the parts section and sold as parts in the bill of sale. lets all wish this guy good luck......... :P I'll try to get one last pic of it....
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for your glow plug set up. it looks nice. did you make a on off switch? how does the solenoid work? why is it needed. im doing my first swap aswell.
i was thinking running it inside and just have a switch to power on and off.
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HEY!! you got an ACN with a N/A... how terrible gutless is it?
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1st....same as GP 4 sp
2...pretty much the same
3...great for in town/city driving
4..great for the 45 mph speed limits where the 4 speed just plain sucks
5..70 all day long in a n/a mk2 in comfort
With the ACN, the difference is all about 3 and 4.
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hey you swap is looking good.
i did a swap pretty much the same as yours.
i have a problem. my car wont heat up as much maybe half way. changed the thermostat and it only goes about 1/3 on the gauge. blows somewhat worm air when parked as soon as you start driving. cold air. i have the gasser big radiator.
does your heat work on highway speeds?
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Mine worked fine. It always ran about halfway between hot and cold