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Messages - ORCoaster

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1
General / Re: What did you do to your car today?
« on: July 15, 2019, 10:24:18 pm »
Rube aint got nuttin on me!

What was I trying to accomplish?  Good straight forward question, glad you asked. 

I was looking to set the pressure on a set of 130 and 155 bar injectors from the multitude of spares I have laying around.  I agree that getting the proper pressure balance across a set really makes a difference in how it idles and runs.  But I didn't have that equipment so I decided to go an alternative method.

I can still see the type of spray that is coming out the end, so is it properly misting or straight streaming and going to bore into the piston?  That is a visual accounting for proper operation is it not?  Then there is the fact that I can turn the pump at various speeds and note if there is any difference at higher or lower RPM.  I can also time the amount of the operation on a set and come back and measure with one of those small syringes for volume.  I can figure out a fair balance between the sets that way.  I tried a comparison with two of the 130 and two of the 155 bar injectors and can definitely note a difference in volume in a one minute run.


So I am not trying to be old school with the pressure thing.  I am trying to do something different and to me it makes sense.  And little in this world makes sense to me now. 

Mostly I was trying to figure out which of the injectors I have are worth using.  Which ones are not atomizing correctly and which ones might get better if I cleaned them up. 

After going through about 6 of the worst ones I only saw one nozzle that was sent to the trash can.  All others cleaned up well enough with a wire brush and a small grinding wheel.  Just kidding, only cloth and paper used.  Solvent works wonders. 

I will pull a set off the Rabbit and see if the 130 bar set I have now will make it run any better.  It is a bit blue on the hard pulls.  Might actually be valve stem seals.  Oil pressure is kinda high, 100 psi

2
General / Re: What did you do to your car today?
« on: July 14, 2019, 11:24:59 pm »
I can't believe that in this town where log trucks and diesels outnumber sports cars 10 to 1 there are no, nada, none, places that will service a set of fuel injectors.  I get responses like, just buy new ones they are cheap, to we send all ours to Eugene or Portland.

What a waste, and not exactly helpful for a Home Fixer.  So out of desperation I thought I would just build a pop tester from a hydraulic jack.  Then I hit the pause button.  Wait a minute, I have two spare fuel pumps sitting around doing nothing.  Time to make a four port pop tester. 


I put the bracket in the vice, bolted up a pump and proceeded to wire it with a 9 volt battery, some hoses and then I found my adapter set for my socket set.  I needed to put the 1/4 inch drive I use in my drill driver in a regular drill chuck and then upsize that 1/4 inch to a 3/8ths and slap on the 19 mm socket to drive the front end. 

I found it works just dandy but now I need containment around the injectors.  I tried a simple baggie so I could see the stream coming off each one.  The first few squirts on some of them was straight stream that cut right through the thin plastic.  So I am fabricating some plastic jars around them.  They will just hang off the nut in top of the injectors. 

I have about 4 sets of 4 injectors that I want to rebuild so this multi port apparatus is going to make it faster than doing them one by one. 

Anyone else have such a setup?

3
TDI Engine -General Info / Re: Boost Gauge (lke to install one)
« on: July 11, 2019, 10:59:49 pm »
I finally flipped my engine over to a 1.6 L turbo and I was using a VAC/Boost gauge to monitor the brake booster but now it is on the turbo doing boost duty. 

I run an AutoMeter gauge, 2 1/16, white face with black numbers and a red sweep needle.  It is illuminated and seems to be well made.  As for instructions, I am pretty sure it came with something more than the classic four boxes with illustrations in them and no words.  Not sure of the price but thinking somewhere in the 30 to 33 range. 

Some gauges do not come with the 1/8 inch nylon tubing and the fittings to hook it to a 1/8 inch threaded port.  I had an oil gauge for the turbo that had me buying a separate kit for that purpose.  So watch if the gauge comes with hardware or you will be down to the local parts place buying a kit.

4
Diesel Swaps / Re: Rabbit '78 how hard is it to add 1.6TD?
« on: July 10, 2019, 11:53:36 pm »
78 Rabbit would have the 1.5 liter engine and most likely a 4 spd transmission.  If I was looking to replace the engine I would look for a 1.9 TD from an early Jetta, and try to grab the 5spd trans with it.  A new shift kit for the five on the floor and the rest is pretty much a bolt on.

But, But before you go that route you could just put a turbo on the 1.5.  Use one from the same era of the jetta mentioned above.  I just tonight got my truck back from the exhaust shop and they did a fab job on putting on a 2.25 pipe, muffler and redoing the flange off the turbo.  They needed to cut it and rotate it about 180 degrees.  I grabbed it used from a guy that had the other style of mount of the turbo.  Exhaust needs to flow out the drivers side on a Rabbit.  Turbo mounts up top. 

I bet all in all I didn't spend 900 bucks on the turbo, intakes, and exhaust and all the needed hoses and oil lines.  Drilled the oil pan myself rather than try to find one off an engine that already had it on there. 

How does it run?  Sooo, smooth and boosts to about 10 psi right around 2500 RPM.  I am blowing some coal so injectors and IP tuning up for this weekend.  Been trying to do this project for over a year.  Things just got in the way.  Hoping for more mileage and that extra kick of power when needed.  I already noticed the EGTs were way down from what I was running on the slight hills in town.  Dropped about 300 degrees and under boost it barely rises. 

Lots to do on a old sitter like that.  Seals didn't get lubed, bearings and brakes likely dry as well.  Engine might be the later thing to be working on.


5
Troubleshooting / Re: Modified ALH : acceleration backfires ??
« on: July 04, 2019, 10:40:40 pm »
EGTs sound normal to me.  I cruise in the 400 range most city driving and 600 if doing 50 on the hwy.  Put the foot down hard to make a long hill in fourth and I will see 1200 at the top of the hill.  All within range I say.

Get the VCDS back and adjust the fuel and I think you will be fine.

6
IDI Engine / Re: 1.6TD head on a AAZ?
« on: July 02, 2019, 07:24:10 pm »
So Knowing that you have a greater compression ratio going than stock can't retarding the timing adjust for that?  Otherwise you would have a very sharp clack going there. 

Rather than the normal 1.6 timing of 88 to 93 could you not try say 85 and see what that gives for performance and then either reduce it some more or bump it up to 88 and see what it sounds and runs like.

Just playing with those what if's in my head.

7
IDI Engine / Re: 1.6TD max fuel screw question.
« on: June 26, 2019, 11:11:38 pm »
Sounds more like timing issue to me.  Once it gets rolling the advance gets over far enough that you come near normal and it starts to run right.  Have you done a timing check on it?  Got the tools?  You may just be able to loosen the IP for starters and see if you push it towards the head it picks up RPM and smooths out for now.  Very tiny movements are all it takes. 

Mark a line across the IP and the bracket it is secured to so you can come back to that adjustment if moving the pump makes things worse.

Best I can think of for someone with a new to them Rabbit and no manual or specific tools.

8
IDI Engine / Re: valve shims getting thinner
« on: June 20, 2019, 10:43:38 pm »
Perhaps the shop rebuilding the head took the time to grind the valves off on top to get a more uniform set of shims under the lifters.  They may have had a large stock of that range and tried to use them up.   

9
IDI Engine / Re: valve shims getting thinner
« on: June 19, 2019, 10:32:06 pm »
Are you wearing away your cam lobes?  Wear marks in the shims themselves?  In order for them to get tighter something has to be wearing down allowing the slack to be less and less over time. 

10
IDI Engine / Re: AAZ oil pan gasket.....RTV or dry?
« on: June 18, 2019, 08:05:00 pm »
I always apply a thin layer of RTV on the pan gaskets.  I may not need to but I have not had oil drips when I do.  Insurance cheap insurance to having to do it again. 

11
General / Re: Time to go elsewhere
« on: May 24, 2019, 10:29:20 pm »
Still finding the fraudsters every now and again.  Just keep reporting them to Moderator.  He will ice them as he has the time.  That is a sideline, to a real job that takes plenty of overtime to maintain.  But it is done for the greater good.  So thanks for that!

The object is not to gain but to do, all about the quest and bragging rights I expect.  We could as a group go flood some Ford or Dodge Diesel forum with VW questions if we wanted to so we could come back here and snicker about it.  But why?  Who has that sort of time these days.  NOT ME and I am retired now. 

12
IDI Engine / Re: 5 liter oil capacity.......how much circulates?
« on: May 21, 2019, 10:47:17 pm »
Nice cuts there fella.  Not done with the saws-all I own that is for sure.

13
IDI Engine / Re: 5 liter oil capacity.......how much circulates?
« on: May 18, 2019, 10:28:41 pm »
Mod the oil pan?  OK if you have to. 

I would think 2 liters is a bit much for all that is circulation.  Maybe counting the head catching some and then the drain down. 

I would suspect that if you keep the pickup tube the same distance from the bottom of the pan you would not have any problems.  The volume in there would be higher at the one end if the capacity was the same.  So do you think you would have problems with the crank splashing into it and creating flow disruptions? 

More oil in the same pan would be similar and don't we get warnings not to overfill past the full mark by more than 1/2 a liter.

Just some thoughts.  Keep us up to date on this. 

14
Troubleshooting / Re: Irritating oil leak...
« on: May 18, 2019, 10:19:52 pm »
Brilliant in the simplicity of it all. 

And no more fungus or it smells like a baby for awhile.

15
General / Re: Time to go elsewhere
« on: May 18, 2019, 10:17:34 pm »
Thanks!!!!  Now we can go back to our abnormal diesel discussions. 
Great site until the hack happened.


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