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TDI Engine -General Info / Re: Bad Turbo?...
« Last post by libbydiesel on Today at 12:52:00 pm »
It's normal for the intercooler tubing to have a somewhat alarming amount of oil in them.  The oil comes from the crank vent as oil mist and vapors that then condense in the tubes. 

A far more likely cause of excessive smoke on startup is that you have air entering your fuel lines or pump.  This can be from anywhere upstream of the pump (very common cause on the mk4's is the fuel sender), from any leaky seal on the pump, the return line, or even the little jumpers between the injectors.  Air entering the fuel system will cause it to smoke until the air is purged from the system.
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IDI Engine / Re: Klaus, the 84 Jetta TD, gets a rebuild
« Last post by wolfsburged on Today at 09:35:19 am »
Thanks for bumping this - I enjoyed reading immensely - would not have found it otherwise. You did a proper rebuild and the longevity proves it as well reaffirming the 1.6's as solid motors.

Few questions. I also found the TT downpipe pricey - maybe I missed it but where did you get your exhaust?
Did you have to cut the telescopic bumper mounts to bring them in? How did you deal with the plastic cover on top of the bumper?

Any issues besides regular maintenance? What would you have done differently? How was it servicing such a busy engine bay? What original components have you had to look at due to age?

I am keeping an 84 alive myself so I'm very curious (factory TD as well)

http://

The exhaust was completely custom from turbo back, done at a local exhaust shop that had a mandrel bending machine. It was around $600 I think, and has held up great despite not being SS.

Bumpers - the last photo I posted is actually a set of european market Jetta bumpers which sit much closer and are much lighter. I previously had run the stock bumpers but had drilled holes in the shock absorbers, released the pressure, compressed, and then tack welded them to stay compressed. That certainly helped a lot but was still not as neat and clean as the euro bumpers. I kept the top plastic covers in place with the tucked bumpers, but had to get creative to keep the clips in place as there was no room to access them on the rear once tucked. I used a nylon tie strap and clip vs the factory clips.

Issues - I recently did a semi-refresh on the car due to a number of small issues that built up, but nothing major related to the rebuild.

Replaced rear wheel cylinders due to leaks, e-brake cables due to age at same time
Replaced fuel tank after my JB water weld repair from 10 years ago finally failed
Patched floor pan due to small bit of rust that popped up

I fought engine gear oil leaks for a few years and finally solved those. I somehow had ended up with a mismatched 020 transmission case and selector shaft cover, and did not have the case vented as a result. I put a few flange seals in only to have them leak. Once we figured out the pressure/vent issue, I drilled a hole and put a vent in and no problems since.

I had a water leak in the cabin from my AC condensate water, a problem most don't have due to broken systems! Fixed that up as well.

I did some interior upgrades, new carpet, later Cabriolet speaker pods to support larger speakers, etc.

Went through earlier last year and cleaned up some of the engine bay wiring better, re-routed and wrapped harness and repaired some wiring that was falling apart due to age.

Engine bay is not too bad now on complexity, certainly compared to newer cars. Biggest complaint continues to be the v-belt system in general with AC. It takes a few adjustments over the course of a few weeks when changing belts to get the tension correct, and it's a PITA to work on.
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IDI Engine / Re: Klaus, the 84 Jetta TD, gets a rebuild
« Last post by oblique on July 19, 2018, 10:28:09 pm »
Thanks for bumping this - I enjoyed reading immensely - would not have found it otherwise. You did a proper rebuild and the longevity proves it as well reaffirming the 1.6's as solid motors.

Few questions. I also found the TT downpipe pricey - maybe I missed it but where did you get your exhaust?
Did you have to cut the telescopic bumper mounts to bring them in? How did you deal with the plastic cover on top of the bumper?

Any issues besides regular maintenance? What would you have done differently? How was it servicing such a busy engine bay? What original components have you had to look at due to age?

I am keeping an 84 alive myself so I'm very curious (factory TD as well)

http://
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TDI Engine -General Info / Bad Turbo?...
« Last post by willbz on July 19, 2018, 09:15:11 pm »
My ALH Jetta is has a very thick cloud of blue smoke both on startup and while being driven. Boost seems normal. Took lower intercooler line off and a large amount of oil is in bottom of cooler. Indication of a bad turbo seal? I have not ran the engine due to fear of a runaway. Could overheating the motor from couple days prior cause this seal to go bad? Although blue smoke was present before it was never Smokey while driving. Thanks all -will


Sent from my iPhone using Tapatalk
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Diesel Swaps / Re: Golf MK2 m-TDI Swap
« Last post by JFKO on July 19, 2018, 07:54:50 am »
Loved the write up. i've had my mtdi running since 13 i think and still strong. but lagging in the top speed department with the old 020 4T tranny, it also screams more than the turbo. but i was cleaver enought to keep the 02A ctn tranny that came with the engine. so the question is. do you remember hvad made the mk3 subframe not fit the mk2? because alot of posts still say i'ts a direct fit for some reason. note my car dont have power stearing or any af that stuff that just brakes anyway.

Thanks
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IDI Engine / Re: 1.6td won't draw fuel
« Last post by ORCoaster on July 18, 2018, 11:43:39 pm »
For clear lines on the IP, both sides, I recommend you go to a motorcycle place and get fuel line from them.  They have the smaller diameters we need.  I wouldn't put PVC on there.  I bet it gets rock hard and will crack from vibration at some point.  Like the darkest, rainiest night of the year.  When you are in Nowheresville and can't get replacement line of any sort.


Not sure why we have that size change from tank to supply?  Might be for uniformity across other VWs. 

All issues big or small entertain and inform.  Hope this  was helpful.
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IDI Engine / Re: What the hell just happened?
« Last post by libbydiesel on July 18, 2018, 07:08:33 pm »
At minimum you need a way to drive out, drive in, and ream the guide to fit.  For replacing the valve you will need a spring compressor and at minimum to hand lap the valve to the seat.   
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IDI Engine / Re: 1.6td won't draw fuel
« Last post by oblique on July 18, 2018, 06:02:36 pm »
So is PVC the way to go for clear diesel lines? How restrictive is a 3/16" (4.5mm) line vs the stock 7/32 (5.5mm) diameter?

On a side question, whats with the tapered hose from tank to supply line? Is it just to use the same tank for bigger engines? Flow? https://www.ecstuning.com/b-genuine-volkswagen-audi-parts/hose/171201543b/

Thanks for all the help btw. I know folks have bigger issues than this on this forum so I appreciate you taking the time.
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IDI Engine / Re: What the hell just happened?
« Last post by RunninWild on July 18, 2018, 11:01:52 am »
No I don't. What's involved in that? I dont have a tool to put the valve in either. Was thinking of bringing it to the shop when i get all the parts
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IDI Engine / Re: What the hell just happened?
« Last post by libbydiesel on July 18, 2018, 01:26:33 am »
Do you have the tools for replacing the guide?
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