1.6 build

[turboedbug]

ell heres a few of my build

[turboedbug]

Just mocking things up. So far I am going to re do the intermediate shaft bearings since they dont feal right. Picked up the alh mains and the thrust bearings that was suggested on another forum. I did a little research on that aspect and felt this was the way to go.

[turboedbug]

Sucks that I am tearing it down again but I want everything to be right.

[92EcoDiesel Jetta]

Are you doing both intermediate shaft bearings? What kind of tools will you be using for the job? I think KS intermediate shaft bearings requires reaming after install. You may want to check if that is true or not before putting them in. I just did the outer in mine and used the Durabond bearings which is sized to fit and requires no reaming.


Edit: Read your post again. You said "re do". So you did them once already? What went wrong?

[turboedbug]

I had installed the vwg-1 intermediate shaft bearings I think I didnt ream them the best. So since I am tearing back into the block I will be installing the ks bearings that do not require honing. I used a socket with a long extension and a rubber malet. I will probably be building a tool so it wont produce such a lip from installation.

[92EcoDiesel Jetta]

Durabond VWG-1 is what I used and they did not require reaming. Why did you have to ream yours and what did you use for a reamer? A reamer got to be big $$$.
After install of the outer bearing, my I shaft turned nice and smooth with no play when rocked side to side.


I used this tool I made for driving of the seal into it's final position. To get the seal started, I pressed it into place first by hand with the oil holes lined up, then used the seal carrier as a punch and a hammer to seat it enough till I can put the two 10 mm bolts in, then pulled the bearing further in, the seal is only partially in but pretty square at this point and I used the tool I made to drive it in the rest of the way. Not shown in the pic but before use, I wrapped the black iron cap with electrical tape so the lip of the bearing is not against metal and the bearing fits more snug. It did not chew up the bearing and create any burrs, the shaft went right in.

[turboedbug]

Anyone have any cooling line and accessory mounting diagrams? I seem to have lost all my pics on my of the dis assembly of the engine :-(

[vanbcguy]

Partsbase.org

[turboedbug]

Well I installed another set of intermediate bearings and it spins very freely

[turboedbug]

Does anyone know a good vendor for replacement nozzles? Going to rebuild these injectors

[turboedbug]

Well it runs! Need to do an ac and power steering delete. Thinking of retrofitting a gm 1 wire alternator.

[libbydiesel]

I just went down to Phoenix yesterday with a friend and have to say that despite the fact that I live where it gets down below 0°F for quite a few days every year and the summer temps almost never get above 85°F, IMO A/C is more important in a vehicle than passenger heat.  It was only 100°F or so in PHX yesterday, but still miserable.  You can always put on more clothes but there's a limit to how much you can take off...  The A/C in my Jetta was very valuable to me. 

While you may feel that A/C is not something that you would want in your vehicle, in my experience, removing even a system that does not currently function will make a big hit in the resale of the vehicle and make it harder to sell.  I would recommend pulling the belt off the compressor, but keeping the system intact.

[turboedbug]

I understand where you are coming from, we just did a summer here with no ac in our duramax with a 3 1/2 ,hour round trip commute each day. We got used to it. Now with the ac components on this car they will eventually go back on. But right now temps are dropping and I need to get this thing on the road as my daily asap. This 100$+ a week in fuel prices is killing me.

[turboedbug]

Well ac and ps are still intact with the factory alternator.  So far so good. I rebuilt the idler pulley for the alternator. They wanted 60$ for a replacement. 5$ for a bearing and now its good to go. I did an oil change at 25 miles and now have a little over 100 miles on the rebuild. Man I should have picked up one of these years ago