~My 91 GLI to 1.6TD conversion build up~

[53 willys]

G40 valve cover back from powdercoat

been reading some threads on Vortex.....and am pretty sure this IS a G40 cover...Vortex says there is only one style G60 cover and the oil cap is on the passenger side...they say if you have an aluminum cast valve cover and the oil cap is on the drivers side it is a G40 cover.


I dont care either way...I bought this one as a G60 cover but....the G40 works better for the 1.6td with bumper mounted intercooler...the intercooler piping would cover the oil fill cap on the G60 cover the G40 works perfect.

[53 willys]

I thought it might be a good idea to link my DIY port and polish thread to my build up thread.
DIY PNP is kinda time consuming but it's not hard at all.


http://www.vwdiesel.net/phpBB/viewtopic.php?t=15823&highlight=

[zukgod1]

Here is what I was thinking of doing for a vent.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=170261414507

Ever sense the Total Seal rings though I don't have enough blowby to worry about it, then where the hell would I put it?

It's already pretty busy under my hood.

[53 willys]

Here is what I was thinking of doing for a vent.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=170261414507

Ever sense the Total Seal rings though I don't have enough blowby to worry about it, then where the hell would I put it?

It's already pretty busy under my hood.

wow great link!
I cant even build my own for that price!!
I'm gonna order one! thanks Dan


wish my new pistons did not come loaded...then I would have got some total seal rings...hopefully my blow by is minimal....

[zukgod1]

That's what I was thinking as well.

Cant build one for $20...

[moise]

good job man

[golftd412000]

it's not a g40 cover beaucause ,you'r cover dont have bypass

this is a g 40 cover(it's a picture of my g40 1989)

[zukgod1]

That and the G40 has center bolts..

[TurboJ]

Since the G40 cover seems to have 3 center bolts, would it fit an AAZ head by any change?

[blkboostedtruck]

Since the G40 cover seems to have 3 center bolts, would it fit an AAZ head by any change?

nope!!! it won't work both ends of the G40 have half moon cut outs and only the AAZ has a half moon cut out on the pully side!
but a little fabrication anything will fit! :wink:
Duane

[53 willys]

well I guess Im wrong again.....all the vortex pic links are dead so I did not have good pics to compare to....I guess it is a G60 cover...







Zukgod1 came over last night and helped me get the car started!!!!! :twisted:


Man she idles REAL smooth!!!!
the VE IP pump cant suck fuel through my stock transfer pump tho....and the pump wont kick on cause the ECM has been pulled and the pump was triggered off the Gasser ECM.

so I got some rewiring to do today....


on the home stretch NOW!!
pics and maybe some vid later today.... :twisted:

[Smokey Eddy]

:twisted:  :twisted:  :twisted:  :twisted:  :twisted:

[zukgod1]

Damn thing sounds sweet!!!

Hopefully he is out driving it right now..

[53 willys]

well I got it running and driving.......problem is when I pulled it out of the shop last night to drive it.

I go around the block 2 times...on the 3rd run the heater core blew open and filled my car with coolant :cry:

the other problem is it feels like I am not getting into 1st gear...the shifter is all the way over but it feels like 3rd when I take off...maybe my trans linkage is out of adjustment???

pretty bummed about it....I wanted to have this car done but now I gotta go back to my regular job...

[zukgod1]

well I got it running and driving.......problem is when I pulled it out of the shop last night to drive it.

I go around the block 2 times...on the 3rd run the heater core blew open and filled my car with coolant :cry:

the other problem is it feels like I am not getting into 1st gear...the shifter is all the way over but it feels like 3rd when I take off...maybe my trans linkage is out of adjustment???

pretty bummed about it....I wanted to have this car done but now I gotta go back to my regular job...

Trans linkage is a pain in the ass to adjust without that little tool but we can get it.

The heater core is another story.
I don't want to bum you out more but that's not a fun job. Have to completely remove the dash so don't be reassembling anything up there right now.

I suspect maybe the necks got weakend when you replaced the hoses, they are famous for leaking after being messed with.

Good new is you have a guide, been there done that so no worries.
Let em know when you are going to start on it and I'll see if I can come help. Now that I've done it I don't think it's that bad but that first dash swap was nerve racking.

At least it runs so you are on the correct path. It's all the little things that seem to take up the time.