Back in the Diesel game

[hiho]

Hello all,

I have finally resolved my golflessness with 2 Mk 1 diesels. The red one is very tidy inside without rust. The fawn car is a bit shabbier but straight. Looks like I'll be spending a bit more time on the forum, especially in the parts for sale thread

[Golf Loon]

Nice work mate. Where did you score them?

[Greg Roles]

You gotta love those older engine bays, not chock full of hoses and gadgets.
Hours of fun awaiting you mate, love a good resto project!!

Gotta do something about that warm air intake though!

[hiho]

East of melbourne, on a farm in the hills. They were advertised in the local trading post. I plan to install a 5 speed box, decent suspension and nice wheels and tyres on the red car or maybe have a TD or TDI fantasy. Do you have any bits for sale along these lines? The tan car will most likely be tidied up, roadworthied and sold.

[gldgti]

nice find mate, happy dieseling

[Jarred]

welcome back to the game!

[GoLfMan]

awesome, another couple saved

[peedman]

Gooo the diesels!!! Nice pickups, do they start and run ok?

The problem with finding a td is that they are rare as rocking horse poop as we didnt get the mk2 1.6td or the mk3 1.9td. U might be able to find an imported engine tho if u look and wait long enough!

[Coaster]

2!! That's just selfish!

Keep us posted on the work

[Bam Bam]

Its not really selfish as there are two of us involved. Hi, I'm Leah, Matts partner in this crazy project!

On the weekend we chased electrical gremlins all over the red car. Whenever something started working, something else stopped. At best we had the interior light, headlights and the occasional indicator working. We decided to swap the fusebox for a spare and viola! everything was fixed! Then we tested the glow plugs, checked the cam timing and valve clearances, all were ok but still it wouldnt start. We're going to check the injector pump timing next.

Today we took delivery of a set of golf mag wheels, tyres and king springs. We also ordered a 5 speed box from Mr Loon. This car is going to be sensational!

Next we will check the tan car and try to start it...... Wish us luck!

[gldgti]

Its not really selfish as there are two of us involved. Hi, I'm Leah, Matts partner in this crazy project!

On the weekend we chased electrical gremlins all over the red car. Whenever something started working, something else stopped. At best we had the interior light, headlights and the occasional indicator working. We decided to swap the fusebox for a spare and viola! everything was fixed! Then we tested the glow plugs, checked the cam timing and valve clearances, all were ok but still it wouldnt start. We're going to check the injector pump timing next.

Today we took delivery of a set of golf mag wheels, tyres and king springs. We also ordered a 5 speed box from Mr Loon. This car is going to be sensational!

Next we will check the tan car and try to start it...... Wish us luck!

Welcome Leah!

sounds like a classic case of fusebox corrosion as far as the initial electrical problems... you can fix them if they arent too far gone and you're handy with a soldering iron. although it seems as not - the fusebox will come apart.

on the starting issue - IP timing is important, but as with most old mk1 diesels the usually neglected thing is the glo-plugs and earth straps. new earth staps and battery leads will help cranking speed (VERY important on an old diesel) and glow plugs a LOT (as well as all the other electrics.) furthermore, a new set of glow plugs is fairly cheap, but since you guys have a bunch of stuff to do on both cars, i reckon this websie will help you sourcing some new little parts for cheap - www.dieselvw.com - none of the parts will say "to suit 1.5diesel" because the yanks had the 1.6 in more numbers, but 99.99% of the 1.6 parts fit the 1.5 (including injector tips and glow plugs).

finally, ensure you have an air free fuel supply to the pump - easiest way is to replace all the old fuel hoses (even the return lines) with new ones.

even if the pump timing is off a little bit, you will be able to start the car if you have good glow plugs and good fuel supply and good cranking speed - try roll starting it or tow starting it.

[hiho]

Today the tan car started! Woohoo! More or less first go too. Cam and valve clearances were checked first and were a little odd. The exhaust clearances were all 0.3 to 0.5 mm but the inlet were 0.2 to 0.3 with the exception of No. 2 inlet which was 0.6!! Any ideas on what this could be a result of?? I suspect that its a rebuilt head. The previous owner testified under oath that it was recently rebuilt motor after a "timing issue" totalled the previous head. It also has a rebuilt pump. None the less, it runs nicely and has little blowby and no oil in the intake.

So, we have a tidy car with a shagged motor, and a messy car with tidy motor. What to do........

Seems obvious doesnt it.

Buy another motor for the tidy car and rebuild the dud motor for a TD project!

Anyone have an ok diesel motor for sale?

[hiho]

What the hell is this thing for?



its connected to the cylinder head where the oil pressure sensor is and drains into the block, see below.



I assume its a filter but what would filtering oil from this point achieve??? If anything its going to reduce oil pressure...... Its coming off.
Also, why doesnt this motor have the coiled oil supply pipe to the vacuum pump?

[Transporter]

What the hell is this thing for?



its connected to the cylinder head where the oil pressure sensor is and drains into the block, see below.



I assume its a filter but what would filtering oil from this point achieve??? If anything its going to reduce oil pressure...... Its coming off.
Also, why doesnt this motor have the coiled oil supply pipe to the vacuum pump?

It could be the oil by-pass filter. They don't reduce the oil pressure and if they block up, it doesn't matter. When you start the engine check if it is the same temperature as the engine, if not it is blocked - replace it with the new one. Amsoil type from the Amsoil distributor, they should have the thread reducer if it doesn't have the same thread. Or disconnect it.

[hiho]

The tan car has been started and driven about 100kms. At first it was very smokey but after a about 10 minutes it came good. It runs very nicely, revs well and blows a bit of smoke when floored. The front suspension is shagged though and the gearbox linkages have 1st and 2nd somewhere over with reverse, its pot luck at the lights! This week we’ll do the following in preparation for a roadworthy:

minor rust repairs to the hatch and the base of the a pillar
adjust gear linkages to make first/second easy to find
adjust rear drums and handbrake
fit new dampers and king springs, cut bump stop in half
fit battery clamp
fit horn button
make wiring loom for rear wiper
replace rear muffler (rusted out)
replace windscreen
oil and filters change
connect speedo cable
swap wheels
replace rear muffler

The red car will be garaged while I build a turbo motor. The following bits I have:

Shagged 1.6NA motor
TD oil cooler
TD exhaust manifold
K-jet inlet manifold
1.6TD Injector pump
Kkk k14 turbo
5 speed gearbox

Still need:
Head studs
Oil supply and return for turbo
Intercooler
Parts for engine build (pistons, rings, bearings, gaskets etc)
1.6TD oil pump
EGT sensor and gauge
Boost gauge
Oil pressure gauge
Coolant tank with level sensor
Rear sway bar
Front lower brace
Front upper brace

Got a question: what bushes should be replaced with new rubber or urethane bushes?