Resurrection of the Great Pumpkin, Charlie Brown!

[jaystone]

annual.

[GTi2OV]

Emissions testing is every two years.

[3WheelnGTi]

Cat yes, secondary air no, egr no, charcoal canister no, CEL no, O2 sensor yes, gas tank cap yes.

I am hoping to throw it on the rollers and pass the sniffer. If that happens, I might be good to go.

Good news is that the CEL and OBD codes are advisory only, and not a failure mode for the test.

Need to beat these limits for 1995 model year (units are in grams per mile);
CO, 15.0 HC, 1.2 NOx, 2.5

http://aircarecolorado.com/about-the-test/

Just had to do this a few months back with my Vrt , I was missing everything emissions related but a cat. The numbers were fine till the driver got the turbo spooling then the numbers went to crap.
That's the only reason why I failed twice cuz the kids that work at the one on Havana will drive you car like crap. I finally put the 1.5 pound spring in the wastegate and a lil e85 in the tank and went to a different testing facility and got mine to pass. You can get Vrt's to sneak pass Colorado emissions.

[GTi2OV]

Denatured alcohol helps a lot too

[BarryV]

Octane boostin!


Light weight waste gate spring is a great idea

[myvwisfast]

x2 on denatured alcohol. Get it down to reserve, put 1 gal of denatured in. Run thru emissions, pass with amazing numbers, go fill up.

[jaystone]

all good info. thanks!

just need to fix the valve stem seals and hope that cures the smoking; and finish a bunch of other little things. Might also need to hook up the O2 in closed loop mode; see if that helps.

[3WheelnGTi]

Does it only smoke at idle? Mine has started smoking too , progressively over the pass week it has been getting more noticeable.

[jaystone]

idle is ok, but rev it a little and it smokes. still under vacuum, plus the fact that early vr valve stem seals sucked anyway leads me in that direction.

[jaystone]

Been busy as hell the past week with work and side jobs (welded a downpipe for a crossflow 2.0 turbo, tuneup on a GSF400 Bandit, work, class, blah)...got the dash flocked again and am waiting for it to dry. Picked up a valve spring compressor tool from the old VW dealership I worked at years ago; grabbed the wrong crossover bar. Will need to swap it out tomorrow with any luck. Top end all tore down ready to replace the valve stem seals (crossing fingers). Spark plugs were pretty dirty, picked up a new set of NGK BKR7E's. Had a chiropractor visit today to address an old neck injury (rear ended at a stop light in my old mk3 GTI VR6); things don't look so hot so I'll be taking it easy this weekend.

Time for a Stella Artois and some dinner.

[jaystone]

Valve stem seals greatly improved the smoking. I still have a very little residual smoke, however after running the car for a good 15 minutes it is getting progressively better so I'm thinking it's just cleaning itself up. I'll run it again tomorrow after sitting overnight. You can see in the last picture the old red valve stem seal compared to the new viton green one. The opening is pretty worn and enlarged.

The VW special tool that I got from my old dealership wasn't the 100% correct one, but I made it work. It still required a little fussing to get the keepers in and out, but all in all not bad. Took about 4 hours. I didn't want to rush; and had to step back every once in a while to grab a beer and stand up straight (hunched over the engine of a car is why I gave up wrenching as a career choice). So much for taking it easy today.

Dash came out pretty good. I look forward to getting it installed in the car.

All in all, not a bad day.

[GTi2OV]

Right on!!!


Getting **** done! Glad to hear it is smoking less.


The dash looks amazing dude. Love it. I got some parts for you to do for me. How much did the materials set you back total on the dash? Are you planning on doing any other interior parts?

[golf3737]

That sounds great bud!

[jaystone]

I'm not planning on doing any other interior parts. I have about $75 in materials into the dash, but that's because I had to do it twice. Smaller parts are significantly easier and now that I've done it, I'm sure could get most anything done in one shot. Check out donjer.com and look at the nylon suede-tex flocking fabric along with the undercoat adhesive. It took about 3/4 of a 16oz can of adhesive along with about 2/3 of a pound of flocking fiber. There is a lot of waste, however if you set it up right you can recover the leftovers. I tried the first time but got a lot of other dust in with the flocking fiber so it was a waste (pollen and crap from doing it with the garage open).

[jaystone]

by the way Robin, I have some leftover flocking materials if you want to me to either show you or do something for you.

[COUPE-VR6]

Yeah, lookin good. 10-15mm spacer on rears?

What tires are those? Tread is crazy

Those tires just went on sale el jeffe! Want to get an extra set?

[ThatA4T]

dash looks great! mine next!?

[jaystone]

I wish, but I don't have any room for a set of tires. As for doing another dash with flocking, I am going to have to pass for now; it's a mess and I gotta finish this dumb car first

[ThatA4T]

I wish, but I don't have any room for a set of tires. As for doing another dash with flocking, I am going to have to pass for now; it's a mess and I gotta finish this dumb car first

Haha I feel ya. I keep contemplating suede wrapping and stitching mine

[jaystone]

Suede is an awesome way to go for sure, I just couldn't justify the cost right now; especially considering the rest of the interior at some point could stand to be redone (it's not bad, but it's not great either).

I ran it some more today after work. Smoke is practically non-existent. It was an absolutely gorgeous day so I decided to drive it around the block. Considering it still needs a lot of assembly, it runs and drives very well. Also gave me an opportunity to clean the garage floor under where this car has been sitting for the past 9 months.

Done for the day. Have to take it easy for a little while I undergo some treatment and crap on my neck which was injured years ago in an auto accident followed up by even more years of working on cars, and the past few as an electrician. My head is hardly ever straight up looking forward, so the natural correct curvature has actually been reversed and is currently 9 degrees forward instead of 35 degrees back. Thank goodness I've got a good chiropractor

[alextakesphotos]

do i still have first dibs for photos? cause i cant wait!

[jaystone]

do i still have first dibs for photos? cause i cant wait!

for sure.

[lo41moneypit]

do.work.son!

[.:baker]

I already used Paris Hilton in another thread..

But love where this is going

just saying ...

[Dubsjetta]

Love this car man can't wait to see it in person!!

[jaystone]

with any luck it will be to a couple GTG's and shows. crossing my fingers.

[Dubsjetta]

with any luck it will be to a couple GTG's and shows. crossing my fingers.

Awesome can't wait to see this thing!!

[jaystone]

When I drove it last week, I noticed a misfire. Cylinder 3 no spark. Tested the wire and found a bad connection at the GM coil plug. Shame I wasn't the original purchaser of the NGP plug wires or I would have pursued their lifetime warranty. Instead grabbed a set from Four Seasons IIRC. Drove around the block again, boost on all 6 cylinders is fun. Now I just nead to put the inside all together and get ready for emissions.

[jaystone]

CSR coolant overflow tank to mount. New Innovate Motorsports wideband controller to install. Messy workbench to clean up. This weekend is going to be busy. Have a little sidework lined up.

[ThatA4T]

CSR coolant overflow tank to mount. New Innovate Motorsports wideband controller to install. Messy workbench to clean up. This weekend is going to be busy. Have a little sidework lined up.

Good work as always! Better be driving that thing over Sunday thanks again for coming to help this weekend! I've been needing those doors done

[jaystone]

still have lots to do before its ready to cruise around, besides I can't fit a MIG welder, bottle, compressor and tools in the back of the Jetta. see you sunday AM around 10!

[coneklr]

Im curious, does the flocking feel like Felt or ultrasuede? It kind of from the pictures has a felt look to it.

[jaystone]

it looks like it but has a slightly coarse feel to it and isn't as soft.

[jaystone]

Made some ramps to make getting into and out of the driveway a hassle free affair. While letting it idle some, I noticed more damn oil smoke. Pulled apart the turbo and found a mess. Best I can tell it's coming from the turbo. Going to send it in to Turbonetics and cross my fingers. Installed the new wideband, but it didn't include the effing switch and LED that the instructions said to connect for calibration (which the aforementioned instructions said were included), going to have to contact Innovate and see WTF is going on. Cleaned up the wiring a little behind the knee bar/dash. Found the vapor barrier plastic needs to be replaced behind the door panels, in addition I need to getting the rest of the windows working (and power mirrors which also do not work as of yet).

Yet another weekend of one step forward, two steps back.

[jaystone]

Forgot to mention I mounted the CSR coolant catchcan as well, fabbed up a little bracket. We'll see how it holds up.