83 Jetta Coupe Turbo Diesel Build Thread

[Jeaster]

killer find, i'm still waiting for my "barn fresh find"

[GTIVWMK2]

if only it was a barn fresh find. but GL I'm always looking in peoples yards!

[Spinelli]

i think i found the wheels!!!!!!! they are vial 14x6 i think... they where on the rare wheel thread

[GTIVWMK2]

They are really close Spinelli but they aren't them. One's I have are 13x6. I'll post another pic so you can get a good look at them again.

[GTIVWMK2]

Major update! Replaced the rear wheel cylinders and the car stops great now. so started in on cleaning up the interior. before we started




And as we got through it.








going to clean the carpets today and finish cleaning the interior replace the speedo cable and start putting it back together!

[ducatipaso]

subscribed. if you ditch that airbox/intake setup, let me know first please.

[GTIVWMK2]

Honestly thinking of keeping it mostly stock. upgrade exhaust and maybe put a manual boost controller in to bring boost up a pound or two maybe. depends on what the EGT's do. thing has low milage for a desiel no need to sup it up. Gunna be LOW and SLOW.

[GTIVWMK2]

steamed cleaned the carpets!



letting them dry before install going over initerior wiring make sure the mice didn't chew anything else up and checking function of A/C controls. Yes this thing has A/C and it will work! after that it goes back together.

[GTIVWMK2]

Reinstalled the carpets lastnight as well as new speedo cable. fixed a few more things as far as the wiring goes. A/C stuff mostly. still have to fix radio wiring harness so I can plug in a radio instead of the hack wiring thats there... at anyrate heres pic of the carpet back in

[Rockerchick]

Honestly thinking of keeping it mostly stock. upgrade exhaust and maybe put a manual boost controller in to bring boost up a pound or two maybe. depends on what the EGT's do. thing has low milage for a desiel no need to sup it up. Gunna be LOW and SLOW.

We have a 2.5" exhaust on ours, downpipe and all. Completely custom though. Also have a Giles IP. Well worth the money. Slow is fine, but you also don't want to get run over! The pump definitely gives a few extra horses to be able to get on the highway easily.

And if you are keeping the AC, you'll want that extra power for when you are using it!

[GTIVWMK2]

I hear ya on the exhaust. My friend is a tig welder. Going to ask him to help me make a custom exhaust. get rid of the toilet bowl and that cast iron adapter. If you have pics of it that would be extremely helpful! Where would I locate a Giles pump? any specific place I should go or just Google it?

[Rockerchick]

Well, some people are selling old ones. But I would say get in touch with Giles directly. He can make your pump work best for what your goals are. Its not a cheap endeavor, but entirely worth it, IMO. http://www.performancediesel.ca/performance.htm

Definitely got rid of the toilet bowl clamp. The guy that did our exhaust had a mandrel bender and everything. We got it all done, labor and installation, for less than we could have just bought one from Techtonics Tuning. Which is just nuts.

Downpipe:


Flex section:


Resonator:


Jump over the rear beam:


Muffler:



We wanted something that would help with performance and EGTs but also sound stock. The car is loud enough, we didn't want it louder. So that's why we have the resonator and muffler. And you really can't tell its not stock. The guy even turned down the tip so we wouldn't be spewing soot all over the back, at least not as much It was a great addition for sure.

[GTIVWMK2]

Sweet. That thing looks nice. Me and my friend will probably do an aluminum exhaust with vband clamps to hold the muffler on and to the adapter coming off the turbo. Drove it down teh street today actually. registered it today and slapped the dash back in real quick. need to make a new start/choke cable. I know it doesn't choke it but changes the timing on the injection. but right now I have to leave it out because i have to use a screw driver to pry it over to start position. starts right up though. Having a few issues still though. the altenator cocks sideways and it threw the belt tonight and still getting that burping from the radiator into the resivoir. anyway I'll post the video up when my friend gets it to me.

[blockheater]

If you ever want to sale those wheels let me know,im in jersey and there just what im looking for

[GTIVWMK2]

don't plan on selling them. might get them refinished. Probably won't sell them unless I can figure out what they are...

[GTIVWMK2]

A bunch of stuff has been done to the car as of recently. seeing as how it has become my daily. My 94 Jetta got crushed by a telephone pole.... at any rate heres what has happened just this Friday and Saturday

Started with a couple bags of parts. Temp sensor, Master Cylinder, Brake light switch, shifter rebuild kit, radiator flush, blinker relay, E brake cables. Started at the shift rebuild. turns out the bushings where all good on the linkage save one. The one we didn't get. Goes from the trans to the relay that moves the shifter left to right has a lot of play. So went to the E brake cables. that was such a pain. The cables where shoot. Passenger side had already broken and the drivers side was about to break. got those squared away. slapped the drums back on. Next was flushing the coolant system. I had already had the stuff in the car and ran for a good 45 minutes. so I just had to drain and flush it. Also cleaned the brand new reservoir I installed weeks earlier that was covered internally with oil from the bad oil cooler. slapped that together. then started in on the master cylinder. Had a few issues with the brake lines coming off the old master but nothing broke. Pulled the front wheels and cut the rotors and cut them. they were badly pitted. knocked the glaze off the pads and put all that back together and bleed the brakes. Car stops well now for the style of brakes they are. Solid front rotor drum rear. Changed the alternator belt and made a new IP advancement cable for cold starts. Filled the coolant back up and went to put fuel in it. Tank is leaking up by the sending unit. easy enough fix once i manage to get through all the fuel to an empty tank again hahaha. More update as i drive it around more.

[ducatipaso]

excellent

[2mAn]

keep it up, love the progress. Giles pump will make a BIG difference and is definitely worth the money. If you add an intercooler you can crank up the boost and fuel and really enjoy that TD

[ducatipaso]

keep it up, love the progress. Giles pump will make a BIG difference and is definitely worth the money. If you add an intercooler you can crank up the boost and fuel and really enjoy that TD

this is on my list too but I really haven't seen a setup that suits my particular desires. it's gotta look OEM+

[Rockerchick]

Intercooler is on the list for us as well. Nowhere to really put it though. We kept the AC so it makes things...interesting. We want to make sure the intercooler will really be doing what its supposed to and not just pulling in hot air from the engine bay. Which is difficult. Might end up doing an air to water system but we'll see. Sitting at stock boost for now which is still pretty awesome.

[GTIVWMK2]

just throwing this out there!

http://www.frozenboost.com/product_i...259239e8d5f77d



If I decide to drop the 1k+ on a custom giles pump, interlooter setup,exhaust and other mods I am definitely going A/W intercooler and using this setup. they have three different sizes. 6, 8 and 10. and Frozen boost's stuff has a lot of bang for your buck.

[GTIVWMK2]

UPDATE!!

drove it to my mother in-laws last night to show a kid my 89 vr coupe I'm selling. drove nice except that getting it into first is next to impossible. the passenger side motor mount is completely shot so the engine isn't sitting in the right spot. Throwing the shift linkage off. Lucky enough the car has enough balls to get it moving in 2nd or third which ever I can get into. HAHA. Also opened it up and brought the revs up to about where I felt it stop pulling and looked in my rear view and noticed the headlights behind me a little Hazey.

Going to gap probably for the mount 12 bucks. wondering though should I throw the poly insert into it so I don't have to worry about it for a long time or will it transfer to much vibration over...

[Rockerchick]

We went with the stock mounts. I would be concerned with the vibrations with the poly mounts.

Make sure that you get the mount pressed in the right way...our mount was so trashed that we replaced it in the position that it was in and it was 180 off. The passenger mount is also a PITA, BTW. I know on our car you had to take the IP off to get the bracket off.

[ducatipaso]

oh, the LAST thing you want in a diesel is poly mounts.
I have the techtonics HDs and they're at the limit, but with the AAZ they're needed.

[GTIVWMK2]

actually that mount isn't bad. done it on my 88 cabrio with an aba swap. my 81 rabbit pickup with a G60 in it and my stock 1.7L rabbit coupe auto. THe auto trans from MK1 was a have pig!!!! undo all mounts except trans mount by the batter. rear trans and pig nose at starter. then block of would and jack on oil pan remove bolt for the passenger side raise engine and pull the four bolts hold the bracket in and it slides right out! Not my first MK1 just first TD

[GTIVWMK2]

Decided last night to take the car down the highway a bit. about 8 miles in (and 2 miles from my house.) the car stalls out and won't start. looked at the injector's and could see the diesel bubbling up out of the return lines... Got it Pretty hot. now she won't start at all. hoping I didn't ruin the head. not sure how hard it will be to find a Diesel head somewhere.

[GTIVWMK2]

The tear down begins today. will be taking pictures as I go and posting them. fingers are crossed that I didn't cause serious damage to the engine!

[foxygrandpa]

Find out anything? Hope everything's good!

[GTIVWMK2]

didn't get the head off yet. had the oppurtunity to go surfing so I took it. All I have left to do is the oil return line and couple of drain hoses. oh and the glowplug wire. I looked at the glow plugs. got the head so hot the black plastic on the glue plugs actually melted..... fingers are still crossed!

[GTIVWMK2]

Picture update.

Cam. couple of rust spots. No pitting just surface. have to clean that up.





intake at the diverter valve then the turbo. little bit of sand and grit in here. not sure how it got there though...





and the engine as it sits now.

[sk8ordie]

actually that mount isn't bad.

actually - yeah it sucks. if you haven't done it on a diesel - you haven't done it on a diesel.

[ducatipaso]

actually - yeah it sucks. if you haven't done it on a diesel - you haven't done it on a diesel.

hahah you took the words out of my mouth.
poly engine mounts + diesel engines = total destruction of driver and vehicle via vibration

you'll have to loctite every single nut and bolt on your car. TRUST ME

[GTIVWMK2]

So got the head off today... block looks ok. some slight scoring on cylinder number three. not sure what effeect it will have but this thing definitely had a blown head gasket. kick myself for not jsut doing it in the beginning. Pics...

Block



Head gasket...



and ruined head.



Already sourced a new head. $150. he said something about larger holes... I'm sure he's talking about the headbolt size. I'll be contacting them tomorrow to get more info and give more info.

[Rockerchick]

FYI, cracks between the valves is completely normal.

[GTIVWMK2]

well my machine shop won't let that slide. besides it's cheaper for me to replace the head than it is to have this one redone.