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    Thread: vw-tim's 1979 Rabbit Diesel Build Thread!

    1. Member vw-tim's Avatar
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      06-25-2012 01:31 PM #126
      Quote Originally Posted by vdubing_it_25 View Post
      you have to test how many amps each glow plug draws. I think about 7 each? You can test the whole rail and if it is reading at lest ~28 amps you should be okay. Mine would *peak* at around 40 for a second
      okay so i checked the glow plugs pulled each out and hooked them up to the battery they get red hot! all of them except #3 so i just got another plug i had that works... now what should i check?? injectors take those off and see if they getting fuel into chambers?

    2. Member vw-tim's Avatar
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      06-25-2012 05:29 PM #127
      also this whole time ive been trying to start the car buy jumping the starter because when i turn the key to start position all i hear are clicks... coming from the 52 and other relay boxs why isnt it getting power to the starter? what should i look for to fix this problem?

    3. Member DieselWabbit84's Avatar
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      06-25-2012 06:43 PM #128
      Try cracking one or two of the injector lines and cranking it over until fuel spits out and then tighten them up.


      if you haven't already.

    4. Member vw-tim's Avatar
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      06-25-2012 06:57 PM #129
      Quote Originally Posted by DieselWabbit84 View Post
      Try cracking one or two of the injector lines and cranking it over until fuel spits out and then tighten them up.


      if you haven't already.
      did it tons of fuel on all four of them! ha im thinking maybe my injectors might be clogged or bad idk gonna check them out next

    5. Member vdubing_it_25's Avatar
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      06-25-2012 08:09 PM #130
      Quote Originally Posted by vw-tim View Post
      also this whole time ive been trying to start the car buy jumping the starter because when i turn the key to start position all i hear are clicks... coming from the 52 and other relay boxs why isnt it getting power to the starter? what should i look for to fix this problem?
      have you had your battery charged / checked by someone like AutoZone? that to me sounds like a dead or dying battery. The diesel starter needs a real well charged battery


      Quote Originally Posted by vw-tim View Post
      did it tons of fuel on all four of them! ha im thinking maybe my injectors might be clogged or bad idk gonna check them out next
      although this is a likely culprit, it should at least crank well and be about to turn over / run ****ty
      LET'S SEE IF THESE BASTARDS CAN DO 90!

    6. Member vw-tim's Avatar
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      06-26-2012 12:51 PM #131
      Quote Originally Posted by vdubing_it_25 View Post
      have you had your battery charged / checked by someone like AutoZone? that to me sounds like a dead or dying battery. The diesel starter needs a real well charged battery




      although this is a likely culprit, it should at least crank well and be about to turn over / run ****ty
      yeah ill check the battery i charged it up its one of my spare boat batterys i just hooked up to the sense when i bought it there was no battery in the car to use i just havent picked up a fresh battery yet...

      yeah it seems to crank really well but it wont turn over / run... so i think im gonna try and re time everything and then bleed to fuel system to make sure it has no air bubbles and then try it again if no luck i guess im gonna pull out the injectors and see if they working good idk im running out of ideas here! haha

    7. Member vdubing_it_25's Avatar
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      06-26-2012 12:59 PM #132
      Quote Originally Posted by vw-tim View Post
      yeah ill check the battery i charged it up its one of my spare boat batterys i just hooked up to the sense when i bought it there was no battery in the car to use i just havent picked up a fresh battery yet...

      yeah it seems to crank really well but it wont turn over / run... so i think im gonna try and re time everything and then bleed to fuel system to make sure it has no air bubbles and then try it again if no luck i guess im gonna pull out the injectors and see if they working good idk im running out of ideas here! haha
      It should still run with air in the lines, it's a 'self-bleeding' system, though you will have to pump the pedal. What's your timing look like? Is the pump's TDC synced with the motor's? Have you taken the IP apart? (reason I ask is, I did and I made a mistake that wouldnt allow the engine turn over)

      The guy I bought my car from told me to time mine at .95. I believe the Bentley / sticker in the engine bay says .88 +/- .05. I am also at an altitude of 5300-6000ft daily.

      The battery should be a group 48. When cold, the engine needs to crank really fast and consistently- the starter on the diesel is much larger and power hogging than that of our gas brotheren

      Are you using fresh fuel in a clean tank? If so, have you added cetaine?
      Last edited by vdubing_it_25; 06-26-2012 at 01:05 PM.
      LET'S SEE IF THESE BASTARDS CAN DO 90!

    8. Member vw-tim's Avatar
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      06-26-2012 02:27 PM #133
      Quote Originally Posted by vdubing_it_25 View Post
      It should still run with air in the lines, it's a 'self-bleeding' system, though you will have to pump the pedal. What's your timing look like? Is the pump's TDC synced with the motor's? Have you taken the IP apart? (reason I ask is, I did and I made a mistake that wouldnt allow the engine turn over)

      The guy I bought my car from told me to time mine at .95. I believe the Bentley / sticker in the engine bay says .88 +/- .05. I am also at an altitude of 5300-6000ft daily.

      The battery should be a group 48. When cold, the engine needs to crank really fast and consistently- the starter on the diesel is much larger and power hogging than that of our gas brotheren

      Are you using fresh fuel in a clean tank? If so, have you added cetaine?
      i havent taken apart the IP but im not sure its at TCD like synced im gonna look ove the the timing and re do it all i dont have a gauge for IP i was thinking about buying this kit.. but idk

      http://www.hansdieselparts.com/VWDie...lsandGauge.htm

      so maybe the ip is out of sync with the motor ill re time it and report back! hopefully that will do that trick then!

    9. Member vdubing_it_25's Avatar
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      06-26-2012 03:17 PM #134
      Quote Originally Posted by vw-tim View Post
      i havent taken apart the IP but im not sure its at TCD like synced im gonna look ove the the timing and re do it all i dont have a gauge for IP i was thinking about buying this kit.. but idk

      http://www.hansdieselparts.com/VWDie...lsandGauge.htm

      so maybe the ip is out of sync with the motor ill re time it and report back! hopefully that will do that trick then!
      Idk about that exact kit, but you need something like it. There's no way you'll know empirically that the timing is correct until you have that.

      If your IP is at TDC with the motor, then it's just a matter of timing, it should at least get some combustion even if the timing is all shwerka.

      What's the status of the fuel / tank? And what's the condition of the rubber fuel line between the tank supply and the filter?
      Last edited by vdubing_it_25; 06-26-2012 at 03:21 PM.
      LET'S SEE IF THESE BASTARDS CAN DO 90!

    10. Member vw-tim's Avatar
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      06-27-2012 12:52 PM #135
      Quote Originally Posted by vdubing_it_25 View Post
      Idk about that exact kit, but you need something like it. There's no way you'll know empirically that the timing is correct until you have that.

      If your IP is at TDC with the motor, then it's just a matter of timing, it should at least get some combustion even if the timing is all shwerka.

      What's the status of the fuel / tank? And what's the condition of the rubber fuel line between the tank supply and the filter?
      hmm okay well im gonna redo the timing today and also on the sproket of the IP i use this hole right?



      and is this TDC mark for the IP?


    11. Member vdubing_it_25's Avatar
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      06-27-2012 01:46 PM #136
      Quote Originally Posted by vw-tim View Post
      hmm okay well im gonna redo the timing today and also on the sproket of the IP i use this hole right?
      I can't tell off the top of my head if that is the correct hole, I have a mark on the TDC of the pulley. I'll go look at mine here in a bit...
      and is this TDC mark for the IP?
      yes

      I need to clarify some things just so we are on the same page and make sure a couple of things are in order...

      First, to do the timing, you'll need to torque that bolt down on the IP pulley. Does it have the woodruff key installed? it's a 'half-moon' shaped thing that sits in this groove on the IP shaft:


      and the pulley lines up with it on this groove:


      Second:
      You'll have to pull the valve cover off and loosen the cam pulley with the cam / block set at TDC. there is a tool you need to lock the cam with. The cam stays in place while you adjust the IP, this way the timing belt moves with the pump (timing belt is tensioned appropriately, of course). Once your timing is set, you lock the cam pulley. theres a lot of little tricks to this.
      Last edited by vdubing_it_25; 06-27-2012 at 01:50 PM.
      LET'S SEE IF THESE BASTARDS CAN DO 90!

    12. Member Rockerchick's Avatar
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      06-27-2012 02:25 PM #137
      You NEED the timing tools, or at least homemade versions to get the timing right.

      Here is a good how-to for the IP that also covers checking the belt as well: http://vincewaldon.com/index.php?opt...d=24&Itemid=28
      Quote Originally Posted by TM87 View Post
      VW-making mechanics out of owners since 1957.
      The project - '84 Jetta 1.6TD
      Hers - '03 BMP 20thAE GTI
      His - '01 Jetta TDI

    13. Member vdubing_it_25's Avatar
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      06-27-2012 03:21 PM #138
      Quote Originally Posted by Rockerchick View Post
      You NEED the timing tools, or at least homemade versions to get the timing right.

      Here is a good how-to for the IP that also covers checking the belt as well: http://vincewaldon.com/index.php?opt...d=24&Itemid=28
      good link, I couldn't remember it haha
      LET'S SEE IF THESE BASTARDS CAN DO 90!

    14. Member vw-tim's Avatar
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      06-27-2012 03:44 PM #139
      okay so i got everything timed now i dont have a dial indicator so i didnt mess with the IP just left it how it sits made sure it was TDC with the sprocket and stuff but anyway now i go to fire up the car and it seems like its almost there almost gonna start! but it doesnt lol it just is really dumping out white smoke from the exhaust! what should i do now? maybe move the IP towards the engine or farther away? would that maybe do it? i know that adjusts like the IP the way fuel goes in? i just cant think what else to do...

    15. Member vdubing_it_25's Avatar
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      06-27-2012 04:51 PM #140
      thats what mine did when i had the timing 180 degrees off.
      LET'S SEE IF THESE BASTARDS CAN DO 90!

    16. Member vw-tim's Avatar
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      06-27-2012 07:49 PM #141
      Quote Originally Posted by vdubing_it_25 View Post
      thats what mine did when i had the timing 180 degrees off.
      really? how can i fix this? im pretty sure my timing is spot on though man..

    17. Member vw-tim's Avatar
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      06-27-2012 10:07 PM #142
      okay so i just want to verify that this is what all timed up and ready to go should look like...






      and all of that is with the belt tensioned am i ready to go?

    18. Member vdubing_it_25's Avatar
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      06-28-2012 01:05 AM #143
      yeah everything looks good. just as long as the cam pulley is loose (i can't tell from the pictures)
      LET'S SEE IF THESE BASTARDS CAN DO 90!

    19. Member vw-tim's Avatar
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      06-28-2012 01:23 PM #144
      Quote Originally Posted by vdubing_it_25 View Post
      yeah everything looks good. just as long as the cam pulley is loose (i can't tell from the pictures)
      yeah it was then i retightned it and tensioned the belt it all stayed like that.

    20. Member vw-tim's Avatar
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      07-05-2012 01:20 PM #145
      okay so ive pulled of the head and have noticed some junk in a few of the head bolt holes so gonna try and clean those all up is there any like tap i could get to just really clean the threads what do you guys suggest doing? i sprayed some wd40 cuz i ran out of carb cleaner ha in each hole and gonna vaccum it all back out maybe they should clean them up nicely bit i just want to make the threads perfect again so i can get the head torqued down perfect hopefully that will fix my compression




    21. Member Rockerchick's Avatar
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      07-05-2012 01:31 PM #146
      What were your compression numbers? I'd think about checking and make sure your ring gap is alright. Ours was horrendous, even with compression from 360-400psi.
      Quote Originally Posted by TM87 View Post
      VW-making mechanics out of owners since 1957.
      The project - '84 Jetta 1.6TD
      Hers - '03 BMP 20thAE GTI
      His - '01 Jetta TDI

    22. Member vw-tim's Avatar
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      07-05-2012 03:57 PM #147
      Quote Originally Posted by Rockerchick View Post
      What were your compression numbers? I'd think about checking and make sure your ring gap is alright. Ours was horrendous, even with compression from 360-400psi.
      compression test before i put ATM in each chamber:

      #1 - 300
      #2 - 50
      #3 - 15
      #4 - 175

      and then after i put in alittle ATF in each chamber:

      #1-420
      #2-160
      #3-140
      #4-400

      i was told that it might not be the rings but the head gasket might of not been on correctly.. but now that i have removed the head the gasket looks okay maybe i didnt get it torqued down there was some gunk in the head bolt holes so im cleaning all that up today.

      i guess sense i have it all take apart i should just do the rings and ball hone the cylinders

      do you guys know the process of doing both those?
      Last edited by vw-tim; 07-05-2012 at 04:23 PM. Reason: i posted wrong numbers for ATF compression test... oops ha

    23. Member Rockerchick's Avatar
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      07-05-2012 04:09 PM #148
      Wait...seriously....15psi? Not a third number in front of that? Something isn't right. Even 300psi isn't great...not sure on the 1.5, but I know on the 1.6, 400psi is the wear limit. Either the compression test was bogus or something is really amiss...
      Quote Originally Posted by TM87 View Post
      VW-making mechanics out of owners since 1957.
      The project - '84 Jetta 1.6TD
      Hers - '03 BMP 20thAE GTI
      His - '01 Jetta TDI

    24. Member vw-tim's Avatar
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      07-05-2012 04:21 PM #149
      Quote Originally Posted by Rockerchick View Post
      Wait...seriously....15psi? Not a third number in front of that? Something isn't right. Even 300psi isn't great...not sure on the 1.5, but I know on the 1.6, 400psi is the wear limit. Either the compression test was bogus or something is really amiss...
      yeahh... it should be at 400 psi.. and well when i put on the head gasket when i was doing the head bolts they were sorta hard to get started a couple of them and then there was a couple that went in real easy so i think the ones that were harder didnt get torqued correctly so reason why i think maybe the compression is so low.. anyway i got the head off and im cleaning up all those holes now

    25. Member vw-tim's Avatar
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      07-05-2012 04:24 PM #150
      Quote Originally Posted by Rockerchick View Post
      Wait...seriously....15psi? Not a third number in front of that? Something isn't right. Even 300psi isn't great...not sure on the 1.5, but I know on the 1.6, 400psi is the wear limit. Either the compression test was bogus or something is really amiss...
      i posted up wrong numbers for after ATF compression.. i got higher numbers ha sorry i was copy/paste from another thread were i posted up the numbers

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