1.9 idi w/1.6 head timing belt help(btw,this is hillfolk im baaaack)

[KingHillfolk]

hey guys i see some familiar names(malone) maybe i can get a hand
i got my dads old 91 jetta coupay(dont worry i still got the 79 tdi-m)
and back around 99 or so the engine went and he got a 1.9 with a 1.6 head from eurospec(i think,we forgot who)
mainly cause it was a driver and he didnt wanna mess with intake manifolds and stuff.
i got it from him around 03 and had it stored since 06
please dont aask y a 1.9 with a 1.6 head,its a driver.
the engine only has about 40k on it but i wanna do the timing belt, fro,but im not 100% surem age.
we cant remember the belt that it used.
is it a std 1.6 belt,or a" tdi" belt?
i thought i remembered something about it being a 1.6 belt but using a smaller intermediate shaft pulley cause of the taller deck height but im not 100%
i guess i could do the easy thing and pull it off and see if its the same length as a tdi belt(i have one),or go to the parts store and match it to a 1.6 and see,but id figure id ask.
i could get the ##s off it again(i lost em grrr)...heres hillfolks coupay


nice 6 year coat of dust.thanks dad(in the pic) for helping me resurrect her,i neglected it and feel so horrible about it
nothin like a father and son project to make ya feel whole again

[flyawa]

Interesting to watch this thread develop. I did not know the heads bolted up interchangeably.

BTW What is the airplane? I'm a pilot since my 17th birthday 45 years ago. Looks too big to be piper but too small for stinson.

[Glegor]

use an AAZ belt..

the 1.9 has a taller deck height than the 1.6 (16mm taller on the 1.9)

if you try and use the 1.6 belt, it wont fit, its too short.

the TDI belt is wrong as well, i believe.. i think there are too many rollers for a TDI belt to work..

so, yea, use a canadian AAZ, or 1Y timing belt.. may be a bit hard to get in the states at a parts store, but most online stores should have what you need..

Wasnt Hagars old screen name Hillfolk or something like that?

OH!!! you must be little hillfolk!

[KingHillfolk]

nice to see a pilot...thats a cub..my dad has a luscombe..im not a pilot yet but gettin there
as u know itll fly itself up there,nothin to it i can do that much...
yea what sort of stinks is the engine has nothing stamped on the block for id ##s
yea a 1.6 head bolts on but noone wants to do it, they want performance..its got a little tq,but short on revs over 4500.it was nice for a replacement engine that drops in with a little more power.ill haveta give that aaz belt deal a try...
no,im the original hillfolk goin way back to the beginning of the internets.i just havent really had time since ive moved back to ny to even get online..and with all the hustle busle i cant find any of my old passwords
it was always me and rabbittree as the hillfolk crew
we used to do waterfest from the beginning but havent gone since 07 i think
actually he helped my dad do the engine swap.since it was my dads car i gotta give it respect,and cant cut or drill one hole,but he does approve if i wanted to swap in my 98 tdi drivetrain
enjoy some pics of our new shop,it collapsed in the winter of 10 from snow and damaged his luscombe
he is just now sending the tailfeathers out for a redo

the cub is one of his friends,the silver one is his luscombe.my 79 is over on the right,and the coop is on the left
skyacresairport.com
heres a shot of the coupe when he first built the hangar circa 98

i got some ats's i know i know...too small,they are really for my 79



im glad my mk3 floorpan is the same,it woulda taken weeks to recreate that
at least its tacked in



heres a pic of my 79 in the collapsed hangar.it was on blocks and missed the roof of the car by 6 inches


idle hands arent good.i built this.now i need a roof rack for it to be on the coop
typical hillfolk style
the stinson is for sale,all orig less than 400hrs
the corby is my uncles,vw powered. ..revtech engine
the corrado is sold to a friend


enjoy the pics and crazy hillfolk action!peace

[KingHillfolk]

woot!!socks on a rooster!
i pulled the timing belt tonite and compared it to the new one i got laying there for my 98 ahu engine.
guess what? same belt!!! good to go.should be running this weekend!
i taped the" tdi" belt to the 1.9idi belt.same deal

since u guys like planes,48 luscombe.65hp upgraded to 75hp
we stripped the tailfeathers off and they are going out for an exchange

heres the 98.its going to be an airport support vehicle.i think ill cut the roof off,strip the interior.i want the gas tank,so ill strap a 2 litre bottle of diesel to the fender.leave the keys in it.if ya need it for some jumping and bashing thru the tulies,go for it! just put fuel in it! it

its also my portable painting table right now
just keepin it 'folk yall

[KingHillfolk]

yea yea yea....me n dad jammed all day...lookin for parts i put away so safely we spent hours to find,but hey a few hours vs sitting 6 years it al came together..the phone audio sucks.it doesnt like open exhaust

i dont know which photobucket link to use for video so ill put em all
http://static.photobucket.com/player...4-22-17-33.mp4

[jaypees_alh]

Parts for the aaz aren't hard at all to source, they are for all intents and purposes identical, except for the injection, to the 1Z/AHU series. T-belt, tensioner, valve cover gasket, etc...

[theman53]

The belt for the 1.6 and 1.9 aaz should be the same. The difference for the deck height was in the IM pulley of the 1.9...it is smaller. The TB tensioners "can" be different as well as some of the AAZ had a smaller stud to help with the taller deck of the AAZ block. Other than that just the belt itself should be the same as the 1.6, 1.9aaz, 1.9ahu, and the 1z, as the 1.9 blocks I just listed are all the same minus the TDI have a crank sensor spot cast into the block...and the stuff involved between IDI vs TDI of course.

[KingHillfolk]

yep now i know that the tdi(the silver 98 pictured) belt worked no prob.i had one for the 98 on the shelf. .
its nice to be my own parts dept
since it was sitting for so long i made an oil pump priming tool and chucked it up in the drill and ran it for a minute or so and pops turned the crank with a wrench some..of course tons of things were running thru my mind before the start up..."hope the pump plunger isnt rusty and siezes".."hope the rings arent stuck"
"open exhaust,hope i can hear any tappin or knockin"
i pulled the return off the pump and filled it with a little fuel,and primed the filter.
i put the battery in and turned the key on....dash lights,yay...ok a quick smoke break to look around and to take the wrench off the crank,thats always a good one to forget
ok action time:injector lines loose try cranking it dad....crap,nothin.....
hang on screw the meter gimme a jumper wire from b+ to the s terminal.bump it cranks..wtf? screw it i got b+ at the pump ill use the jumper to start it.maybe 10 secs and i had 3 lines spittin.i closed em all and glowed again.crankin and its pickin up and started up albiet a little lumpy for a second,but not a mosquito fogger like i was waiting for..shoot i didnt even have the cold start on...yay 6 years of dormancy is over!!!!!
ha my buddy said" your ign switch is messed up,no crank"...close but no cigar
try the seat belt interlock.years ago dad put in a jumper because ya had to wiggle the belt upon startup and it was annoying.
so out with the meter...hmmmm no ringeee dingee goin back to the belt switch.the jumper musta broke/corroded apart.whatever,make a new one under the dash at the plug.yay now she starteee..
slow down,stand back think about it and find a dumb problem.i forgot about the interlock till i looked at the diagram then it was like duh so simple...now i gotta do a bunch of little crap things to actually drive it.
maybe it would be a good idea to get the title switched from ohio to ny
at least i got the whole airport to drive around to test it out before i actually put it on the road,and maybe ill have some of august and september to roll around in it
oh score yesterday too.my buddy called as he was at deutsche classic and scored me a set of mint front power recaros for 250 yay!
sorry its sideways,thats how he sent it
hey if its not gonna be fast,make it pretty and comfy!

[KingHillfolk]

ok this makes it all done.complete.yay.
yea right
we hillfolk like to slap some soot on the vag before we hit it though

[KingHillfolk]

not much goin on tonite i didnt go do any work on it

but heres some old school awesomeness.
if ya dont feel it why r u here?

http://www.youtube.com/watch?feature...&v=i_NeqJlrINc

[pho]

Interesting to watch this thread develop. I did not know the heads bolted up interchangeably.

Subscribed.

[KingHillfolk]

thanks man,i 'preciate it!
this is gonna be my slow low cruiser for takin the lady out to din din and cruisin slow on sunday
no work tonight again
im a generator tech and we had some bad storms today..i pulled a 12 hour no lunch day..oh well more dough for the cars...i gotta finish getting the 2 patches in the trunk floor and rear seat area done,i wanna get the fuel tank back in it very soon..i wanna be driving it by august,or sometime in august.
since im doin the pretty parts,i got these cool front turn signals from bfi with city lights
the headlights got em too,for them dirty city bastids
im figurin amber so the cops dont bug me.
i got a foglight switch ill use
im figuring the 1st position will turn the headlight citys on
the 2nd will turn on the blinker citys,and the rear fog.ill cut thestock bulb holder in the rear and use an led for that
heres amber


then i found some old purple bulb covers and put them over the amber bulbs
cop bait,id expect


ill get some cooler stuff when i actually get some stuff done tomorrow hopefully

[theman53]

Not only do I want your seats I also want a sooty vag

[KingHillfolk]

yea lol im even jelly of myself...i used to like speed,i still do but this car looks good so ill go with it
i just gotta drive to my buddy down in pa to put em in and pay him..thats a real friend too he scratched his tailgate bringin them home.i said ill even it up and go key my own car
to most,its just a car...to me? its memories man......i remember when dad brought it home
6-29-91 was the bill of sale
im houndin him to see if he can find more of the orig paperwork like the window sticker and stuff

[KingHillfolk]

haha,like the sig sez.....slap soot on that vag before ya hit it!
and if ya like diesels its gotta be a dirty sooty vag

[pho]

Not only do I want your seats I also want a sooty vag

Hmmmmmm, sooty vag, you say?

[KingHillfolk]

Hmmmmmm, sooty vag, you say?

yep.sooty cause i gots diesel runnin thru my veins
vag for volkswagen audi gruppe
or the other vag if you so prefer

[KingHillfolk]

hey heres a question for the paint and body dudes.
i see" they" have this new fangled paint color matching eye thing
i guess you put it on your car and it matches the paint almost perfect.
because of fading and whatnot, matching it the old way by trial and error is no longer an issue

so i guess you can get a batch of touch up paint that matches almost perfectly instead of just matched to the code
my question is: is it better to match it up now,or after i colorsand and buff?

i guess i could rub out the diesel fuel filler door if thats the way to go.
gas filler door?gas is for washing parts,diesel is for power
all ive done is hit it with the clay and waxed it,but it definately needs to be rubbed out for optimum excellence

[pho]

hey heres a question for the paint and body dudes.

Very simple.
a) Wash car, buff exterior paint with buffer + buffing compound, then detail.
b) Exchange your mechanical work for someone that does paint.
c) Pay a pro to do it.

Most cars look really really good after a good buff job, even when the paint is fading, btw cars with faded paint are the new thing. Detail car, then invest in some cool wheels, then people will think your paint was faded on purpose.

[KingHillfolk]

yea maybe ill have my detailing friend gimme a hand.its just oxidized a little and popped up nice even with a little wax.
i figure thick orig. waxed paint is better than rubbed out thin paint.if it got oxidized again ya got nothin left.
not that its gonna get that way again,but even when dad had it it would oxidize in a few months...it looks ok now even with a little wax vs when i first got it out of storage.some minor rubbing compound should do it.hey if anything i dont wanna be agressive cause ya can always do it again.puttin paint back is a @#$%&*%$#$&*
and its only original once.preservation mode....
yay its gonna be shop night.welding the patches in hopefully for the finish of that problem so i can get the diesel tank back in(after getting it to the shop,2 straps were broken,im glad the tank didnt fall in the street!)
its either welding time or shifter linkage install time..right now i need a nap cause some idiot at work almost killed me today with 208 3 phase,or at least a major injurie like limb loss....
TRUST NOONE with a diagnosis on electrical work.i should have known better i admit cause that dude is a hack...
either a nap,or a stiff drink...oh yea and some unsoiled underwear

[KingHillfolk]

i ground down the tacks and played connect the dots tonight


got it mostly all connected,except right behind that seat brace,and ground em down some



i gotta get it ground down all the to undetectable mode....im not looking forward to going underneath and welding upside down.i still got spec marks on my arms from 3 years ago workin on the 79.at least its only about 2 inches of length in that spot in front of the seat brace



boring tedious work..i gotta get a led spotlight,that halogen roasts you out!!

[KingHillfolk]

im trying to post a little vid clip from my photobucket acct,but i dont know which of the 4 links will work for yall..ill put em all up?

http://s1260.photobucket.com/albums/...4-22-17-33.mp4


http://static.photobucket.com/player...4-22-17-33.mp4







if any of those work,the sounds a little crappy....my phone is lame

[pho]

Parts for the aaz aren't hard at all to source, they are for all intents and purposes identical, except for the injection, to the 1Z/AHU series. T-belt, tensioner, valve cover gasket, etc...

Oh, a nice kevlar tbelt on that aaz would be nice.

[KingHillfolk]

hey lets play a game.its similar to wheres waldo.ill call it find my weld seams
this is the patch in the rear seat area from underneath.i painted it with por 15
enjoy


screw waldo.find veedub.i count 6,plus aa plane or 2..ok its hard to see in the shop a little
from left to right,inside:my 79 tdi-m,dads 03 golf coupè,my 98 tdi,and the 91 coupè
outside is my buddies new to him 09?jetta tdi,and my girls 04 passat tdi...
i read an article about diesel fuel getting in our drinking water supply.i say whats the problem?its already in my my veins...


remember gasoline is for washing parts

my buddy with the 09 said,dayum,are you building a show car?i sez yea cause its not a go car with 52(stock) horsies

oh i got the silver basecoat on the subframe,and the bearings pressed in the spindles,and a coat of por on em tonite

[theman53]

the pic of your welded back seat reminds me of the time I welded new floors in my 86. I caught the car on fire, right about the same spot you were welding. My plastic fuel line was right under and some of the weld dropped through onto it. It melted and I didn't know as the new pannel was in place. It was getting hotter inside the car and I smelled kerosene burning...then it hit me it wasn't kerosene it was diesel. Which normally won't really burn but since it had such a nice dribble coming out of the burn hose the entire underside of the car was a ball of flame. Long story but I got it put out. You looked a bit higher up and over more. Good work BTW.

[KingHillfolk]

wow that sounded like a blast,literally. ..folks is this thing on????
thanks man,it as a pita to get it nice with no warping.my goal is for it to be undetectible
for the gappy spots pop layed underneath with a copper bar as i welded. .that works awesome.the weld doesnt drop thru and needs minimal grinding.
at least we havent killed or maimed ourselves too much hopefully
its a good way to learn tho eh?i bet ya wont do that again
on my old lifted hillfolk caddy the strut towers were severely rotted and i was sorta new to welding on that scale.
i ended up smelling smoke in the car and had flames goin up the windshield pillar.
i caught the whole airspace inside the body between the wheelwell and inner fender on fire.that was fun
i also learned that cavity was filled with some kinda wierd foam.
like i tell them at work.you asked if i can weld...you didnt ask if i could weld good

[KingHillfolk]

i did 3 16 hour days this week...theres been alotta storms this week.i finally got to the shop last night to do finish painting on the rest of the front suspension.now i hope to reinstall it this weekend.



i had to stop at a hardware store in the sticks to try and find something for a downed generator
while i was in there,i saw this.i figured a 10$ gamble to see if itll remove white crap from aluminum is ok
thanks epa for making us buy green products that dont work....
its good to see theres still toxic stuff that will melt skin and damage eye sight and still works.i tested it on a few cruddy spots,seems to work ok



i was at a customers house,this cat was a cool dude
look, a lemon peeler,an apple crate,and a pea picker!!!!!way too cool!!!

[KingHillfolk]

hey guys and gals......
come on over for dinner.....on my frickin front suspension!!!!!!!!!!!!!!



dinner is served,on my front suspension yummy

[theman53]

Nice. I like the braided stainless lines on the brakes.

[KingHillfolk]

thanks man.may as well do some upgrades while im in there.for the cost,stock rubber is dumb cause they are about the same..i threw in those r 32 rear control arm bushings,and poly fronts.
how about the rear beam bushings?they look like no fun to change.ive seen poly ones for those,but also ive seen the motorsport hard rubber ones also.im not too concerned with road noise and whatnot,i want tightness
what u guys think im better off with?
i do like those ae rotors too,my dad put a set on his 03 a few months ago and they still look mint!
its gonna be slow so i may as get it thru the curves as fast as possible
i knocked off the drums and backing plates tonite.actually back in 05 or so i redid the rear brakes,new drums and all...they just need prettying up.the shoes are good as is the hardware.ill replace the cylinders for safety tho
the brake pressure regulator looks like it came out of a dead whales butt so i gotta snag one of those up too
im waitin on my buddy who is a salesman for fuelsender.com to get me some brakeline and that awesome flaring tool that does correct bubble flares.then ill swipe the tank out of the 98 and put that in.
oops i need an exhaust.thanks summit for 2 sticks of 4' pipe,2 u bends a few ss band clamps and a glasspack for about 90$.the pic is just showing the dtm tip i got in london in 99,and how im just gonna weld it to the 'pack lol
just a glasspack is good enough.i may as well be loud and slow like a wheelbarrow...whoops i mean harley!

momentum is the name of the game...until someday i swap that 98 tdi drivetrain into it

[pho]

Nice. I like the braided stainless lines on the brakes.

Nice upgrade.

[KingHillfolk]

man its been a rough week!
first i had to do this to keep out the crackhead neighbors from breaking in while im home....

then i caught a pic of this cat..hes smart cause its a tdi..i see him all over...peace yoe

then im glad to see that is still 1977 in livingston manor,ny..
dual fours on a tunnel ram...spotted at work on the road

then me and pops fixed that stupid ball on the shift linkage..the clip rotted off or whatever,i dunno the ball comes off easy,so we fixed its wagon..glad to have a machine shop in our hangar

see simple as cake,or pie. ..i like the hair variety of pie myself
its all countersunk and whatnot.dad made a cool jig to clamp the post in to hold it in the mill
basically a aluminum plate that fit the shaft,with a saw cut in it,and clamped in the mill fixture so it crushed down on it and held it tight...thanks again pop for getting me out of yet another jam

[Glegor]

Hair pie... LMFAO...

love the anti-tweeker door locks as well!

[KingHillfolk]

yea the door locks work great..i recommend it for anyone in a crappy part of town!
nice 3.5 inch screws will slow em down..nothings anti tweaker,just itll buy time(to grab my shotgun)
got some good stuff done today at the shop..
my buddy works for s.u.r+r
aka fuelsender.com
he got me an awesome brakeline flaring tool.it takes like 30 seconds do do a bubble flare,and im slow!hah
check it yoe


it actually makes doing brake lines fun.i made the one from the prop valve to the rubber flex hose (right rear)
so easy my cat can use it.i got a nice lil bender and straightner too.
this line is sooo easy to work with,you can literally tie it in a knot and it doesnt kink


heres the right rear that runs from the hose to the wheel cylinder.
the only reason that i can think for all the crazy bends in the stock line is that it wont get hit if ya have a blowout
something to think about if you are redoing your lines folks

i cleaned and por'ed the rear beam,dropped out the mk3 tank today also