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Old January 18th, 2011, 06:34 PM   #21
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

It didn't run away completely, it started to rev up and I just shut it down. Soot came out from under the car (from the toilet bowl gasket)

It is diesel fuel in the oil, you could smell it and the oil was thinner because of it. I do not think there is much damage done if at all because it did not run very long. Im just wondering why it decided to overfuel, but it only happened when i put it under load. The engine would start and run fine, easy to start when cold - and idle with no issues.
The oil was changed with a new Mahle filter and 5 qts of 15-40 Rotella letting it idle for about 15 minutes before I drove it from the shop to my house and then shut it down for about 30 minutes.

I have no idea why it is overfueling, I will definitly check the injection pump timing again tomorrow.

That is the same compression tester I bought as well.
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Old January 19th, 2011, 09:47 PM   #22
Baron VonZeppelin (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Holy Crap on the fuel in oil deal - on a fresh build ... of Engine/Inj's/Inj Pump
[scratching my ass with one hand, and my head with the other one]

My thoughts in order of relativeness:

1. static timing would not be an issue at all.

2. run it again and pull pcv hose at breather - and see if strong fuel odor/vapor/mist.

3. the fuel would have to be going past the rings - which is odd on fresh high compression -
so i'd do the compression test ASAP. Seems excess fuel would blow out the exhaust instead.
Unless some really bad rings.

4a. one or more of the rebuilt injectors may be hung open ?

4b. Inj Pump could be WAY overfueling/improper governing.

4c. Call Giles

The easy cold starting makes compression/rings sound Good (hmm)
I'd still do the compression test. For the data if nothing else.

My Harbor comp tester will do Injector hole or Gplug hole.
You'll get similar results either way with IDI engine.
But like Bill said - Inj hole is much easier.

Rotella 5w/40 Synthetic is all i use.
Except my TD Truck - it uses oil - so it gets Dino.
5k-8k is what i've been told about switching from Dino after rebuild.
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Old January 19th, 2011, 11:45 PM   #23
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

- Engine timing is correct

- Checked the injection pump timing and it is around .88-.89 so I will re adjust it.

- I ran thru the fuel lines and vaccum hoses, and found the hoses on the rear right beside each other where the vaccum line and the small line going to the OUT-return line from the overflow from the injectors were swapped. It was getting dark outside when I was finishing up.
So I switched them and will try again tomorrow after I check the cylinders. Hope this has done no damage, but the only vaccum on the engine is the mechanical vaccum pump on the engine being turned by the intermediate shaft.

Compression check tomorrow, and call Giles if it still acts crazy after this.
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Old January 20th, 2011, 12:32 AM   #24
Baron VonZeppelin (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Glad you found that out Couga.

I'm not certain if you mean the fuel return hose hooked to #4 injector -
or the fuel return hose hooked to the Pump that should have been going to #4 injector -
- was connected to a vacuum pump nipple ...

But either way - i think you found the whole problem with fuel in the oil.

Hopefully the 'acceleration surge' was from vapor/mist created
when the fuel went past spinning pump vanes and lower drive gear mesh -
and the PCV was picking up some of the vapor/mist.

Would be great if thats the answer to both problems.
Good Luck

Timing is plenty tight at .88-.89 if your range is .90
.85-.95 is stock variance on yours.
I wouldn't bother it again until after the fuel in oil / power surge is re-tested.

At the end of all that - then i'd wanna test some different timing settings too probably -
especially with a Giles pump. :]

These 89-92 pumps fitted with altitude aneroid are the bitchiest ones to do fuel timing adjustment/checks on
that i have dealt with (nothing to do with the aneroid- its the other aesthetics). And i've done all the 1.6 IDI variations. Just makes it more of a pain when you know the others are easier to deal with.
You get spoiled/pissed. I've worked on three 89's lately.
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Old January 20th, 2011, 01:11 AM   #25
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Thanks!

Mine has the Alttitude aneroid on top with the altimiter mounted on the firewall.

So the Harbor Freight diesel compression tester will work for the Injector and the glow plug? Great! The instructions stated that for my year it used the glowplug adapter.

cant wait to wake up tomorrow and get this thing running again.
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Old January 20th, 2011, 05:24 PM   #26
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Update:

Double-checked the timing again, changed the oil / filter and did a compression check.

The harbor freight tester worked great, and I used the injector adapter as well.

Cyl:
1) 470
2) 460
3) 460
4) 490

Tomorrow:
Retorque the injectors
Reset the injection pump timing - I think I will set it around .92 this time.
Re-install the fuel lines,valvecover,and misc vaccum / overflow lines.
Prime the fuel system.

And see what happens.
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Old January 20th, 2011, 07:09 PM   #27
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Compression numbers look great, hope everything goes well!
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Old January 21st, 2011, 10:06 PM   #28
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Timed the pump again back to .90.
Buttoned everything else up.

Purrs like a kitten. Took it out to get some fresh fuel and some Diesel Kleen.

Now I need to replace the front wheelbearings. ( I have the parts - just have to remove the spindles and have the new bearings/hubs pressed in )

Which I will start tomorrow to get the spindles off.

I also need to get new rubber bushings for the rear struts and the front so I can install the cup kit. Chad mentioned about using the front bushings from a MK3 VR6 but I forgot the part #'s.

So I need to get those ordered and get this thing done and ready for paint.
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Old February 3rd, 2011, 10:51 PM   #29
Baron VonZeppelin (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Couga, hows your car doing ?

Did any more fuel get into the oil ?
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Old February 3rd, 2011, 11:11 PM   #30
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Nope, no more fuel in the oil. Runs like a dream.
Had to remove the front spindles to have the wheelbearings replaced as the passender side was worn out and "roaring" pretty bad. Gerich said that there was no grease left in the old ones when he replaced them.

Found out that the ball joints were bad as well, so as while the front was in pieces already, I decided to just rebuild the suspension as it is cheap anyway.
Parts should be here tomorrow:

Ball joints
Tie rod ends
Control arms w/bushings
Front strut mounts
Front strut mount bushings
Rear strut mounting kit
A few other pieces I might have forgot about....

I did not get sway bar bushings as I read on the MKII DIY that the MKIII swaybar was a bolt in upgrade and might do this in the future.

So this weekend I will be installing all the new parts and the 60/40 cupkit I bought from Chad that he had on his 85 Gti.

I am hoping to have the alignment done on Mon-Tue and get it back on the road.

Last thing to do after this is new wheels / tires, paint, and swap out the interior to the one I just picked up.
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Old March 6th, 2011, 10:32 PM   #31
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Updates....
Installed:
Front lower control arms w/bushings
balljoints
60/40 cupkit and 15mm drop spacers in the front
tie rod ends
spindles with new bearings and hubs pressed in - Thanks Gerich!
front strut mount bushings
rear strut mount bushings

front end alignment done

Replaced the vaccum "t" so now my heater controls work.













Took it for a little day run to Morehead City on Saturday. On a full tank, drove to and around Morehead ( went to the Aquarium, to the Mariner's Museum , the beach and to dinner) and back on a half tank - Estimated 542 miles. My Odometer does not work, I have the original cluster out reparing the odometer/trip odometer and have another cluster with a working speedometer.

So hopefully once the odometer has been fixed and swapped back in I can give a more accurate estimate. Today I drove to Knightdale once and to Wilson once, and now have drove it to work (Cary) and the gauge reads between the 1/4 and the 1/2 mark.

The only issue Im having now is that it is having issues starting cold and I am thinking of advancing the injection timing to .92-.93 to see if this helps. Might have to look into replacing the glowplugs.

Also, I will have to get a few updated pics, I believe the car has settled a little bit since the trip.
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Old March 7th, 2011, 10:31 AM   #32
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

coming together nicely man. now paint it already!
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Old March 7th, 2011, 02:04 PM   #33
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Space shuttle style.
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Old March 30th, 2011, 04:57 PM   #34
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

try this one Extang 2660, Blackmax Tonneau Cover: 2004 Chevrolet Canyon/Gmc Colorado: Short Box
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Old July 29th, 2011, 02:55 PM   #35
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

Update:

The 60/40 cup kit has settled but its now eating the inside of one of the front tires.
So I will take it to have the alignment re-checked and go from there.

?: Since the cupkit was for a golf, since this is a Jetta would it set lower?

Possiby I may need to get some new camber bolts. (ones designed for more than stock camber adj )
I failed to ask Chad if he used camberbolts on his GTI. Or I may take the cupkit off and go with coilovers.
Right now I am running the kit with no bumpstops (mine were dead) so I may buy new ones
and install them.

I have a few new parts to install:

Drivers side window regulator
Pass side window regulator
radiator fan
headlight switch
turnsignal/hazard switch

Complete interior swap

Also in the works:
Complete new exhaust
Finish bodywork and paint.

I need:
Small rear bumper in great shape. Mine decided to break where it slides onto the tab
on the body.

I would love to get those 13 BBS from Tom, but I dont think it would do them justice
to run 185/70/13's on them.

Also to note, I had to re adjust the Injection pump timing to .095 and it runs alot smoother.
Fuel mileage went up 640 Miles for 13 Gallons.
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Old July 29th, 2011, 03:08 PM   #36
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

What do you have planned for the exhaust?
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Old July 29th, 2011, 05:08 PM   #37
Couga (Offline)
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Default Re: 1989 Jetta 1.6 N/A Diesel Rebuild

I have a 8v Dual Downpipe that I have not installed, but Im thinking of just putting back a complete stock exhaust. Or install the Dual Downpipe and a stock GLI exhaust.
Im wondering if the 2.25 pipe would be too much for this motor.
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