View Full Version : ~91 Jetta gas GLI converted to a 1.6 turbo diesel build up~
53 willys
09-15-2008, 02:08 PM
In my quest for better MPG's I ran across Zukgod1's diesel jetta build up thread...then I noticed he was in the same state as me..so I PMed him about his car...after talking back and forth with him I decided I would buy a Gas GLI jetta and just convert it to the simple mechanical diesel..I really dont like VW's electronics in the newer ones so I figured a old school diesel swap would be best for what I wanna do.
thought some guys on here would like to see the progress so he goes....
I set out to find a REALLY clean body car..I did not want to mess with the body stuff I just wanted a clean car that was not BEAT!
I found a California car that was a one owner GERMAN built car..I flew out and and drove it back to Utah.
here is the car..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0403.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0404.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0406.jpg
I picked up one of Zukgod1s spare engines 1.6TD
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16td1.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16td2.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16td3.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16TD4.jpg
I torn the engine down and had it rebuild...I port and polished the head myself..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0431.jpg
I also lightened the intermediate shaft
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0434.jpg
some go fast goodies!!:evil
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0429.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0428.jpg
Mercedes benz injector tips..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/injectorMB.jpg
K24/26 hybrid turbo:ft:
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/hybridturbo2.jpg
I almost got the engine put back together..I will post some more updates soon...
haloman
09-15-2008, 03:36 PM
Looks like a fun project!
CTD03
09-15-2008, 06:59 PM
let me know cost i got a old body style 99 and was thinking of replacing the old but true 2.0l gas with a little green house diesel haha:)
dieselbeef
09-16-2008, 09:00 AM
how ya gonna make the rest of the car werk w/o the engine mangement. my 02 would be impossible to make werk for the swap
Smokinrebel
09-16-2008, 09:09 AM
that is awesome. Keep us updated.
53 willys
09-16-2008, 09:29 AM
how ya gonna make the rest of the car werk w/o the engine mangement. my 02 would be impossible to make werk for the swap
make what work??? the engine management is different wiring harness then the rest of the stuff....the only thing the 1.6td wants is a keyed power(that will come from the distributor power wire) and a glow plug relay system.
that's the whole point of this is that it is a EASY conversion...Im not the first guy to do this either..it's been done MANY times.
even if the check engine light was on after this it would not matter..I could pull the bulb out and the diesel or the rest of the car wont know the difference.
never say impossible:poke:
jaredb900rr
09-16-2008, 05:32 PM
Lookin good Mark!
Big Angry
09-16-2008, 08:19 PM
Very neat project!
GOT-Torque
09-17-2008, 09:49 AM
Cool project...
Is there someplace online to read about the model of 1.6 engine you are using? No electronics would make it an ideal swap into alot of things. What's the power rating on the engine and what do you plan to tweak it up to?
53 willys
09-17-2008, 10:05 AM
Cool project...
Is there someplace online to read about the model of 1.6 engine you are using? No electronics would make it an ideal swap into alot of things. What's the power rating on the engine and what do you plan to tweak it up to?
this is the best forum I have found for the VW diesels... http://www.vwdiesel.net/phpBB/
if you want a real power house the 1.9TD(non ECU version) would be best....this little 1.6td engine i have is only about 68hp factory...but there are a few guys with 200hp 1.6td's:ft:
I am shooting for about 150hp for mine...I commute so I want it fast...but I dont want to lose my reliability either..the 1.9's are also harder to find and ALOT more money then the 1.6td's
my intercooler should be here today!!!!!:rockwoot:
GOT-Torque
09-17-2008, 11:18 AM
Can you list a rundown of what mods you will be doing to the engine in order to get around 150 hp and probably around 300 to 400 ft lbs?
JD Dearden
09-17-2008, 12:29 PM
she's a real bute Clark
53 willys
09-18-2008, 08:43 AM
Can you list a rundown of what mods you will be doing to the engine in order to get around 150 hp and probably around 300 to 400 ft lbs?
Well so far my list is something like this
BIG hybrid turbo k24/k26....stock is a k14 or smaller
Benz injector tips
intercooler
injection pump tweaked to the max!
gov mod
ground down fuel pin
3" down pipe and exhust
I may end up needing a bigger ip pump head to make my goal but once I get it together I will see how it does..the pump head is a pretty easy change.
Got my intercooler set up last night!! I will post some pics later....
luvinacummins
09-18-2008, 10:09 PM
she's a real bute Clark
Your killing me smallz!!! :rockwoot:
LMFWAO!!!!:hehe::hehe:
luvinacummins
09-18-2008, 10:10 PM
Well so far my list is something like this
BIG hybrid turbo k24/k26....stock is a k14 or smaller
Benz injector tips
intercooler
injection pump tweaked to the max!
gov mod
ground down fuel pin
3" down pipe and exhust
I may end up needing a bigger ip pump head to make my goal but once I get it together I will see how it does..the pump head is a pretty easy change.
Got my intercooler set up last night!! I will post some pics later....
Hellz yeah brothat that is bad ass... Didn't i see some ARP studs in them pics too!!! Your are a diesel junkie just as much as I am!!!:bang:hehe::rockwoot:
53 willys
09-19-2008, 09:16 AM
Hellz yeah brothat that is bad ass... Didn't i see some ARP studs in them pics too!!! Your are a diesel junkie just as much as I am!!!:bang:hehe::rockwoot:
yeah I am a diesel dirt head!!!...I sold my CNG car cause I missed and liked running oil burners more:evil
I punched out the gas tank to fit diesel nozzles this week..I used some 1.5" DOM tubing and heated it up with a propane torch...punched out the little metal flapper...I was nervous if it would work but it actually worked better then I expected!
forgot to take the camera over so all I have is phone pics..and I forgot to snap a pic of the tank opening.
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/gastankpunchout.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/gastankpunchout2.jpg
blacknd
09-22-2008, 03:12 PM
The GLI/GTI spec trans are a bad choice for a diesel if you want decent mpg. They are close ratio and have a final drive that puts you at about 3500rpm at 65. If you can find an early FF code trans they have the best final drive ratios to put behind a engine with torque. Or even any non gti/gli trans would work. I used to use them in my turbo cars I built. your old 2.0 16v and trans is worth a lot to the VW guys and should have no problem getting some good $ out of them. Good luck and have fun driving that thing!
53 willys
09-22-2008, 07:07 PM
The GLI/GTI spec trans are a bad choice for a diesel if you want decent mpg. They are close ratio and have a final drive that puts you at about 3500rpm at 65. If you can find an early FF code trans they have the best final drive ratios to put behind a engine with torque. Or even any non gti/gli trans would work. I used to use them in my turbo cars I built. your old 2.0 16v and trans is worth a lot to the VW guys and should have no problem getting some good $ out of them. Good luck and have fun driving that thing!
Yeah I know I picked up a ASF trans..it has the same ratios as the diesel trans..I also swaped the 2Y (16v trans) 100mm axle flanges onto the ASF so I dont need diffrent axles..
thanks for the heads up:Cheer:
53 willys
09-27-2008, 02:06 PM
I have more done then this...these pics are from last week..I will post some new stuff up later..
got a pic of the governor mod..
I use a steel roll pin for mine...it fit the shaft real nice and allowed the spring to stay on there for some slight give...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/govmod.jpg
also got my ARP studs installed
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/studs.jpg
stock 2 notch gasket...1mm over bore pistons
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/studsandHG.jpg
I replaced some more seals on the trans...while I was doing that I decided I would change that bushing in the end of the shaft...I had to make a tool to pull it out...I ended up using a tap welded to some nuts..then the nuts attached to the slid hammer...worked great!
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/transbushing.jpg
the engine is put together for the most part...I should have it installed by middle of next week(my next days off)
if I can get my coolant hoses by then I may even drive it next week 8)
53 willys
10-02-2008, 10:45 AM
well I have got the turbo mounted and pretty much got the supply and drain lines figured out....
I had to make a spacer for the turbo so it would not hit the intake manifold...it worked really well and was super easy to make.
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0435.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0438.jpg
more spacer shots...you can also see my BOV eliminator cap...Zukgod1 gave me the idea....you take a VW strut cap turn it down till it fits in the same spot as the stock BOV and I also weld in a 1/8" NPT steel fitting for my boost gauge...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0445.jpg
here you can see the oil drain....
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0440.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0441.jpg
I cut the stock metric threads off the pan and welded a -AN fitting (10) to the old metric pipe fitting....I LOVE -AN fittings so I wanted to change so I dont have worry about finding weird fittings or threads for a drain.
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0442.jpg
-AN oil supply and and -AN water supply too...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0439.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0444.jpg
53 willys
10-02-2008, 10:46 AM
Clutchnet.com race sprung hub clutch and lightened flywheel
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0436.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0437.jpg
pretty much got everything ready now!!!
this here is a beautiful thing!!!!
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0443.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0448.jpg
kinda cleaned up engine bay...I still gotta gut the stuff I dont need out og the harness...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0449.jpg
got my new gauges installed too!!!
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0451.jpg
GOT-Torque
10-02-2008, 11:30 AM
Lookin' good...
Billysgoat
10-02-2008, 09:09 PM
Niiiice....
53 willys
10-10-2008, 05:39 PM
Well I made some exhaust this week..I spent about $200 total for the 3" mandrel bent turbo back system.
of coarse all the labor is me witch is the only way I can afford my projects
it not a tig welded SS down pipe....but I am kinda proud of this one.
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe1.jpg
painted with some 1500* flat.......yeah I know it will probably burn off.. but the same stuff lasted over a year on my cummins....
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe2.jpg
downpipe
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe9.jpg
downpipe connection
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe8.jpg
over the axle arm
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe6.jpg
4" gloss black turndown..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe3.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe4.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe5.jpg
53 willys
10-10-2008, 05:40 PM
engine in!
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/enginepics.jpg
G60 valve cover back from powdercoat
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/enginepics1.jpg
glow plug relay base..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/glowplug.jpg
glow plug wiring...in place of old ECM...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/glowplug1.jpg
Innovative
10-14-2008, 03:32 PM
Great job so far. The VW TDI's are excellent commuters. We have an 02 and 06 Jetta. Both are Auto's. I have injectors and tuning on the 02.
I've been thinking about building a 2 Door Golf to have some fun with! :Cheer:
UpstateDiesel
10-16-2008, 05:49 AM
Looks Great! I'm hoping to do some exhaust work on my '92 Jetta ECODiesel soon and open her up. Chris
53 willys
10-17-2008, 06:23 PM
Update
well I did not make my goal I had to start it this week....I probably could have but I worked some other stuff on the car and not just the "get it started stuff"
I did most the glow plug wiring....I used Vince W's write up to get the idea on it but I went with a different style fuse block.
I have all the wiring hooked up to a VW style glow plug relay..then it's ran through the ford style relay and then to the fuse block, then to the glow plugs....
here is my glow plug wiring
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0475.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0473.jpg
53 willys
10-17-2008, 06:23 PM
some pics of my water and oil supply lines..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0484.jpg
turbo coolant return line hooked into the old oil cooler line...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0480.jpg
turbo coolant supply line..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0477.jpg
this is my "connectzilla" bonus points if you can tell what I made my oil manifold from :lol:
I have a few things hooked or will be hooked up there that why I have the manifold..OEM oil temp sender, OEM oil pressure sender, turbo supply..then I will have one extra spot for a incab oil pressure gauge or just a pressure checker spot for my shop gauge. (yeah I know I dont have the oil cooler hooked up in this pics....I still debating on if I should use the non thermostatic sandwich I have or ..just buying a new thermo version)
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0476.jpg
53 willys
10-17-2008, 06:24 PM
I cut some of the lip off the front bumper so I could mount my intercooler on the bumper..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0487.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0471.jpg
this idea is Zukgod1 idea...another big thanks to him for all his help and advice with this build...
this is a dodge cummins fuel canister/water separator
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0481.jpg
water drain
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0488.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0489.jpg
53 willys
10-17-2008, 06:25 PM
new engine bay pics...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0467.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0470.jpg
air filter tubing...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0469.jpg
53 willys
10-17-2008, 06:25 PM
how it sits now....
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0490.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0491.jpg
turbo diesel badge replaces the "jetta GLI" badge :twisted:
thanks for the badge Zukgod1
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0492.jpg
GOT-Torque
10-17-2008, 09:07 PM
Looking good, should have it on the road soon...
Your oil line adapter looks like a 3 way splitter for an air hose connection. (what do I win?):hehe:
53 willys
10-17-2008, 11:31 PM
Looking good, should have it on the road soon...
Your oil line adapter looks like a 3 way splitter for an air hose connection. (what do I win?):hehe:
yeah I hope to have it on the road next week...:st:
Nice job on the guess!!!! you are the winner!!!
I dont really have a prize....but if you want to send me your address I will send you a Uinta diesel performance sticker:Cheer:
nomercy
10-21-2008, 11:57 PM
mark you are a true diesel guru if you can mod a jetta you are indeed a bada$$
53 willys
10-24-2008, 09:18 PM
well I got it running and driving.......problem is when I pulled it out of the shop last night to drive it.
I go around the block 2 times...on the 3rd run the heater core blew open and filled my car with coolant :cry:
the other problem is it feels like I am not getting into 1st gear...the shifter is all the way over but it feels like 3rd when I take off...maybe my trans linkage is out of adjustment???
pretty bummed about it....I wanted to have this car done this week.....
here is a few shots of the single round headlight conversion I did (smoked E-codes).....I made/converted my square headlight radiator support to a round.....it was a PITA!!
also you can see my intercooler piping...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0479-1.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0478-1.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0480-1.jpg
adjustable intercooler bracket
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0481-1.jpg
UpstateDiesel
10-25-2008, 11:37 AM
Those Heater Cores are a Biotch! I did one at the end of the summer. It is a lot of tugging and such. Looks Good! Chris
Billysgoat
10-26-2008, 07:26 PM
Don't you just hate it when everything goes right.............just to go wrong? :(
At least it's together and driving, that's something!
6BT2500
10-29-2008, 10:04 AM
heater cores are fun dash has to come out and the a/c box unbolted of the fire wall then the dam thing just sits in the box no screws or anything, and its much easier to buy the single round support than try to mod a factory
Diesel Fanatic
10-29-2008, 07:23 PM
Damn nice job!!! Also, where is Uinta Diesel Performance?
luvinacummins
10-31-2008, 08:44 AM
Damn nice job!!! Also, where is Uinta Diesel Performance?
Lehi Utah!!!:rockwoot:
Mark that biatch is looking PIMP... Very nice work brotha!!!:Cheer:
dwitt0187
10-31-2008, 08:58 AM
mark it looks awsome sorry to hear about the heater core hope you get her going soon and i want to see some dyno numbers out of this beast. are you planning on dynoing it?
danny
zukgod1
10-31-2008, 04:47 PM
are you planning on dynoing it?
danny
This is something we should do Mark.
As long as we can find a place that wont rape us financially.
53 willys
11-01-2008, 11:45 PM
heater cores are fun dash has to come out and the a/c box unbolted of the fire wall then the dam thing just sits in the box no screws or anything, and its much easier to buy the single round support than try to mod a factory
yeah I thought I could bust out the single round radiator support quick...but it ended up being a major PITA...I would just buy one next time.
Damn nice job!!! Also, where is Uinta Diesel Performance?
thanks buddy...we are in Lehi
Lehi Utah!!!:rockwoot:
Mark that biatch is looking PIMP... Very nice work brotha!!!:Cheer:
thanks Shane!!
mark it looks awsome sorry to hear about the heater core hope you get her going soon and i want to see some dyno numbers out of this beast. are you planning on dynoing it?
danny
thanks Danny..yes I want to dyno it for sure!!!
This is something we should do Mark.
As long as we can find a place that wont rape us financially.
Dan soon as my engine finishes breaking we should hit up the rollers!!!:st:
Update
I got the heater core done...now I'm chasing a few small issues..I hope to have them figured out by first of this next week?....
small oil leak
heater/ac blower inop
coolant leak at turbo coolant feed line
CCV issues
I will post some new pics too!
53 willys
11-09-2008, 08:21 PM
Well its pretty much done!!! I'm just working out the last few issues..but for the most part it's ready to drive and commute...and soon after that it's time to hit the rollers!!
I was out cruising today and figured I would stop off at the lake and snap some pics real quick....it's super dirty...you can even see greasy finger prints!!:doh: but it still looks ok...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0494.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0498.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0499.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0502.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0507.jpg
UpstateDiesel
11-09-2008, 09:05 PM
Looks Great! How is it running? Chris
Diesel Fanatic
11-09-2008, 10:01 PM
Looks real good, I like the round head lights:rockwoot:. Now I'm just trying to figure out what lake that is...
53 willys
11-10-2008, 06:49 PM
Looks real good, I like the round head lights:rockwoot:. Now I'm just trying to figure out what lake that is...
thanks!
Utah lake/ AF boat harbor
53 willys
11-10-2008, 06:52 PM
well apparently I popped my headgasket:(
I got coolant coming from the block and head.....I'm thinking it has been blown/leaking since I got it running....
time for the MLS gasket mod:bang
Phunking VW's:bang
53 willys
11-14-2008, 12:39 PM
pulled the head....the fiber headgasket was blown in 2 spots!!!
I guess 20psi is too much for the fiber gasket...even with ARP studs...
UpstateDiesel
11-14-2008, 06:24 PM
Damn! That sucks. I hope you can get that head to hold tight. Chris
Mountaineer
11-14-2008, 06:54 PM
Omg , that is beautiful !!! . :clap: If you get tired of it, pm me.
53 willys
11-14-2008, 07:39 PM
Damn! That sucks. I hope you can get that head to hold tight. Chris
yeah tell me about it!!!
the reason I went stock fiber was cause I thought the ARPs would hold it down....but I guess not...there is a multilayer steel gasket for the 1.9 IDI engines that I ordered for it...it does not fit perfect tho and takes some modding...yeah I know modding a headgasket does not sound right!!!lol..but lots of guys have been running them with good luck...definatly better results then my fiber gasket!...:kick::hehe:
thanks for the positive comments Chris
Omg , that is beautiful !!! . :clap: If you get tired of it, pm me.
haha thanks buddy! thats a great compliment!
I don't think I will be getting tired of this car for awhile...it runs pretty damn hard for a engine that only has 58hp stock!(of course mine is not stock hp)
its a fun car!! I cant wait...I'm rebuilding the control arms and rear axle bushings next week so it should run and drive better then new!
LONG AS i CAN KEEP THE HEAD CLAMPED DOWN!:ft::evil
i'm pretty happy with how it turned out!!
I would like to lower it some and powder coat the wheels gloss black
thanks for the positive comments guys....I need them after all this!:bang
Big Blue24
11-18-2008, 01:54 AM
Looks great, wish I still lived in Provo so I could stop by for a ride in that beast. Can it spin the tires in the Utah 4500' valley air?
zukgod1
11-24-2008, 12:09 PM
It will once he bolts the top back on.
I've scared my self a couple times now in mine.
onebadf150
01-06-2009, 09:45 PM
Truely awesome work !! :rockwoot::Cheer:
53 willys
01-08-2009, 09:15 AM
Truely awesome work !! :rockwoot::Cheer:
thanks! I'm still waiting on my MLS gasket...wish it would hurry up and get here..
onebadf150
01-08-2009, 02:37 PM
53 willys, when you get the car back together could you take a video of it to so we can see and hear that monster running !!!
thanks for an awesome write up and build ! :bow::woohoo:
Atchley
01-08-2009, 03:12 PM
Beautiful car. The round headlights look 100 times better. It would look good lowered with black wheels for sure
53 willys
01-30-2009, 09:19 AM
Well I have not done an update on here for a while so here is what I have been doing on the diesel dub.......
got some more stuff done this week..
daisy chained my lighting for the gauges
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0576.jpg
also built my drive pressure gauge tubing..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0568.jpg
I drilled out and through the old turbo support bolt hole...tapped it with some 1/8NPT and screwed in my compression fitting and my Custom coiled brake line tubing(by custom I mean I coiled it around my Mag light :lol: ) to cool the gases before they hit the poly tubing....I also made a soot filter(filled with brilo pad)
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0567.jpg
53 willys
01-30-2009, 09:20 AM
I also got this little bundle of joy!:twisted: :twisted: :twisted: :twisted: :twisted:
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/MLSgasket.jpg
opened it up... and found both theses little beauties...
2 notch
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0550.jpg
3 notch
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0552.jpg
out of the package...
it looks great!!! I am pretty impressed with the quality..
it did have some slightly rough edges around the #1 and #2 bore hole...but nothing to be worried about..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0553.jpg
hurried and took it outside to check it against the head...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0566.jpg
PERFECT MATCH!!!!!!!(it looks a little off in the pic..but that cause I'm trying to hold it with one and and take a pic with my SLR camera)
:D
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0566.jpg
note the steam pocket holes!! 8)
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0564.jpg
Put the new MLS on the block..marked the holes with a sharpy
laid out some painters tape and drilled the steam pocket holes.
the holes end up being pretty darn deep...at least 1/2"+
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0557.jpg
Done..
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0558.jpg
53 willys
01-30-2009, 09:21 AM
on the block it looks just as pretty!..lol
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0559.jpg
you can kinda see the rough edge in this pic.
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0560.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0561.jpg
I slapped the head on TQ'ed it in steps and proper sequence to 80ftlbs..I will start and run it WITH NO COOLANT CAP to get it up to operating temp.then I will let it cool and do a re TQ@90ftlbs..
Drive pressure gauge installed...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0569.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0574.jpg
I have ran it tonight...I'm waiting for it to fully cool and I will re torque it in the morning and then it's GO TIME....
:twisted:
finally!!!
I'm gonna be nice to it this time....no 20 psi rally runs:lol: ...least not till I get some time in the drivers seat...
53 willys
01-30-2009, 09:23 AM
well I got it put together the day before yesterday...I warmed it up and retqed it yesterday...took it for a ride..10psi was the most I pushed it..
came back home feeling great!!
look under the car and see red coolant dripping down...at the back of the engine! Sad
grab my inspection mirror and start looking...the damn head gasket is seeping coolant on the back side of the head and block!!!! Crying or Very sad Evil or Very Mad Crying or Very sad Evil or Very Mad Crying or Very sad Evil or Very Mad
so after punching a few holes in my garage walls!!!!(jk)
I started to take the car back apart to see why...after I got it apart I pretty much came to the conclusion that I did not get the gasket FULLY smashed...I clean the surfaces again..and this time I applied some permatex Aviation form-A-gasket sealer...and put it all back together.....head off, cleaned, inspected and reinstalled in about 2.5 hours!!! I'm getting good now! lol
I took the studs to 95ftlbs...I'm gonna warm it up and go to 105ftlbs
if this SOB does not seal now..well I dont know what I will do!!!!!!!!!
to be continued...........
53 willys
01-30-2009, 09:25 AM
well I just finished taking her for a nice burn around the block..
apparently 110ftlbs!!!! is what it takes to crush this MLS and I think the Aviation sealer help a ton too...
WOOT WOOOT!!
53 willys
01-30-2009, 09:28 AM
well here is what I did ..
1~aviation permatex sealer on both sides of the gasket..
2~torqued in proper sequence and steps
35ftlbs
50ftlbs
75ftlbs
95ftlbs
then I filled it with coolant and plugged in the block heater...
I knew I wanted to take the studs way past the ARP spec and I noticed that when I retorqued the studs after RUNNING the engine it has was most the molylube off and I was getting "popping" and "jerking" when I retorqued...so my thought this time was plug the block heater in let it warm the whole block over night..then come out and clamp the SOB down with 110ftlbs.....
as I did the retroqued I could tell the gasket had not fully crushed and I was getting nice and tight as I kept going Cool
I only had 1 stud "pop" on me witch made me feel like I was getting some good even clamping force from nicely lube stud threads..
as of right now I dont think I would go much past 110ftlbs....that was starting to really get tight..
I'm gonna take and run some more testing on it in the am...I had to work today so my time was limited..
I was beginning to think it was never gonna seal!..
15PSI AND HOLDING STRONG!!
man it's running even better then before(weird but it ran nice even with a blown HG before)
I would say the MLS is a success!!!! I drove to and from my work last night with no engine issues at ALL..the worst part is my heater resistor pack is blown...and my blower motor is shot so it rattling and bouncing around!!
so hey I would say success if that all I can complain about!!
I took it up a nice big hill on my way home...18-19psi... holding strong..
Twisted Evil
I'm trying to keep the boost down under 20psi......
UpstateDiesel
01-31-2009, 07:39 PM
Sounds Good. Who would've thought that you would get to a point where holding the head down would be tricky. Chris
SKYNYRD
01-31-2009, 08:00 PM
i can't wait to finish my 79 rabbit. i'm going to get is running NA then turbo it. or maybe twins. oh yeah and a 5 speed with 4 speed gearing and a 5th gear for highway rolling
willys do you have where you got the arp head studs and mls gasket from?
onebadf150
02-01-2009, 08:43 PM
53 willy's sounds like you're moving in the right direction I'm sure you're glad to be driving instead of wrenching.
53 willys
02-02-2009, 01:57 PM
Sounds Good. Who would've thought that you would get to a point where holding the head down would be tricky. Chris
I know...I knew the head did not seal well with fiber..but I also did not think it would take soooo much to crush the MLS gasket...
i can't wait to finish my 79 rabbit. i'm going to get is running NA then turbo it. or maybe twins. oh yeah and a 5 speed with 4 speed gearing and a 5th gear for highway rolling
willys do you have where you got the arp head studs and mls gasket from?
sounds like a sweet project!
I'm a ARP dealer so I bought them from me....
the custom MLS came from "gasketstogo.com" (Thailand)
53 willy's sounds like you're moving in the right direction I'm sure you're glad to be driving instead of wrenching.
thanks bud! yeah I'm ready to rive this for a bit and NOT wrench on it...although we know it's a VW so there will be wrenching no matter what!..lol
SKYNYRD
02-02-2009, 02:29 PM
willy can you see if you can find a set of arp head studs for a 79 vw rabbit diesel i'm pretty sure its a 1.6L
blackandstacked
02-02-2009, 08:37 PM
i can't wait to finish my 79 rabbit. i'm going to get is running NA then turbo it. or maybe twins. oh yeah and a 5 speed with 4 speed gearing and a 5th gear for highway rolling
Just be careful charging an na engine they dont have piston cooling jets like the factory turbo engines.
SKYNYRD
02-02-2009, 08:57 PM
Just be careful charging an na engine they dont have piston cooling jets like the factory turbo engines.
oh i know i already plan on having the pistons ceramic coated and i won't be running anything more than 15 or 20 pounds.
53 willys
02-04-2009, 09:14 AM
oh i know i already plan on having the pistons ceramic coated and i won't be running anything more than 15 or 20 pounds.
if your going to that kinda trouble and expense....I would just buy piston squirters and add them to your NA block...they are just about $100 bucks IIRC??
53 willys
02-16-2009, 01:29 PM
Well I blew my turbo up last night....I dont know if I did something wrong on the rebuild or what?? but the compressor wheel was getting pushed into the compressor housing..:badidea:
I'm thinking BB turbo???
we will see.....
malibu795
02-16-2009, 01:51 PM
Well I blew my turbo up last night....I dont know if I did something wrong on the rebuild or what?? but the compressor wheel was getting pushed into the compressor housing..:badidea:
I'm thinking BB turbo???
we will see.....
over speed it?
53 willys
02-16-2009, 02:05 PM
over speed it?maybe?? i'm not sure??
I only hit 22psi on it....ungated tho..so maybe..
right now I think BB with an ED external gate:ft::st::evil
zukgod1
02-17-2009, 01:39 PM
I've eaten 2 turbos on my car so far Mark so find something that works will ya please?
Once you do the R&D then I'll jump in for my car. Cause the way it looks right now I'm keeping the suka :evil
53 willys
02-18-2009, 11:34 PM
I've eaten 2 turbos on my car so far Mark so find something that works will ya please?
Once you do the R&D then I'll jump in for my car. Cause the way it looks right now I'm keeping the suka :evil
those turbos REALLY need a gate!!
I think thats what killing them..
zukgod1
02-19-2009, 11:27 AM
Could be?
Wouldnt be to hard to use the one they have.
UpstateDiesel
02-19-2009, 04:21 PM
Damn, and I thought that I was getting somewhere when I went from a 1.6L N/A to the ECODiesel. You have blown me away! It must be one hell of a ride. Chris
53 willys
02-24-2009, 09:11 AM
Damn, and I thought that I was getting somewhere when I went from a 1.6L N/A to the ECODiesel. You have blown me away! It must be one hell of a ride. Chris
haha thanks chris!....yes it's a blast to drive....now if I can just keep it together!! lol:bang:charger:
turbonetics is supposed to spec me a turbo from all my mods and fueling...but they quoted me 5-7 working days as the quote time frame..
their engineers are gonna find me a good turbo for the results I want.
53 willys
03-10-2009, 05:16 PM
ceramic Ball bearing turbo and ED external wastegate ON ORDER:ft::ft::ft::rockwoot:
luvinacummins
03-10-2009, 07:10 PM
When's that sob goona get there????
53 willys
03-11-2009, 10:03 AM
When's that sob goona get there????
turbonetics and Chris at engineered diesel told me they would be shipping this week....
so hopefully I can start the build up next week!!
53 willys
03-26-2009, 06:55 PM
GOT SOME TURBO PORN TODAY!!!!!!!
MONEY SHOT!!!
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0627.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0628.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0622.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0623.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0624.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0625.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0626.jpg
I will get some side by side pics with it next to my K26.....still waiting for my wastegate......
Oh yeah I will have my down pipe up for sale soon if anybody needs a 3" down pipe that will fit KKK turbos...
UpstateDiesel
03-27-2009, 06:01 AM
Nice Turbo. After you remove it can you take a picture of the Down Pipe? Chris
53 willys
03-27-2009, 10:25 AM
Nice Turbo. After you remove it can you take a picture of the Down Pipe? Chris
this is what the DP looks like.....this pic is from a few month ago...but the DP looks the same since it has only had like 900 miles put on the car since I got it back together...
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe2.jpg
SKYNYRD
03-27-2009, 11:13 AM
Let Me Know Willy I'm Going To Need A Down Pipe Like That For My 79 Wabbit
53 willys
03-27-2009, 11:22 AM
I have already had a few people wanting it.....I'm gonna be selling it in the classifieds on the VW diesel forums....I'm sure I can get $250 plus shipping.....lots and lots of guys want or need a full 3" DP...
vwdiesel.net:Cheer:
'strokeThis_'07
03-27-2009, 06:40 PM
Lookin real good Mark! Cant wait to see what itll put down, if it ever stays together long enough for ya. Ive been seriously looking at getting one of these VW diesels, and we all know it wouldnt stay stock long. Is this the one thats got a VE pump on it?
How much larger are the Benz tips than the stockers? How much is the pump modded? And do these things lay down some good smoke or what? Never seen one modded, so dont know how bad the smoke is...
And wheres the build up of the race truck? :poke:
53 willys
03-29-2009, 12:26 PM
Lookin real good Mark! Cant wait to see what itll put down, if it ever stays together long enough for ya. Ive been seriously looking at getting one of these VW diesels, and we all know it wouldnt stay stock long. Is this the one thats got a VE pump on it?
How much larger are the Benz tips than the stockers? How much is the pump modded? And do these things lay down some good smoke or what? Never seen one modded, so dont know how bad the smoke is...
And wheres the build up of the race truck? :poke:
thanks Tim...yes this VW diesel is run on a VE IP...I'm getting ready to pull the merc tips out and rebuild the bodies with some GTD(euro spec) injector tips...
my pump has all the big mods....no governor, advanced timing..fuel screw maxed out...minus the bigger pump head...I'm thinking about building it up some more by putting a 10mm pump head or maybe even a 11mm cummins 4BT pump head??? I got a feeling i'm gonna need more fuel to light this t-3 off???
you can drive around mos the smoke...but it all depends on hoe you tun the VE pump....you can choke it down if you want no smoke. or you can smoke like a trian if you want too...lol
as for the race truck....that's in progress...I will do a build up thread once I get some more parts and a truck lined up....I'm really needing the VW to run
before I start the race truck....but it's coming:evil
'strokeThis_'07
03-31-2009, 02:39 PM
Sounds good. So basically all the tricks one does on a 1st gen Dodge can be done on the VW? Im assuming theyre more or less the same pump, other than one has two extra delivery ports on it...
I hear ya on needing it to run before starting on a truck. I keep going through my trans every 6 months or so.
gdr.1991
07-03-2009, 11:10 AM
hey were did you get the intercooler abd the piping because i own a 1986 jetta 1.6 td also and ive been looking for one but no luck? and one more question were did you get kit for converting the lights to round?...
53 willys
07-16-2009, 12:24 AM
hey were did you get the intercooler and the piping because i own a 1986 jetta 1.6 td also and ive been looking for one but no luck? and one more question were did you get kit for converting the lights to round?...
most all my IC and pipes came from ebay...bought a few silicone boots from some place in Colorado...but I forget the name??
my headlight conversion came from..
http://www.performance-cafe.com/index.php?cPath=7_19&osCsid=3ad439c53b10d446941f8a49391b7a97
SWALLDOG
08-24-2009, 07:01 PM
sick build, subscribing to see more on this. :rockwoot:
next time i'm down that way i'll have to check it out!
:charger:
53 willys
08-29-2009, 03:28 PM
sick build, subscribing to see more on this. :rockwoot:
next time i'm down that way i'll have to check it out!
:charger:
Thanks bud....anytime you wanna see it just let me know
I got a few more updates here..
http://vwdieselforum.com/forum/showthread.php?t=6
53 willys
09-05-2009, 12:51 AM
got the ED wastegate plumbed up.....down pipe done...
hope to drive it monday?? probably could drive it tomorrow or sunday....but I did not get my boost hose's built for the wastegate(compressor boost and drive pressure) and the house of hose is closed for the weekend.....
oh crap..just realized it's a holiday on monday...guess it's gonna be tuesday....
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/VWDP2.jpg
http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/VWDP.jpg
SWALLDOG
09-08-2009, 05:23 AM
lookin good man! still need to come buy and check it out some time. so what do ya have to do to get it registered when ya put a diesel in a non diesel car? emissions? might have to look in to something like this for a daily driver. :rockwoot:
tony597fitter
09-08-2009, 10:36 AM
I love your car, that is one of the cleanest jettas I have seen and its better with the diesel!
I'm getting my 83 Mercedes 300sd back together. The headgasket blew on it about a year and a half ago. Been to busy to work on it. I would like to get some more power out of it.
zukgod1
09-16-2009, 09:56 AM
Get er done Mark!!
53 willys
09-16-2009, 04:25 PM
Get er done Mark!!
it's done and running!!!
now if Chris at ED would just answer his phone or return a phone call I might get this ED gate tuned???
tony597fitter
09-17-2009, 06:29 PM
it's done and running!!!
now if Chris at ED would just answer his phone or return a phone call I might get this ED gate tuned???
I find that texting him works the best.
neilden
09-17-2009, 11:00 PM
congrats i just got my 89 jetta 1.6 n/a runnign after some timing issues. and i cant wait to make it quicker it is ungodly slow for me. do you know when you are going to get to the dyno?
53 willys
09-18-2009, 10:46 AM
I find that texting him works the best.
he called me back...and I'm ready to tune this in....lighting off this T3 is gonna take some FUEL!!!:st:
congrats i just got my 89 jetta 1.6 n/a runnign after some timing issues. and i cant wait to make it quicker it is ungodly slow for me. do you know when you are going to get to the dyno?
thanks I will probably take it to industrial injection when I dyno???
jlpst94
09-24-2009, 05:31 PM
I'm planning a build this winter. Where did you get that intercooler and tubing
zukgod1
10-17-2009, 09:50 AM
I'm planning a build this winter. Where did you get that intercooler and tubing
E-Bay.
Just intercoolers is the name.
53 willys
11-07-2009, 11:20 PM
Probably gonna sell this car now....on to the next project...lol
I'm taking offers so PM me if your interested....:Cheer:
Big Swole
12-14-2009, 07:05 AM
Probably gonna sell this car now....on to the next project...lol
I'm taking offers so PM me if your interested....:Cheer:
:pop:
Man, after all that AWESOME work you did!! Wow!
I truly Envy you mech/fab skills!!!!!:bow:
53 willys
12-15-2009, 12:23 PM
:pop:
Man, after all that AWESOME work you did!! Wow!
I truly Envy you mech/fab skills!!!!!:bow:
thanks bud.....I could not bring myself to sell it though...I had some good offers..but when it was all said and done I chickened out..lol
I got some funny gas to play with now...:ft::ft:
gonna spend the winter getting it ready for some track runs this spring....:tree:
neilden
12-15-2009, 07:36 PM
Are you ever going to put it on the dyno?
Big Swole
12-15-2009, 07:50 PM
thanks bud.....I could not bring myself to sell it though...I had some good offers..but when it was all said and done I chickened out..lol
I got some funny gas to play with now...:ft::ft:
gonna spend the winter getting it ready for some track runs this spring....:tree:
Man! I'm glad you didn't sell it!!
Thats one of those things that I even knew you'd regret!!
:Cheer: Can't wait to hear how she runs at the track with the Squeeze!!! :rockwoot:
dankcorey22
01-07-2010, 06:48 PM
man you need to post some videos of that car. i bet that turbo screams:charger:
YOUNG GUNS15
03-14-2010, 07:34 PM
Cool little project! need some vids of it now!
53 willys
03-31-2010, 10:47 AM
Are you ever going to put it on the dyno?
found a dyno this week...6 pulls for 65$...waiting for my speedo gasket to show up then I'm gonna take it in:st::st: I will report back with the results soon as I get them.:Cheer:
SmokeShow
03-31-2010, 03:38 PM
any videos of this little beast?!?! Nice build up!!
53 willys
04-06-2010, 11:13 PM
Well I'm back off the wagon....again:doh:...I'm ready to sell this car again give me some offers!!
let me know if your interested!
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