mk1 jetta coupe

[pinky]

there are some pics here:
http://forums.ncdubs.org/showthread.php?p=201497#post201497

specs now:
9a 2.0 16v
11:1 wiseco pistons 83.5mm
scat 144mm rods
autotech valve springs
supertech ti retainers
lightweight cam followers
stock cams (for now)
mild port (gasket match)
lightened & balanced im shaft
lightened flywheel (maybe before reassembly?)
02a with cable clutch
aba serp belt swap (including oldskool crank pulley)
megasquirt (MS1 v3.0 - MSnS Extra firmware)
TT 4-1 race header
venair coolant hoses
koni red/h&r sport
team dynamics pro race 2
other stuff, feel free to ask.

[zooyork155]

Flat beige and tough are contradictory don't you think? :p

[pinky]

not really

http://www.aikensairplanes.com/images/FMB648_Humvee_actual.JPG

[zooyork155]

Touche.

[pinky]

http://www.apextuning.com/images/pinky/jetta1.jpg

[dexter047]

looks like a nice project. ANY color has to be better than street sign green. lol.

[BigSandwich]

What are you planing on doing about brakes? Are you sticking with the 9" fronts or are you going upsize?

How much will getting the bottom end balanced run you?

Looks like a fun project. When are you planing on getting done.

[pinky]

not sure what the engine work will cost... i've been thinking about building it with forged rods/pistons.. i may just do that later.

i'm gonna worry about the brakes after i get it running, but i will certainly make them bigger at some point, and probably switch the rears out for discs

[pinky]

well.. just an update...

i'm thinking i'll stick with beige.. maybe black small bumpers like this:
http://www.vwvortex.com/artman/uploads/008__scaled_600_039.jpg

maybe different bumpers.

i'll probably go with an old OEM rabbit beige color (mexico beige or sahara beige)

hope to have the engine and transmission together within the next couple of months...

[8------D]

what are you looking at as far as weight and whp once everything is done? 2200lb/300whp or so?

[gerich]

I think it's gonna be under 2000lbs

[pinky]

yeah.. probably less than 2000 lbs and 300whp

[pinky]

a guy with a mk2 scirocco put down 408whp with a similar setup (aba 16v, t3/t4). iirc, that was around 23psi.

[pinky]

i'm about to spring for these:

http://www.hostdub.com/albums/Dick/my_vw_pictures_075.sized.jpg

team dynamic pro race2
15x7
14# each

[98blkgti]

http://i21.photobucket.com/albums/b255/jrchecker8/aa.jpg

[pinky]

close.. no rubstrips. scirocco1 grille (without the red stripe). black wheels (above).

[Shiftlink]

One of my buddies has a miata sporting those team Dynamics wheels. They are light, but not as light as some
http://i93.photobucket.com/albums/l52/Shiftlink/Bowie.jpg

[pinky]

i wasnt looking for the lightest wheel out there..

they're light, they're black, they're cheap.

sounds like a winner to me.

[Shiftlink]

Yeah, well that's sorta what I meant to say, probably a good choice for mixed useage, street/autoX.

[IN-FLT]

i'm about to spring for these:

http://www.hostdub.com/albums/Dick/my_vw_pictures_075.sized.jpg

team dynamic pro race2
15x7
14# each

:oddeye-hellyeah:

[pinky]

i have the wheels now... going to my parents house today to pick up the head so i can take it to the machine shop.

i had bid on some je pistons on ebay, but the autction was snipered at the last minute :mad:

i guess i should have re-bid since my winning/maximum bid was right at the reserve... (i wanted to bid higher...)

oh well.. guess the bottom end will have to wait a little while longer.

[Yareka]

sorry to hear that auction fell through...that was such a good deal and good momentum in the right direction.

Guess you've got the funds for a mountain bike now...:yum

[IN-FLT]

nice color combo

http://www.mkippen.com/gallery%5Ccarshoots%5Cdmoney%5Cbig%5Cimg_1542copy. jpg

[Ak-Abe]

nice color combo

http://www.mkippen.com/gallery%5Ccarshoots%5Cdmoney%5Cbig%5Cimg_1542copy. jpg

BEAUTIFUll

[GTi AngeL]

i love that car

[mk5mike]

well I just few in love that color combo is great that is exatly how I want my mk2 its red now but silver is hot. and the poke it has is great

[pinky]

http://motionblurphoto.com/temp/forforums/treffen06/IMG_6605-.jpg

[mk5mike]

even hotter I love how much they kind look like the 6 and 5 series bmw from the 80s

[FatBastrd]

http://motionblurphoto.com/temp/forforums/treffen06/IMG_6605-.jpg

Kevin, that's got you written all over it man. That's hawtness!!! :upyeah:

[pinky]

head is at the machine shop right now. it's a 9a 16v head.. it's getting:

head resurfaced
3-angle valve job
check valve guides (replace as necessary)
replace valve seals
gasket match intake ports
clean up/smooth exhaust ports
reassemble w/ TT HD valve springs and tit. retainers


hopefully soon i'll be able to get the exh. mani cleaned up on the inside, replace mani studs on the head, and get the two bolted together.

i'm also gonna try to find time to do a little modification to the valve cover...

[sciroccodriver]

What you gonna do to the valve cover?

[pinky]

thinking about changing the engine plans slightly.

the head is at the machine shop...
i've been considering switching over to a 9a bottom end. from what i understand they have a forged crank and oil squirters (pleasant surprise gerich found when disassembling his brothers engine)

i'm not too worried about pistons or rods as i will be going with aftermarket forged units.

why you ask? it will be a lot easier for me to determine CR (since its a 9a head and block) and i wont need any strange hybrid parts (crank pulley, blockoff plates, timing belt, etc)

the biggest benefit of the obd1 aba is the forged internals and oil squirters. as i said before, the 9a has squirters, and the crank, rods, and pistons will all be forged by the time i'm done.

so if anyone knows where i can get a 9a block/crank, i may have an obd1 aba bottom end for sale soon. i got it for cheap, so i'd sell it for cheap (it needs a little work, ie rebuild)

also, dan, i've been considering smoothing off the ridges that run the length of the valve cover (on the top) and painting or polishing it.

[sciroccodriver]

I've got a block/crank... the one that came out of my green B3 wagon that had a bad piston. I'd have it checked if I were to use it. I was going to pull the pistons/rods out anyways so LMK if you're interested. I've got 2 1.8 16V blocks also... gotta do something with all this stuff.
I like the idea of the polished stripes on the vavle cover..... ie what I did here but can barely be seen in the shitty pic... (don't forget crossmember reinforcement)
http://i6.photobucket.com/albums/y218/sciroccodriver/Install2.jpg

[pinky]

any idea if the 9a block will take a slight overbore better than aba?

dont worry, i'm gonna reinforce the crossmember...

[sciroccodriver]

I would imagine it would... the one in my scirocco got bored out for 83mm pistons to 2008cc and I'm sure folks have gone further with bigger pistons...

[pinky]

i'm kicking around the idea of a 2.1L..

probably wont happen, tho.

[pinky]

just picked up the head from the machine shop....

[pinky]

just a little update..

i've worked up a parts list for the engine, and i hope to get it finished up soon.

head is pretty much complete.. gotta drop in some Ti retainers

i scored a 9A block/crank in great condition this is going to the machine shop to check the bore size (i was told it is stock, just want to be positive).. going 1st overbore with JE pistons which are 9.5:1 & je rings

scat rods, arp head studs, arp main studs are on the way. just waiting to get a measurement on the bore before i order the pistons.

then it will be bored, honed, balanced, new int. shaft bearings, etc.

after i get the guts back, i'm going to assemble the bottom end and bolt on the head.

next mini-project will be the gearbox. 02A VR6 gears in a 4-cylinder case. refresh seals and synchros (and whatever else it needs once we get in there). and a peloquin.

then i gotta get a clutch and mate engine to trans and mount it in the car for a test-fit...

that's about as far ahead as i have planned at this point.

[volthause]

So... considering you started the project in May of '06, and you finally have the plan for the engine complete, I guess we'll see this thing done in... oh, let's say, June of '15?

:D

[pinky]

the engine is beyone the planning stage...

scat 144mm rods and je forged pistons are on order. i have the rings and bearings.. need to dig up the intermediate shaft and some other parts (that are in the car at my parents' house)..

engine should be all together in a couple weeks... i just gotta get the parts here, to the machine shop (for balancing, boring to 1st overbore, etc), and assembled..

the headwork has already been finished. i still need to get a few components (tit. retainers & valve springs)

[pinky]

oh yeah.. i think i'm gonna send the pistons off for coating, so that'll add about a week.

[zooyork155]

Good to hear it's getting closer to completion.

[pinky]

just an update.. i have the rods and i think travis has the pistons (havent had a chance to get those from him yet.. but tonight)

i'll probably send the pistons off next week. i'm shooting to have the engine early next month (in a few weeks)

[pinky]

so a little background on the car (that i just realized)..

H2O, a few years back... i saw a mk1 jetta coupe that made me go "damn, that's awesome.. i want to do a mk1 jetta project"..

well, that just happens to be the EXACT same car that i've got now.. at the time it belonged to some dude in NJ.. and when i saw that he was selling it, i jumped all over it..

so, in essence, i am building the exact same car that motivated me to use this car as a project.. pretty cool..

[pinky]

:)

[IN-FLT]

Damn that shit says "Nascar" on it... u knowwww that shit has to be fast!!!

[sciroccodriver]

Dooooo iiiiiiiiiit!

[pinky]

as much as i hate to do this... i'm even having second thoughts as i post this...

truth is, i have thousands of dollars left to spend to build this to be what i want it to be.. and that's really not feasible right now. i have student loans to pay off and there are some things i want to buy for the a4 (which would become the new mild project/dd)..

this is going to be a really tough decision to actually go through with. this is the exact same mk1 jetta that i saw at h2oi years ago that made me decide to do a mk1 jetta project. i found it for sale later and snatched up the shell...

i know this is ultimately my decision, but i'd like to hear some other opinions on this.. i'm on the fence.

http://apextuning.com/images/pinky/jetta1.jpg

anyways, here is some shit that may be for sale soon..
- '83 mk1 jetta shell w/ scirocco grille setup (quad round).. poly suspension bushings and spherical bearings in the rear beam (per the previous owner).. suspension is on there to make it mobile, but i wouldnt drive on it.
- black rabbit euro bumpers
- 2.0 16v block and crank
- 2.0 16v head, gasket matched intake ports, smoothed exhaust ports, TT HD valve springs, stock valves & retainers. resurfaced and valve job done a while back and has been sitting ever since
- 2.0 16v JE pistons & rings (low CR for forced induction)
- 02a tranny, vr6 gears, VR or 16v case can be worked out
- mk1 02a patatron mount brackets
- misc 16v parts (intake mani, valve cover, etc)
- scat 144mm rods (i'll probably keep these)
- tial wastegate (probably keep also)
- team dynamics pro race 2 wheels in black, 4x100, iirc the prev. owner put tires on but never mounted them on the car, then took the tires off and sold the wheels

if someone is interested in something, i'll get a price.

[pinky]

:(

[IN-FLT]

dude there is a lot left to do... but just take it one step at a time and build yourself a show winner!

Most of the engine work is done... get it all finished up and start getting the body prepped and cleaned up.

leave the A4 alone.. ur not breaking any records there ya know ?

[zooyork155]

No one can really decide for you but as Jason said, leave the A4 as a daily and call it a day.

[pinky]

as of right now i need to get the pistons coated and the bottom end work done, and bearings/gaskets to get the engine together. the machine shop needs a flywheel also to balance the crank. i'll also go 1st overbore to fit the pistons.

then i'll be at a stop again. and i still need a clutch, diff, axles, suspension, fueling, turbo, exhaust, cooling, interior, paint, $tandalone, etc etc etc...

it sucks b/c i want to drive it.. i want to be putting money into something that i wont be waiting years to be able to enjoy. plus it seems like the a4 (quattro) is a much better platform to start off with when trying to make big power.

i'll have to think this through.. im not gonna sell off anything until i'm 100% sure

[IN-FLT]

maybe you should go for more of a show status for the car then,,,, have some good power.. but make it all around a sick car.. then do some power monster on something else ?

[pinky]

yeah.. the thought also popped in my head to scrap all the FI stuff and go n/a 16v.. try to get some higher cr pistons, cams, etc...

[sflemon]

As for BIG power, unless you like being an armchair general and having a "fast" car with a dyno sheet but no track kills, I wouldn't go BIIIG on the A4.

Honestly, the quattro is great for easy 60' times and good times out of the box, but in the end won't see deep 11's without significant work and effort.

A lighter, older car like the MKI with about 300whp would turn great times at the track much easier than an A4. And see 11's on much less power.

Keep the A4 as a daily (stage II car), and make the MKI your fun car.

[pinky]

that's the problem, stan.. i dont have a bunch of $$ to keep dumping into the mk1.. i dont care so much for drag racing (i'll probably do it some), or specifically having a drag-only car.

sure building 300-400whp in the mk1 would be nice in an ideal world, but i just dont see myself finishing it for years.. it adds up quick when you need to buy a turbo, ic, custom piping, custom dp, intake mani, standalone, etc etc etc...

like i said, i had kicked around the idea of going na with it.. and i think that may be a much more viable option.. i could find a cheaper engine management solution (didnt want to cheap out with FI).. i would probably still do the diff and 16v/02a.. perhaps with some nice cams and 11.2:1 CR JEs.. i bet that would be fun without being over the top.. plus there are already a bunch of available parts for doing a 16v in a mk1...

i'm still unsure, but i need to decide before i do any more to the engine.. maybe i can start to tackle the suspension work or trans first...

edit: not to mention the stuff you have to do to a mk1 chassis to be able to handle 300+ whp...

[a4wdhybrid]

maybe all you ppl should quit running your mouth about this and that and what you want to do and would like to do and think will happen if you do "x" ...or maybe youll do "y" instead...or or....or..i cant decide what turbo...what bore....what whatever...

and quit running your mouth about your textbook theories and all the other garbage you read on the internet

and get off your ass and actually build something that runs and drives

who cares what it looks like....just build it...accomplish something

[pinky]

uhm.. is that directed towards me?

i would LOVE to finish this the way i originally planned.. but its gonna take forever because i dont have thousands to dump into it right now.. i'm at a crucial stage where i kinda need to know the direction before i get the crank balanced for the pistons i'll be using.

and i DO want to accomplish something.. that's why i'm thinking about changing directions.. so it will get done sometime before 2009...

i was considering selling off the project and putting $$ into the a4 b/c i can enjoy that every day instead of staring at a useless pile of metal i've spend thousands on and still isnt finished.

[a4wdhybrid]

its directed towards anyone that reads it

[a4wdhybrid]

i was considering selling off the project and putting $$ into the a4 b/c i can enjoy that every day instead of staring at a useless pile of metal i've spend thousands on and still isnt finished.
so do it

quit thinking about it

and just do it

[IN-FLT]

who cares what it looks like....just build it...accomplish something

some of us are perfectionists ... its a horrible curse :(


Kevin i say get the body cleaned up and right along with the suspension.. throw an engine in there n/a and focuse on stance etc... then u have nice lookin car that runs. You can more easily add on FI stuff later if you want to.

[pinky]

jason, yeah.. that's probably what is going to end up happening..

and, ian, you gotta understand that i want to do shit to the a4, but this exact car is the reason i wanted a mk1 jetta project. its gonna be hard for me to let that go.

i think part of the reason i'm losing motivation is b/c the car is at my parents house and i havent really done anything to it due to lack of time and space.

[a4wdhybrid]

so put a working engine in it, throw some suspension on it, and put it on the road

buy dan's running 16v and go from there

atleast then it would be on the road..then youll have time to do whatever to your current set up and have a working car that you can enjoy

[pinky]

its not exactly that easy.. i would need a everything from the engine bay.. suspension, tires, etc.

the only thing in the engine bay right now is the brake booster and master cylinder.. and the power lead that runs to the battery box in the trunk.

[pinky]

and fwiw, i actually considered buying a wrecked (rear ended) rabbit diesel and swapping everything over...

[MkII Fi]

I'm with Ian 100%.

It wouldn't be hard at all to throw in an 8v or 16v that is known to be running and get the bitch on the road. You don't need the car at all, you have a daily driver, so you can take your sweet time (or not).

Get it running and driving somewhat reliably then focus on the interior and exterior (parts car would be great here, or complete jyard mk1 to pull it all out of) get it comfortable (or whatever you aim for) inside and shiny on the outside.

At that point, you'll have a nice looking and drivable mk1. That in itself is a huge accomplishment.

Get it that far and the rest will fall into place.

Start SOMEWHERE and do SOMETHING!

You'll end up losing $ and end up kicking yourself over and over if you sell it.

Of course this is all just my opinion, which not only counts for jack shit on this forum - but should not determine what you'll do with YOUR project.:)

[pinky]

your opinion is valued..

i was actually looking at megasquirt boxes on patatron.com earlier today.... i think that plus the 16v n/a would be a decent way to go to get it running asap.. but i really dont want to swap in an entire drivetrain with the intention of pulling it right back out.

i guess i'll hold off on the engine work for a little bit and get other shit squared away. anyone got a mk1 suspension for sale?

[MkII Fi]

Some advice on Patatron...do NOT buy from him. Ever. Ever ever. (at least in terms of MegaSquirt)

This place is THE place to go IMO. Quite literally a one-stop-shop for MSEFI stuff :

http://diyautotune.com/

...they just came out with a PnP setup for OBD1 Miatas, pretty neat (but not relevant).

About pulling the motor...

Pulling and swapping in that car is cake dude. A day? maybe two? Two days is a drop in the bucket when you're considering a turbo'd ABA 16v.:)

Knowing it's coming back out eventually and letting that extra labor delay you is totally unnecessary. Get a running motor in it and get it back on the road. Get all the kinks worked out and have a blast with a motor that you can feel ok with grenading. Sort the interior, sort the exterior, sort the hundreds of nickel-and-dime issues you're gonna have...THEN worry about the build 16vT. Wouldn't it be nice to have one already installed to do your mocking-up for piping and whatnot too?

Less thinking - more wrenching.:p

[pinky]

so what is the difference between all those boxes.. MS1 vs MS2.. etc.

[evan@absolute]

this car has already been on here for more then a year with a thousand views and it isn't even started. It has a long long way to go to live up to the hype.

[MkII Fi]

The versions can be kinda confusing:

MS1 comes in 2 varieties:

MS1 v2.2 is the "older" setup (green PCB), MS1 v.3.0 is the "new" version (blue PCB).

The main differences are in the control of injectors and ignition, among other things. MS3.0>MS2.2.

Then there is MS2, which is an "add-on" to the MS1's. It basically replaces the MS1's main "chip" with one a lot more fancy. Gives you 12x12 tables, 100x the resolution, faster MegaTune interface, blah blah blah.

MS1 v2.2 is pretty basic and can do a lot with a firmware upgrade (free...about 45sec of work). (Cheapest route)

However, I'd recommend MS v3.0. Especially if you're thinking about sequential...not to mention the ASSLOAD of "add-ons" it can easily support (the biggest upgrade IMO). Boost control, meth, etc... It's just much more flexible than the older v2.2.

As for MS2...that's up to you. It can always be added later.

I'm sure, being an engineer, you are used to reading pretty dry material. That's exactly what I'd do with this - download and read ALL the manuals until you aren't left scratching your head. Then hit the MS forums and lurk/search/learn until you figure the rest out.

Despite how disorganized the support literature can seem, pretty much all the answers are there for any problem you may come across.

I can promise there is no application you can dream up that hasn't been done probably 10 times already which is what makes it such a great option. The users are very diverse and all seem unusually willing to help where they can on the forums (in a good way). But it will be immediately apparent if you haven't read the manual, so if you end up posting on the forums don't take it personal if someone tells you to "RTFM".:)

[jetta-the-hut]

i think part of the reason i'm losing motivation is b/c the car is at my parents house and i havent really done anything to it due to lack of time and space.

I'm in the same exact boat,wanna swap projects?

I am goint to my parents Sat. to measure everything and start putting the engine together. I finally just said its time to build or sell, no exception!

Honestly, Pinky how much are you looking for the car? I am not really intrested in the engine cause I have no need for a boosted anything. I am geting to the point in my life where I just want it clean looking and as near to stock as I can get it.

[sciroccodriver]

I had HUGE plans for my scirocco that started when I was 25(9 years ago for those of you keeping track) and you all know I just got my car running on the 2.0L with motronic a few months ago. Stuff like kids, or in your case businesses, and other cars/etc all get in the way. I dumped a TON of cash into the MK1 scirocco that Cameron has now and if I had just spent it on my 16v it would have been completely finished about 5 years earlier. Truthfully, I didn't really finish my engine but I needed to sacrifice and get it driveable. I'm running my original 230k 1.8l head which is as noisy as a diesel. I'm slowly accumulating the parts to do a head right.... already have those shricks and some HD springs but still need lifters, valves, and guides.
Before you contacted me, I had no idea what you were planning (wasn't reading this thread yet.) MS and a 16v is suppposed to be pretty cool. :-)

[pinky]

drew,

would you recommend using the relay board or just wiring it up using the existing relays with the pigtail harness?

[MkII Fi]

drew,

would you recommend using the relay board or just wiring it up using the existing relays with the pigtail harness?

Relay board is a waste of money that should, IMO, be spent on the harness kit. I would not even consider doing the install for one minute without the diyautotune (or similar) harness. If you do a little research, you cannot duplicate it for anywhere near the price. The connector end is pre-soldered and nicely wrapped (seems trivial, but you ever soldered a connector like that? It's a royal PITA), and all wires are labeled every few inches as well as being nicely color-coded. Makes installation MUCH easier.

I found a guy on ebay selling Bosch relays w/harness & plugs - it was about $12 for 6 of them. Considering most places charge that much for just 1 relay w/o plug or harness, it's a kick ass deal. I used a few for the Megasquirt install and the rest for relaying my headlights.

Autozone sells small fuse blocks (4-6?) which is perfect. $10.

Some folks re-use the relays on the factory block, but I really liked having the MS stuff isolated from it. The time you save using new relays more than makes up for the headache of pulling the factory relay block wiring and splicing.

You can also do some other cool stuff like use a multi-pin bulkhead connector for the harness. I always thought that was neat. Then you can totally separate the engine side of the wiring without pulling wires. Totally optional and not necessary though.

So, in short: No, I don't think you need the relay board. And my #1 advice is to use the ~$70 universal harness.

[pinky]

ok, well an update if anyone cares.

i got the MS box in.. a new-to-me bone stock 2.0 16v (thanks dan) that needs a head gasket (bearings look good, just some nasty goo on the inside.. kinda like travis' mom)

the new "project" is to get this thing running in as little time and money as possible (shooting for jan/feb)

i think most of the stuff i still need wont be too bad..

if anyone knows where to get some good 16v rocco or late mk1 cabby axles $cheap lmk. i also need a scirocco 16v exhaust mani/dp or some sort of header. and rear mk1 spring hats. thats all i can think of right now..

car will hopefully make it up to the shop in the next couple of weeks (after the engine is back together.. waiting on gasket/bolts).. still have a few big things to get squared away.. but we'll see how it turns out.

the low CR, turbo'd engine will be built after the car is running, and i will then source all the parts i need for that...

thanks for the kind words.. and if you contacted me about buying it, thanks for helping me change my mind.

[Shiftlink]

yeah.. the thought also popped in my head to scrap all the FI stuff and go n/a 16v.. try to get some higher cr pistons, cams, etc...

There you go! then go do some tarheel track days, autocrosses, or whatever. That's the thing you know, you don't have to have huge power to have fun with a car. a 10.5:1 16V with a nice tranny in it would be killer fun at VIR or CMP, or Rockingham, or Lowes Roval action. Use the money and time you would dump into building some monstrous Turbo set up and keep it running and spend it on tires and track days and have more seat time and more fun than you can possibly imagine. And there are like four roadcourses within a few hours drive from you to have fun on. Hell maybe one day you'll decide to go W2W!

I know I'm biased, but when you look at it, it makes sense. . .

[pinky]

well. replaced the head gasket & bolts.. replacing pretty much every gasket and seal on the entire engine, along with all the hoses and crap.. lots of new bits (man do they add up fast)

still need quite a few things, but i think i'm still on track for having it drivable by early 08 (hopefully by feb fling)

as of right now i'm just trying to clean and freshen up the engine..

[pinky]

anyone got a scirocco 16v exhaust mani laying around? anyone know if i can use that and the b3 downpipe?

what about some usable (used but not broken) 'rocco 16v axles?

[pinky]

also, if you didnt notice, i merged the two threads (orig. "build thread" and the considering getting rid of it thread)

paint is UGLY.. thinking quick and cheap for now.. perhaps olive drab or flat white

[pinky]

well.. the engine is together.. need a few sensors and some small things.

heres the vortex build thread
http://forums.vwvortex.com/zerothread?id=3557747

[Mk2Jettaboy16]

:gt-ogb-spank:well.. the engine is together.. need a few sensors and some small things.

heres the vortex build thread
http://forums.vwvortex.com/zerothread?id=3557747

[pinky]

eh.. its coming along.. been a little slow lately.. i need to get the trans together...

i pulled the dash and ripped out a bunch of wires that (i hope) i dont need.. radio, ac, that kind of shit.. not sure if the dash will go back in or not.

i decided against heat b/c i got a non-ac box but it was from an earlier mk1 (theyre a different size).. and it didnt fit quite right.. so im gonna sell it and scrap the whole heat idea.. mostly just wanted it in case i had to drive in the winter or in the rain (defrost)

havent really touched it in at least 2 weeks, tho.. been kinda busy lately.

[pinky]

gearbox is assembled!

[sciroccodriver]

Kevin, got any pics of those silicone hoses on the motor?

[pinky]

not since i put the hard coolant pipe on...

[pinky]

clutch setup is on the way.. should have the engine and trans together and mounted in the car very soon.. then the fun begins..

[pinky]

steady progress... maybe nate will throw up that pic...

[pinky]

engine and trans are in the car.. i have suspension waiting.. H&R sports and koni reds.. i have some spring hats are on the way, which is the reason i didnt get the front susp. installed over the weekend.

i need to do some mods to the MS box and wire all the sensors in..

i need to get the suspension on and install new wheel bearings and drive axles.

[Vampire Cockroach]

does it have a turbo?

[pinky]

no.

i put a stock 16v (all new gaskets/seals) that i got from sciroccodan in there.. the turbo engine will be built later.. i have most of the parts to put the actual engine together, but not much of the actual turbo pieces... i just want to drive the damn thing..

most important shit that i still need:
- starter (4-cyl 02a)
- scirocco 16v exhaust mani/dp (some guy was supposed to be digging one up for me)
- the rest of the exhaust.. will probably be something simple
- spring hats (on the way)

[pinky]

the thinking was that i could build the turbo engine and still be able to drive the car, or just go this route, drive the car and build the other engine as time and funds become available.

[Vampire Cockroach]

word :)

glad to hear there has been lots of progress recently.. is it still lime green? (please say yes)

[pinky]

some of it is...

it is sorta 2-tone (hood, roof, trunk, pillars, etc is flat black)..

[pinky]

the megasquirt mod pieces i need to run IAC and spark control came in today.. hope to get those in and then start wiring. i'm still not 100% decided on the CTS.. either going to use a regular VW one with easytherm or somehow try to find a way to mount the GM one..

i also got a GM IAT sensor...

got one side of the front suspension taken care of over the weekend. i still need to put a new tie rod in there and it feels like the hub/axle is binding a little.. so a little more work to do on that side, but its close. the passenger side will probably prove to be a huge PITA as well..

btw, i need a front strut housing..

and if someone has a pair of late cabriolet or scirocco 16v steering knuckles around, lmk.

[pinky]

megasquirt mods are done. the pass. side axle and knuckle have been ground down for clearance.. now i just need to find some time to replace just about everything on that corner (front left)...

[jetta-the-hut]

megasquirt mods are done. the pass. side axle and knuckle have been ground down for clearance.. now i just need to find some time to replace just about everything on that corner (front left)...

so now you've got a 16v running on MS?

I want the same thing,so when I decide to go for it, you wanna help?

I am glad you didnt sell it, my wife who hates my vw told me I could not sell mine and to get off my ass and get it running, WOW talk about a 180* switch!!

[pinky]

no, it doesnt run yet.

i had to modify the box so that it would use the stock hall sender, be able to use IAC, and on board coil control (basically on-board ICM).. removing a few components, jumpering some connections, and putting in a couple resistors and transistors

i still have to run wiring and stuff, but i have finished all the mods to it, which are detailed in the 16v technical section

[sciroccodriver]

I am glad you didnt sell it, my wife who hates my vw told me I could not sell mine and to get off my ass and get it running, WOW talk about a 180* switch!!

Oh come on... I'm thinking of a Star Wars line with that dude that looked like a giant shrimp. "Stop, its a twwwwap."

[jetta-the-hut]

ha,ha, I think your right.

Got a chance to see the Coupe yesterday and it looked good, Kevin I think we just need to get a weekend together and finish this thing.

After mine is running and the swap is done, It would be a cake walk on yours plus after seeing the engine bay and coming home and looking at mine yours is so empty.:eek:

[pinky]

yeah, i still need to find a few parts but havent really been trying.

'rocco 16v exhaust mani (may just have a mk2 dp modified to work with the mk2 manifold), a front strut housing, and a 4-cyl 02A starter. i've been "looking" for these for awhile, but havent really put much effort into it.

i also need to run all of the wiring in the engine bay and deal with the front right suspension. i could probably do it in a weekend if i worked the entire time, but who has time for that?

[pinky]

quick update. got a starter in there that came off the b3. replaced front right tie rod, axle, wheel bearing, ball joint, hub. put a mk2 (or passat) exh. mani on there and cut off the downpipe a few inches from the flange. tightened down the rear suspension and got the front motor mount in place.

next i gotta mess with pulling the cabin wires i dont need (a/c, radio, etc) and get that stuff squared away. then i can make the engine harness.

i also pulled the piece that was broken on the throttle body and i have a few leads on that.

made some decent progress tonight..

[jetta-the-hut]

hey Kevin I have a 16v TB at my parents if you need it, I think I just need the throttle cable arm for my 8v TB and the switches, not sure what the diff is between the 8v and the 16v except the 8v is one piece and the 16v is 2.

Let me know!:D

[pinky]

made some decent progress this weekend..

[pinky]

and some more...

[SuperStuff]

Good deal! :oddeye-hellyeah:

[pinky]

still going.. pretty much all that's left is exhaust (downpipe -> tailpipe), shift linkage, clutch cable/linkage, and wiring..

i also have to swap the upper intake mani and while i'm in there i think i'm going to switch over to VR6/AAA injectors instead of the smaller ABA injectors that are in there now.

oh yeah.. i need to put some seats in there also...

[jetta-the-hut]

milkcrate will work for a seat for now!

Got any update pictures yet?

Why are you changing out the upper manifold?

The one that was on there was a regular 16v are you going with a rocco mani?

[pinky]

its a regular mk2 manifold. i had a bung welded in for IAT, so that is why i have to change. the "new" one has fresh paint as well.

no pics right now. did get some work done on the fan harness last night.

i have seats, but they are at my house in the attic.

[jetta-the-hut]

did you plug the end piece on the upper manifold, not sure what went there but I have to make a plate to cover mine. The digi-2 doesnt need it.

[pinky]

cold start valve? no i have on in there that isnt plugged in just to cover the hole. gotta figure something out with that at some point, but i just want to drive it...

http://ncdubs.org/forum/picture.php?albumid=48&pictureid=463

http://ncdubs.org/forum/picture.php?albumid=48&pictureid=464

http://ncdubs.org/forum/picture.php?albumid=48&pictureid=462

megasquirt wiring, exhaust, and the clutch and shift linkages are pretty much all i have left.. i'm hoping to get some more done this weekend, but i swapped the intake mani and coolant reservoir today, finished up the fan harness, and replaced the injectors with VR6 (higher flow) ones. also put the IAT sensor in (the reason i had to swap manifolds... and this one was painted...

[Vampire Cockroach]

lovin it dude :upyeah:

looking great so far. good progress.

[pinky]

its kinda funny b/c every time i work on it i think about you saying "do work son"

:)

[sciroccodriver]

Excelllllllllllllllllllllent. I should be out fixing the scirocco.... This weekend!!!!!!

[pinky]

made some decent progress last night on the wiring harness....

[jetta-the-hut]

did the shop fair ok in the storm?

[pinky]

yeah man.. just some rain and shit.. it got windy early morning, but the doors were closed.

[pinky]

almost done with the engine side of the harness.. still have a little wiring to do, but its getting knocked out pretty steady. i just need to make an injector harness, get terminals for the coil, and wrap the harness. still a few other wires to sort out but all of those will be on the inside of the firewall. i still need to make a final decision on where to mount the ms box, relays, and the fuse block. i got a separate block for all of the ms wiring (coil, injectors, ecu, etc). i have a couple different places in mind, but it wont affect the harness because they are all within a foot or so of each other. once i figure that out decide if i want to keep the stock stuff in place for the fuel pump or rerun wires (i will probably re-run and use a new relay along with the main relay, coil relay, o2 sensor relay, which is part of the MS wiring). i also need to put ring terminals on all of the grounds (sensors and such) in the bay and connect those to the post on the end of the valve cover. i'm also going to run a few other grounds just to be sure (tranny to chassis for sure, maybe one or two in other places, there is one from the coil bracket to the cylinder head already)

i think i have everything i need for the shift linkage on the parts passat and i have to order a cable clutch conversion (wrd). after that i need the exhaust (at least past the o2 sensor) and i could either buy a TT downpipe or just have one made. everything past that is just getting the settings right, loading a base map, and trying to fire it up. i need to sort out what i'm going to do about an intake, but that should be easy. pretty much just a pipe with a filter and a bung or two (isv & pcv)

i've also been kicking around some ideas for the "until i get real paint" paint job. i'm pretty sure i'm going to re-do the black (its faded as hell) with some better stuff (what's on there was the $1/can shit) and bring the black down to the body line just below the door handle.

i also need to get the seats and wheels (and order tires) from my house.

i had a water leak into the car when it rained, but one of the sunroof drain tubes (which is supposed to just run through a hole in the front door jamb) was pulled through and was just draining into the driver side floorpan. so there is a little surface rust there that i need to take care of at some point.

all of the glass seals are fucked, but luckily nate works at an autoglass place :)

[pinky]

i need to finish mounting the shift box, but the linkage is connected.

also, the engine side of the wiring harness is complete (including injector harness).. most of it will be fairly hidden. i've also started kicking around ideas about the in-car layout of the fuse block, relays, and ms box. i think i have one i like.

still need a wideband, downpipe, and wrd cable clutch conversion, but that is about all that is left.

[pinky]

wideband and knock sensor setup are on the way. i still havent connected everything inside the car up yet (waiting on those two parts to get here).. i got some ideas on the mounting, but you'll all just have to wait and see... :)

and the shift linkage is all connected up.

i still need downpipe and cable clutch setup, which will come soon....

[pinky]

ive also started working on the cover plates for the holes in the raintray from where the heater crap used to be.

[xcracer87]

what kind of wideband are you going to run.

[pinky]

innovate LC-1.. wires directly into megasquirt

[xcracer87]

innovate LC-1.. wires directly into megasquirt

Nice have you ever seen the NKG wideband?

[pinky]

yes.. but i really dont know if i want a gauge. i can display the readout for lambda on the screen with megatune (or megatunix, depending on which i choose) so there is no real reason to pay more for one that has the gauge and i need output. i looked at the AEM but the gauge is the controller, so i would NEED to have the gauge. so the LC-1 was basically the cheapest one because i wasnt paying for stuff i dont need.


http://tim.kent.googlepages.com/20080429-megatune-calibrate-tps.png

[2.slowduo]

:oddeye-hellyeah:nice jetta
my brother runs megasquirt on a 2.0 16v with gsxr itbs.:ohyeah:
screamin fast about 225hp.
look for it on vortex 2008 wmass euro season
I would also like to build an aba 16v for bbm charger for my 96jetta
or maybe the 98 gti.either way . funstuf:dunceblock:

[chris@pwrhaus.com]

you have a dyno for that?

[pinky]

so i've been thinking about sage green when it comes time for a respray
http://www.ncdubs.org/forum/showthread.php?t=12441

ive been working a little on the current paint scheme... but the real goal is to get it running. still waiting on a few things before i can make some progress, and still a few parts i need to order before it will run, but progress is progress i guess..

[wolfsburged]

I think that's too drab a color for the Mk1. Why not go with one of the mk1 greens?

http://www.slowcarclub.com/santapod-07/mini-quick-golf.jpg

[pinky]

*shrug* its still up in the air because i've probably changed my mind 3 or 4 times but i saw a sage green mk5 (which would techincally be a rabbit color :) ) at h2oi and i remember commenting to jason how much i love the color.. its so clean and subtle (looks a lot like a metallic dark grey with a hint of green).. it almost reminds me of a dark version of inari silver, a color i was considering for a long time.

but i could always just pick an old mk1 color.

here's a good resource for that:
http://www.mk1dubs.com/paint.php

[pinky]

some new goodness

http://www.ncdubs.org/forum/picture.php?albumid=48&pictureid=647

just a little wiring left and i should be able to at least *try* to start it. :)

need a few other odds and ends before its roadworthy but it will soon move under its own power.

[IN-FLT]

sweeet !!! a start up video? :D

[pinky]

http://www.youtube.com/watch?v=3_CVbY1upP0

???

[IN-FLT]

ROFL wow... that was crazy

[pinky]

i have to run wires to the fuel pump and put one terminal on the +12v power source...

gonna try to fire it up in the next couple days. hopefully the settings i've chosen and base maps (from here (http://spitfireefi.com/downloads.shtml)) will be close enough to get it to start up and hold idle.

[pinky]

got some strut housings in today.. so i can finally finish up the front suspension....

[pinky]

over the weekend i got the front suspension taken care of and tried to start it. found a few issues and fixed some of them.. but i'm making progress. thats all that matters, right?

[sciroccodriver]

Rabsoroootly. VROOOM!

[pinky]

this page needs a new pic.

http://forums.ncdubs.org/picture.php?albumid=48&pictureid=787

[IN-FLT]

i like it ... mean looking!

[pinky]

made some more progress...

http://www.youtube.com/watch?v=Os9APERiwTU

vid sounds like shit..

[IN-FLT]

werd! start tuning biznatchhhh :D

[wolfsburged]

I saw it actually idle tonight!!

[JessaBug]

I saw it actually idle tonight!! Me too! went for about 2 minutes or so.

[pinky]

so i drove it a little last weekend... still needs a bit of work, tho..

[IN-FLT]

video!

[Yareka]

GET SOME!!!!!!!!!!!!!

YouTube - pinky001

[IN-FLT]

hahahaa YES!!!!!

[gerich]

:gt-ogb-spank:

[sciroccodriver]

What kind of power are you expecting out of this setup?

[pinky]

havent really thought about it.. i just want to be able to drive it on the street...

[IN-FLT]

havent really thought about it.. i just want to be able to drive it on the street...

thats not true...

i remember the words " I want it to be able to break em loose in 4th" coming out of his mouth ;)

[sciroccodriver]

I guess what I'm really wondering is how much more power compared to my setup... motronic with a chip. I figure I'm making 140hp or less even though I bored it out/etc. Honestly, I don't like the way my car is running right now. Drove it today and I REALLY need to throw those cams on it... not to mention its not idling well(despite not having those cams yet) and needs some attention before I take any more steps. :-) It seems that between digi and these do-it-yourself setups, its what all the cool kids are doing when in the old days everybody wanted what I've got. I just haven't done any research to see what kind of numbers these systems can make to convince me. Oh, I need a fargin wheel bearing too RIGHT after having it aligned. Go figure. hehe

[pinky]

thats not true...

i remember the words " I want it to be able to break em loose in 4th" coming out of his mouth ;)

eventually.. not on the current setup.

[pinky]

ok well i found out that the idle problem was with the base map i was using. the lowest MAP reading on my fuel map was 30kPa, which is above what i am seeing at idle. so, essentially, i was off of the fuel map at idle.

lots of progress in the past few weeks:
- replaced front pads/rotors/lines and did a brake fluid flush
- fixed small leak at valve cover gasket
- replaced windshield seal (thanks nate!)
- replaced driver seat and added passenger seat (nate's old seats)
- cleaned out the excess from inside the car
- removed front flares (didnt have rears on there, one was broken)
- got a new battery

not sure if i missed anything since i last updated this thread.

[pinky]

http://www.forums.ncdubs.org/picture.php?albumid=48&pictureid=1562

[2.slowduo]

lookin good man!

love the coupes

[pinky]

so i got a tach in there.. and in the process of wiring it up i decided to pull the unused parts of the harness.

everything in the engine bay and associated with MS is obviously staying, but i'm not putting a dash (or cluster) back in there. all the wiring for that, misc crap like seat belt buzzer and rear defroster, etc. is coming out.

fucking wiring diagrams.. ugh..

[pinky]

went through the chassis harness last night and removed all the unused parts. it wasn't nearly as bad as i was expecting.

the front tires rub when cornering.. i need to roll the front fenders and touch up the paint in a couple places.

[IN-FLT]

got a chance to drive it today... effin awesome... so raw, i love it! needs one more part tho...

http://www.sunnyhillsportingclays.com/images/ear_plugs.jpg

:D

[JessaBug]

Yeah, I think those should come in the car. And have some pop out for those who are around it when it drives by!

He gave Bill a ride in it when we were at the shop a few weeks ago. Its coming together nicely!

[pinky]

i was thinking more about:

http://i.pbase.com/o4/27/673327/1/61586246.ID33Jut0.PurpleHorny.JPG

[Vampire Cockroach]

i was thinking more about:

http://i.pbase.com/o4/27/673327/1/61586246.ID33Jut0.PurpleHorny.JPG

delicious. :nod:

[pinky]

a friend started calling the car "green goblin".. those would go along with that theme, i guess.

[pinky]

i added some pics. not current, but close. the car has bumpers on it again, a few wires are removed (reran lighting so that the corner lights are both running lights and turn signals. prev owner had switched it around and used the lights in the bumpers. i also have an all-black valve cover on there that i put on when i replaced the cam seal which was leaking (i should have replaced it when i was putting the timing belt on but didnt)


http://forums.ncdubs.org/album.php?albumid=48

http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1562

seats
http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1810

"dash"
http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1817

trunk
http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1812

megasquirt/relays/fuses
http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1813

note: added iat sensor
http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1811

main engine ground. where the harness comes into the engine bay and splits
the one unwrapped wire is the tach signal. tach was added recently, but it bugs the shit out of me.
http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1815

patatron mount (o2a mk1) and cable clutch linkage
the big red wire is a chassis ground that goes to the engine/trans. not pretty but it works for now.
the blue/black wire is a previous-owner lighting thing. those wires are not in there any more.
http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1816

[pinky]

http://forums.ncdubs.org/picture.php?albumid=48&pictureid=1887

:hiya:

[wolfsburged]

Is operation black and tan a success?

[pinky]

turned out better than i was expecting

[vdubb16]

ah im not sure what shades u were goin for, theres a good chance of score'n some of the actual black and brown used on the cami patterns on humvees and other equip, from ppl around this site..

[pinky]

nah.. i just wanted to get rid of [most of] the green

[pinky]

old
http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010007-edit1.jpg

new
http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P10100122.jpg

[IN-FLT]

solid! :gt-happyup:

[Yareka]

wait a sec, you remember the deal....first one to paint their car was supposed to get the apextuning flag masked in:asa:

looks good

[sciroccodriver]

Werd!

[pinky]

just a little update. i've taken it on a few short trips. still loud as hell with no exhaust.

painted a few trim pieces. i'm going to start mounting the box for the electronics soon, possibly tonight (i'm about to go start mocking it up).

the tune still needs work but it feels pretty strong. a few other loose ends that need to get tied up.

[IN-FLT]

moar pics

[pinky]

made more progress yesterday on what i was working on.

[IN-FLT]

u posted that to spite me didn't you?

[pinky]

the batteries are dead in the camera at the shop. i guess you will just have to come by and check it out.

hope to get a little more done on it today, but it all depends.

[pinky]

a little more progress today...

..maybe.

[pinky]

painted trim and remounted duckbill. the PO had those toggle bolts you would use to hang stuff on drywall. i just welded some nuts in the holes and used bolts. it is straighter now. i used duplicolor (i think?) trim paint in the green can. thanks chad for the bumper lights.
http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/DSC00139.jpg


i wanted a way to hide the wiring and electronics. i wanted it to be somewhat sealed.. i'll just let the pics do the talking.

yes, chad, i know the door jambs are still green. :p

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/DSC00132.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/DSC00136.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/DSC00141.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/DSC00142.jpg

rubber spacers are under the board to try to keep the electronics at least a little isolated from vibrations.. also offers me a place to stash my registration
http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/DSC00135.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/DSC00145.jpg


i also put some rust eliminator stuff on the floor (you can see quite a bit of surface rust in older pics)

[LifeAsASuffix]

Dope! I dig the ammo glove box!

[Mr. Chan]

Omg wtf gdj!

[Yareka]

Next week it gets carpet
http://prmeetsmarketing.files.wordpress.com/2007/11/astroturf.jpg

[SuperStuff]

You have made alot of progress since the last time I saw the car. Digging the ammo box idea and the tan instead of green.

[pinky]

well it has exhaust now.. kinda...

[washburnmotorsports]

well it has exhaust now.. kinda...

how much of Kinda. any videos with sound.

[Yareka]

subdued at idle, a nice crack when the throttle opens. Enough to piss off the neighbors, enough to not really need the monster tach:gt-ogb-spank:

[pinky]

tt header, pipe, pipe, mk4 resonater, pipe, turndown

[washburnmotorsports]

tt header, pipe, pipe, mk4 resonater, pipe, turndown

WE WANT TO SEE A VIDEO WITH A BIG BURN OUT:gt-happyup:

[Pete-Diddy]

WE WANT TO SEE A VIDEO WITH A BIG BURN OUT:gt-happyup:

:upyeah:

[phill0046]

Where abouts are you located?

[pinky]

i am in raleigh

[pinky]

messed with the cold start/warm up/afterstart enrichments. my settings were pretty far off, especially on the lower temperatures (below 50).. it is closer now, but still not perfect.. it has started every time since i changed these, so better than it was

also wired in the wipers and reinstalled the motor/arms/blades (thanks chad for the plug)

and i read something about the alternator exciter going through the dash dummy light, so i checked and, sure enough, it was not charging at idle. i ran switched +12v to it and it started working. then when i tried to shut the car off (removed key), it kept running. you DO need that diode in there. makes sense, but i didnt have one. went to radio shack and picked up a 12v zener diode and it is all squared away now.

just a few little things, but definitely made some progress over the weekend.

[pinky]

changed the engine plans. i have started collecting the rest of the parts to get it together.

[pinky]

9a head
ported, resurfaced, guides, seals, etc
autotech valve springs
supertech titanium retainers
cams - probably stock for now but looking into getting TT 268/276

wiseco 11:1 pistons
bored to 83.5 (2nd overbore)
hot tanked and painted
scat rods
balanced crank
possibly lightened/balanced im shaft

and i guess i'll be keeping the TT race header

and maybe itbs down the road

i will be pulling the drivetrain out of the car once i get the engine built. i have to figure out what is up with 1st gear (making a clicking sound when the car is moving).

[pinky]

some quick pics

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010434.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010435.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010436.jpg

gonna assemble the head when the valve springs get here
when the pistons come in the bottom end will be off to the machine shop

after the longblock is assembled i'm pulling the drivetrain and trying to figure out the clicking in the trans. then it all goes back together and back in the car.

i don't really have a schedule, and i will only be working on it when i can find time, but i'd like to drive it before the end of the summer.

[pinky]

to do list
assemble cylinder head (waiting on valve springs)
machine work on bottom end
paint block
assemble bottom end
clean and prep block/head for assembly
assemble long block
remove existing drivetrain from car
swap timing components & accesories to new engine
machine work on flywheel
tear into trans to see what is up with 1st gear
reassemble trans
install flywheel/clutch/trans on longblock
install drivetrain into car

[pinky]

after removing old valve springs/retainers

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010440.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010439.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010438.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010437.jpg

[pinky]

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010410.jpg

[Yareka]

nice teardown table:gt-ogb-spank:

[Mr. Chan]

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010410.jpg
That actually looks good.
And shiny. But only one kind.

[pinky]

it is shiny in the pic b/c it is still wet.

valve springs, cam chain, and head gasket showed up today. new lifters should be in tomorrow, and the pistons should be on the way sometime this week.

[pinky]

some quick pics

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-201.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-205.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-203.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-202.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-204.jpg

[pinky]

cam followers should be in today, so i can finish putting the head together.

pistons are ordered and the bottom end will be going to the machine shop when they come in.

[gerich]

followers just showed up.

[pinky]

yay!

[pinky]

pistons showed up today.

head is assembled and the bottom end is off to the machine shop...

also did some datalogging yesterday and messed with some of the warmup settings.

[pinky]

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-04-292.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-04-293.jpg

[pinky]

i also picked up some scirocco 16v brake parts today

[pinky]

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-5-13.jpg

it's not done yet

[Vampire Cockroach]

sweet ladder

[Mr. Chan]

sweet ladder
Fookin Noob
That ladder is as regular as all hell. I've got a vintage glass fiber reinforced ladder under my house that I will sell you for 7,000 USD. While I admit it's not mint; I will include a box of Andes Mints for free. Everyone knows how tasty those are.

[jetta-the-hut]

That looks like NO fun. After my little adventure I never wanna rebuild another engine. At least not a water cooled one.

some quick pics

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-201.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-205.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-203.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-202.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-4-204.jpg

[pinky]

started prepping the parts for the brake upgrade. got new front calipers (for 10.1) and painted the carriers.

also picked up a few go-fast parts today.. 4 to be exact.
http://i30.photobucket.com/albums/c309/scrapdo/2001SuzukiHayabusathrottlebodies.jpg

[pinky]

itbs are here.

just sent $ for this:
http://i123.photobucket.com/albums/o302/16vguy/eacd0ce2.jpg

http://i123.photobucket.com/albums/o302/16vguy/7baf8c52.jpg

[jetta-the-hut]

nice oil cooler what did it come off of?

What kind or radiator are you going to run or does the bay have the same issues as the mark2 does with clearance?

[pinky]

i got it from vortex. the core is a setrab.. the filter housing came off some european vw. (seller said it came from a heron). i think the seller had the lines custom made.

i have a mk1 w/ a/c radiator (i don't have a/c but it is bigger). there is space next to it for the core on the passenger side.

you can kinda see where it is going in this pic... in front of the alternator.
http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/P1010435.jpg

[Mars85Golf]

slim fan shroud should do away with any space problems yes? that or do that whole passat rad support thing and mount it in another way. UGH I LOVE ITB's! Pinky... teach me your ways*no homo*

[jetta-the-hut]

are you going to have to drop the alternator to the lower holes, my buddy in washington did. There wasn't enough room on the first intake hole. It may work though but its got to be close.

Are you going silicone hoses & a cut intake or going to have a plate made so the ITB's bolt right up?

i can get lines like those, having a pops in the aviation field help though, they had a bunch lying around.

I thought of doing the oil cooler deal too and also the power steering in those lines. Makes the engine bay look different and then throw in a set of those blue coolant hoses you guys have.... damn i need another dub!

[pinky]

i have no idea if i am going to have a clearance issue. there is quite a bit of room so i think i should be able to figure something out without too many issues (knock on wood)

i will probably use a cut intake with silicone couplers. i am also trying to weigh my options for mounting the IAT sensor.

[pinky]

cleaned up and painted some of the scirocco brake parts (knuckles, dust shields) over the weekend.. came out pretty nice, i should be able to get some pics soon.

still waiting on the machine shop guy to get the parts for one of his machines so he can do the hone. hopefully i will get it back this week and can start assembly.

[pinky]

oil cooler and early front upper strut mounts came in today......

[pinky]

cleaned up and painted the rear disc stuff tuesday. i need some rear calipers, tho (they were pretty messed up)

the guy at the machine shop finally got the part he needed for his machine, and i hope to have the engine back soon (tomorrow?).

after i get it back, i am planning on putting some serious time/effort into this.

i was also told (vortex) that the oil cooler flange i got won't fit a 9a, but the guy that sold it to me said it came off a 9a.. so we'll see about that.

[pinky]

picked up the engine parts today. i still need an IM shaft and a few other things, but i got the crank back in the block.

fwiw, the oil cooler is going to fit.

[sciroccodriver]

i was also told (vortex) that the oil cooler flange i got won't fit a 9a, but the guy that sold it to me said it came off a 9a.. so we'll see about that.


Hmmmm.... I've heard of the crankcase breather being different because there were two different 2.0L blocks, but not the oil cooler specifically.

[pinky]

yeah, the breather and oil filter flange are both different.

[pinky]

got the bottom end back from the machine shop. the guy, for some reason, did not gap the rings, so i need to do that still.

now the part everyone wants.. pics

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-192.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-193.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-194.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-195.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-196.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-197.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-198.jpg

[pinky]

quick summary of where it stands currently and short term stuff.

the block is going to get a fresh coat of black.
i need to gap the rings. then plastigauge and install the pistons/rods. then arp head studs and the head.
i need a front main seal plate (the aluminum cover plate). hint hint.
i guess i should also dig up some oil squirters. i think i have a set in a bag somewhere but i have to find em.

the brake setup is 16v rocco all the way around. new (rebuilt) calipers all around. painted all the stuff with black brake caliper paint (except the calipers, interestingly)
i have the master and prop valves also.
ordered the rotors and i will be getting hawk hps pads very soon.
the front knuckles dont have hubs in them yet because the hubs that were in there were a little messed up, and i put brand new ones on the car about a year ago, so i am just going to swap those out when i pull the old stuff.

i painted the parts you can see of the front upper strut mount and i am still waiting on poly bushings for that.

[pinky]

block is painted
rings are gapped

pistons/rods go in tomorrow
might put the head on too.. it depends how i feel.

and i found some oil squirters.

not sure how soon i will start disassembling the current setup, but its running really well and i almost don't want to take it apart... almost..

[pinky]

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-221.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-223.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-222.jpg

[evan@absolute]

Jesus dude. There's a pair of vise grips on your crankshaft.

[pinky]

more torques that way

[pinky]

i had to modify (bend) the oil squirters a little to get them to clear the piston and the rod. i think i got it taken care of last night (i'll check clearances when i put them in, probably tonight)

i also got the head studs into the block. i will hopefully be putting the cylinder head on tonight.

i also found the cover plates for the ends of the crank (front/rear main seal housing) and threw a quick coat of black on them. those should also be installed tonight, as my crankcase gasket set showed up today.

[pinky]

got the head on and the front main seal

[pinky]

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-241.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-242.jpg

[Yareka]

fugginay :upyeah:

[Mr. Chan]

That VC is nice.

[pinky]

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-25.jpg

[pinky]

got the rocco knuckles in yesterday.. still using the stock (smaller) brakes.. i will swap out the rotors/calipers/carriers when i get the pads.

hope to really start tearing into it this week sometime.

[jetta-the-hut]

Jesus dude. There's a pair of vise grips on your crankshaft.


Maybe he has a little crank and that's the only way he can grab it?

[pinky]

well i cleared out some space in the shop to start taking stuff apart, but it didnt stay cleared out long enough for me to move the car in. very soon, tho.

[pinky]

a little more work done. got the drivetrain pulled and stripped down, the brakes swapped (still need to do the lines and pads)

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-031.jpg

http://i626.photobucket.com/albums/tt350/kevinhassell/83%20Jetta/2010-6-032.jpg

[pinky]

pulled the coil, engine harness, brake cables, coil, headlight harness, etc. out of the engine bay today.. prepping for a good scrub and maybe some paint. trying to decide if i want to remove the raintray.

[Mr. Chan]

Nice progress.
Don't forget about the coil!

[Yareka]

Don't forget about the coil!

good call, internetz diag ftw.

Whats that big barrell over on the left :holyshit:

[pinky]

i can only assume you're refering to the fact that the coil mounts to the rain tray. this is not really that big of an issue, as i can find somewhere else to put it.

[Mr. Chan]

You are giving me far too much credit for not acting like a dick...
pulled the coil, engine harness, brake cables, coil

[chris@pwrhaus.com]

However, after considering the time, effort & gargantuan forethought involved in removing the coil, I can see why you listed it twice.

[pinky]

nah.. removing the coil is easy. so easy, in fact, i removed it, reinstalled it, and removed it again.