[Vwdiesel] Re: [vwpickups] Rebuilding the TD

[Pam & Doug Boes]

Did you happen to take any pictures of the bottom end that you could send
while it was going together?
----- Original Message -----
From: "Hayden Chasteen" <dieseltdi at earthlink.net>
To: "VW Diesel Mail List" <vwdiesel at audifans.com>;
<Audi-VW-Diesels at yahoogroups.com>; "VW Pickups Mail List"
<vwpickups at neubayern.net>
Sent: Saturday, May 10, 2003 9:25 PM
Subject: [vwpickups] Rebuilding the TD


> Well, after several months of sitting in the corner of the garage, I
> finally decided to start the rebuild of a CY Jetta turbo engine that I
> bought about a year ago.  This engine will go into my 81 Pickup once I
> morph the two into one.  Anyway, when I first got the engine, it had a
> new head on it that had not been properly torqued down and no heat
> shields under the injectors.  I thought that I would just hone the
> cylinders and replace the rings to give the engine some new life and
> that is what I did.  Well as the months have past, the more I thought
> about the possible condition of the engine, I mean if the guy couldn't
> properly torque down a head and doesn't put heat shields under the
> injectors what else could he have messed up?  Anyway, to make a long
> story short, I tore the engine down, took it to a local VW machine shop
> and had it bored to the first oversize, bought new Mahl pistons ( a
> steal at $355), new rod and crank bearings and all new gaskets.  All
> external engine parts have been cleaned and repainted either aluminum
> (water pump, oil cooler, etc) or low gloss black (vacum pump, all pump
> and alt brackets and the oil pan).  (BTW the oil pan is an VW
> replacement part that holds 5 quarts).  I tried to find an engine color
> to match the VW green.  First I used a Detriot Diesel green, but it was
> too dark and kind of a blue green color.  Eventually I found one called
> Grabber green that is probably a bit too bright but looks really good
> with the other repainted parts on it.  I assembled the entire lower end
> today and feel really satisfied with the ease at which it went
> together.  Although I have rebuit many, many, many air cooled engines,
> this is the first total water cooled engine rebuild for me although I
> have honed, reringed and put new bearings on several so I guess
> practice makes perfect (a good engine stand is also a must).  It now
> will have to wait for several weeks to get the head on it because I am
> about to go out of town (and off list) on Thursday for 2 1/2 weeks to
> teach a summer field course in Rocky Mountain Geology to 14 community
> college students.  BTW, I have the original pistons from the old engine
> that were cleaned, decarboned and have new rings on them if someone is
> in need.  2 of them have valve impressions in them but they are OK.  If
> somebody wants them let me know what you think they are worth.  Hayden
>
> Visit my homepage at http://home.earthlink.net/~dieseltdi
> 2002 Jetta Wagon TDI GLS with Upsolute Powerbox
> 1998 Jetta TDI with Wetterauer Chipset and Dual Fuel Propane System
> 1981 Rabbit Pickup (Caddy) Currently have 2 that will morph into one
> with a TD engine, WVO system and Propane Injection
> And many, many, many VWs both air and water cooled long gone and too
> many to count but certainly not forgotten.
>
>
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