[Vwdiesel] Misc '79 Rabbit questions

[Tony and Lillie]

Well, I've finally torn into a 1979 Rabbit 1.5 Diesel (CK, I think) 4-speed with A/C that I bought about nine months ago. I have a few questions.

I'll start out by saying I've had a fair bit of experience on all makes of cars, but it has been about 10 years since I've done anything significant with a Diesel. Also, this car ran (but not well) before I tore into it. It ran a lot like it was on two or three cylinders. It also would not idle. I do know that all the work I'm currently doing probably won't fix that. The only hope I have is with the head gasket :)

I've pulled the engine and trans, then seperated them. I'm replacing everything on the engine that is generally considered maint, plus a few things. So far, I've done the oil pan gasket, rear main, clutch, cleaned and inspected the oil pump and pick up tube. I've rebuilt the vac pump. I've also replaced the front main and intermediate shaft seals. Which brings me to:

        1. The front of the intermediate shaft was pretty messed up where it meets the front bearing and the cap that holds it in. It had a bunch of carbon looking stuff chunked up on the cap. I cleaned it out, and other than that, and half of the front (thrust) surface being gone, it appears ok. Is this common? I'd say from the looks of it, it was starved of oil at some point in the past (go figure in a diesel).

        2. Upon removal of the head, it appears that the pistons have come in contact with the valves, but not now (more like in the past). There are no cracks between the valves, however. There is also a slight ridge in the cylinders, but the air filter isn't very oily at all. I'll keep my fingers crossed.

        3. The old head gasket had four notches (it looked like three on the car), and I ordered one with three. Is there an easy way to check clearance, and what is the difference in thousanths (or mm) for each notch on the head gasket? I also have some pics of the pistons, hoping to post them shortly.

        4. What trans fluid should I use? I'd prefer synthetic if possible.

        5. This car has the stock solid front rotors. Is it possible to use the GTI rotors with the smaller GTI pads on these calipers, or do the calipers have to be changed?

I'm planning to replace all the coolant hoses, the valve, the heater core, and the cable. I'm replacing the hose for the vac pump feed, all the gaskets and seals. Also doing the clutch, all CV boots, trans oil, the compoete shifter ball and socket and all the bushings. Doing the TB, WP and thermostat, the fuel lines and plug on the last injector. Contemplating doing the injectors (rebuilt they are about $45 each) and having the pump rebuilt ($450 locally). Anything else I might be missing that should be done would be greatly appreciated. Oh, I'm also doing all the filters, and already did the brake fluid. Suspension and brakes will be done in the spring.


Thanks in advance,

Tony Hoffman
Oklahoma City
5 Audi's, 2 VW diesels, and 2 Ford E-vans