[Vwdiesel] 1981 n/a Jetta

[Terry Briggs]

I'm competent at engine rebuilds, I rebuild several old vw and porsche 
air cooleds every year and have rebuilt more than a few V8's, just 
never opened up a vw diesel block. I know I've heard through here about 
the minor cracks around the valves.  Are there any issues with cracks 
at the crank journals ?I figure I'll do a compression test prior to 
pulling the head off just to see where I'm at for a starting point. 
Does the bentley have diameter specs as far as crank journals and the 
like. On your advice I'll probably have the head and block magna fluxed 
to check it out completely.  does anyone know what color the stock 
blocks are, I think they are black like the gasser, but I might get 
creative and go with something a bit more flashy to spruce it up a 
little. It will be an entire winter project, so I'll have time to do it 
right the first time { I hope }
On Oct 1, 2006, at 9:13 PM, Doyt W. Echelberger wrote:

> At 01:45 PM 10/1/2006, you wrote:
>> Just got a 1981 n/a jetta with a good engine and tranny. The body is
>> shot, lots of rust in the rear door arches. I do believe it's a 1.6.
>> Could it be a 1.5 ? if it is, would it still work as a spare motor and
>> tranny for my '86 Golf. The engine is fairly low miles at around 170k,
>> no leaks and ran great last time it was started several years ago. My
>> plan is to just rebuild it and then drop it in my golf and then 
>> rebuild
>> that engine. What should I look for upon tear down.
> >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
> Cracks between valve seats, burned valves, broken valve springs, worn 
> parts, scuffed/out-of-round cylinder walls, out-of-spec cranks, 
> cracked blocks/heads, head warpage. You could consider having the 
> engine cleaned and checked at a machine shop. Talk to a specialist at 
> such a shop, at least.
>
> Specific answers would involve lots of details that would be found in 
> a manufacturers service manual. You would disassemble, clean, measure 
> everything, and address out-of-spec conditions, then reassemble and 
> test.
>
> Here is a typical reference to diesel engine rebuilds......not 
> specifically VW, but widely available and probably can be obtained 
> from a public library. It will give you an idea of what is entailed.
>
> http://www.themotorbookstore.com/diesenrepman.html
>
>
> Perhaps you could consider enrolling in a community college course for 
> diesel engine overhauls. Below is a general outline of such a course:
>
> Small Diesel Engine Overhaul course will include topics such as:
>    * The operation of small diesel engines
>    * Systems disassembly procedures and parts cleaning
>    * Inspecting
>    * Use of measuring instruments
>    * A assembly procedures
>    * Injector testing, tune-up procedures and dyno testing procedures.
> Please Note - Participants will be responsible for safety footwear, 
> work clothes and safety glasses. Manufactures' service manuals and 
> handouts will be provided to the participant.
>
> This course offers a hands-on experience overhauling a diesel engine 
> and functions much like a diesel engine repair shop. Students will 
> individually disassemble, inspect, and rebuild at least one diesel 
> engine. Emphasis is placed on component identification, measuring, 
> inspection, analyzing wear, and detecting parts failure. Students are 
> introduced to various methods for cleaning parts using the latest 
> cleaning technology as well as identifying fasteners and using 
> measuring and hand tools. Particular attention is given to attendance, 
> quality of work, productivity during class time and the ability to 
> follow detailed written procedures from service manuals. Shop safety 
> is also stressed.
>
>