Philips Mk1 Jetta 1.9 TDI PD130 Project

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Hey everyone, so progress has been ultra slow trying to gather parts, trying to figure out major headache issues like the evaporator gas pipes fouling the clutch pedal were they come out of the heater box. Trying to get a condenser to fit that's not too tall and conforms to R134a gas.


 Well I think I've figured them out, I'm going to turn around the evaporator and seal the original opening on the heater box so it comes out in the passengers side and I've managed to find an Audi A4 b8 condenser that's short but just fouls so going to modify the front most frame to accommodate it.
Going to spend a good few hours at it on Friday, the engines almost out again so get access but also going to clean the engine up and possibly do a partical wiring tuck. 

Friend of mine had a Mk1 Jetta, love 'em. Cool looking cars and a bit different.

Hey everyone, it's been a while but here goes…. Got engaged and our wedding is in October 2023 😁

Anyway over the last couple years the car has been sitting in the shed under covers, I've postponed the a/c conversion due to a massive hurdle being the air con pipes coming out of the evaporator came out where the clutch pedal was since it was designed originally for a left hooker. Some day I'll continue with that project but since then removed the head and rebuilt it after finding the valve stem oil seals were leaking causing a bit of smoke out of the exhaust going down long hills. All new bearings, seals, stretch bolts and head gasket and it's back together. That being said it just needs the engine put back in and a mot booked, possibly it's last mot maybe? 

Before it goes back in, I really wanted to fix the torque steer as best as possible so managed to find an absolute legend that manufactures his own lower strut brace accommodating for a modified / different drivetrain, the finish is sublime, just need a day to fit it 🫣

 

So a tiny update but with less than 3 months till our wedding, it's time to get the car back on the road, we both want the Jetta to be a part of the big day by having it as the car to the wedding for me and in the convo on the way to the wedding reception.


 Fitted the lower strut brace and it fits perfectly, I was kinda worried the frame had been twisted due to the lack of strength in the chassis, it even warned me about this in the fitting instructions that came with the strut brace but it fitted fine. 

 Along with that, I figured the timing belt kit was due replacing as it may have only done around 10k miles but it was close to 10 years old so had little faith in it holding up, plus the only way to replace it was with the engine out so it made sense to get the full timing belt kit, water pump and aux belt replaced. Plan is to now refit the engine in the next few days and book an MOT soon 😃

 


 

 


 

So yesterday, I set about dropping the engine back in again, it's so stressful to do every time as you all can see lol






 
But I found the rear dog bone mount bolt fouling on the strut brace, which I was worried might happen, cue the music and time to modify it, so took it over to the father in laws to be and we got it chopped and put right 😄 

So it's now welded and restrengthened, the piece that was cut out was flipped upside down and set inside then welded up with a splash of paint on it, so refitted it and hey presto, perfectly clears 

So fired it up and found it was misfiring on all 4 cylinders, instantly suspected they where at fault so plugged a computer to the car and found all injectors maxed out at 2.99 each, not good…. I managed to get hold an another set of injectors and put them in, that cured it and was running smoothly once fitted. Time to book an MOT.

So straight after booking the MOT 2 weeks ago and getting a cancellation for last Tuesday, the car started misfiring again, 2 injectors failed instantly so had to get yet another set of injectors and a new wiring loom to put the nail in the coffin and get it running right. 

Finally got it running and test driven confirming it was all good to go thankfully. 

So it went to the MOT centre and got a pass 🤩 possibly it's last MOT before it's except 😁

So me and the little lady got married last week, we both had a fantastic day surround by friends and family. Even got the Jetta driven the two hours drive to Harvey's Point in Co.Donegal by her father and mother, they loved it 😁