Philips Mk1 Jetta 1.9 TDI PD130 Project

Thanks! Here's the starting of the boot build













It's surprisingly a good fit, so needs a few more things installed before I carpet up everything lol all in time 😉

How have I only just found this! awesome work mate! Perfect engine, that's what is going in mine over winter! 

What wheels you going for? 

Here's mine! 😊
 

Wow guys, haven't I been a slow coach but getting back at it again!
Decided to finish off the boot build and haven't I been busy lol
After 4 years of searching for a perfect mint new old stock rear bumper I finally found one and after 2 months of negotiation using google translator I finally had this sent over from Germany, anyway that's the boot almost finished

 

Willcrook8 said

How have I only just found this! awesome work mate! Perfect engine, that's what is going in mine over winter! 

What wheels you going for? 

Here's mine! 😊
 

I'm going for the standard 15 inch pepper pots from an A3, they are fitted on some previous pictures

Also managed to get the passengers door back, fitted and now with working latches, Windows and seals fitted

Amazing build. Can't wait to see it finished

Thank you Mike




I finished off wrapping a pair of orginal chassis leg cover trims to tidy it up mores and trial fitted! Nearly there 😉

Need more updates!!! 


 

Just going to jack the post with mine! 😂 



Keep it up dude!! 

Willcrook8 said

Need more updates!!! 


 

Just going to jack the post with mine! 😂 



Keep it up dude!! 

I know I need to get more photos when things happen!!! Which they have been, I've decided to go back to the orginal dash and blower motor unit because quite simply the modern dash just doesn't suit the car at all, I've bought a donor car which as you can see is being broke for every single part so not only do I now have spares (including a beautiful spare front and rear window with both seals)  but now have any trim or wiring loom including some rarer parts ;-)

I got some welding done to the firewall to bring it back to standard so going to seam seal it tomorrow and paint the firewall black!
I've got some things for sale if anyone wants to check the breaking section also.

😜😉

Finally purchased a new sach dual mass flywheel kit with pressure plate, friction plate and slave cylinder after stealing it for my old golf before I sold it on lol! Now question is do I get the old gearbox (O2M) that was fitted with a quaffie limited slip diff that I bought back from my old seat Ibiza 130 (as the guy that owned it after me split it for parts a few years later) and fit the diff to the current 6 speed box (O2M)

Finally fitted ☺️🤗😆

So today I set about getting the pin hole drilled in the steering rack pinion as the splined section would rotate freely and the centre shaft wouldn't turn with it, I drilled a hole for it and I'm waiting on the correct style of pin to go in snug, also I noticed is that the power steering fluid wants to come up between the 2 parts, so I'm going to see what I can use to stop this, aka apply a really hard setting sealer or the likes





And getting the firewall cleaned down / prepped of resin that was going to originally grip the rubber lining

This past 2 weeks I've focused on getting the firewall section somewhat tidied up and smoothed in areas, this is how it played out plus also getting the mk1 heater box and blower installed
 















I'll get more updates posted asap

I'm just after buying some goodies for the car that will be arriving within the next week or two! Finally getting hold of a GTB manifold and a Newmans fast road camshaft with 9.7mm of lift including 8 new black top tappers/followers, just something to keep me busy over winter 😝

Finally I'm getting some really good vibes about the project after much debate of what the heck I was going to do with it… it's been 5 years since I started 😞

So I finally bought this gtb manifold so the Q7 turbo can bolt on to the 1.9TDI asz engine, I'll get the gaskets for it and get it fitted soon….
I'll be honestly saying that it's been a relief getting this part finally

Finally on… what do you's think of them welds

Also refitted the gearbox and inlet manifold was cleaned and now has been installed with a new gasket

Finally got the gaskets needed so whipped this bad boy on

Before fully tightening the manifolds on, I figured since this is the only and easiest time to do it, I might aswell change the headgasket, and upgrade the headbolts to the harder 150 ARL headbolts

The process took maybe 2 hours with a lot of careful cleaning with a friend helping, it was finally done, not to much signs that the old gasket was going to fail but since I was going to fit the upgraded headbolts, then this was the best time to do it all in one go













Tightening the head was simple enough, it's done in 4 stages.

First off is the pattern that the bolts are tightened
10 5 2 3 7
  9 4 1 6 8

Is the method I used for the 10 long bolts that clamp the head down, this is done to evenly spread the gasket as its tightened

Tight is as follows
Stage 1) torque to 40NM
Stage 2) torque to 60NM in the same pattern
Stage 3) using a breaker bar, tighten the bolts 90 degrees
Stage 4) tighten a further 90 degrees

A useful tip if the engine isn't in the car is get a mate or two to hold the engine as best they can lol but yes there you go, that's the headgasket finished.
I'm going to fit the water flange, tandem pump and thermostat tomorrow. 😀

I fitted new seals to both the water flange and the tandem pump, if anyone was wanting to know why the newer pd engine is called a pd engine, PD standing for pump duse or two pumps, is souly down to the tandem pump… it is a vacuum pump for the brakes and has a pump internally for the fuel pumping the fuel at 7 bar into the head.

 



Also the newmans camshaft finally arrived but I'll not be fitting it until the engine is started and running smooth as the first time it's started with the camshaft, it needs to be revved to 2000rpm for 15-20 minutes and I'd rather wait till I know factually that the engines sweet with no leaks etc before doing that