(Another) pickup project blog

[syncroandy]

As some of you know I acquired a 1990 TD single-cap pickup late last year, which I'm now frantically trying to get sorted for CF. Wish me luck and good weather (this is all being done in the street) !

Work completed

• Oil change (after dealing with stuck plug using Clives special chisel)
  Renew filters with Mann ones
  Cold start handle (missing)
  New throttle cable (stiff and crappy as)
  Replace manifold hanging on by four studs with fresh studs/manifold/turbo
  Renew cambelt covers melted due to leaking exhaust manifold
  Repair airbox to turbo pipe (slightly cracked at lower end)
  New cambelt/tensioner/alternator belt
  New late-pattern Ernst exhaust downpipe/muffler
  New pedal rubbers (MOT)
  Renew front flexis (MOT)
  Service noisy alternator (Aidan's mate Bill, top chap)
  .
  Fitted 15" BFG MT's on Merc steelies, plus two part-worn spares
  Renewed coolant
  Removed front diff and fitted overhauled unit with fresh mountings, oil and VC
  Serviced front driveshafts and swapped over
  Fit refurbed front bashplate
  Secured loose engine cover
  Disabled tired blow-off valve
  

Work to-do before CF !

• Renew front and rear brake friction parts (and hydraulics if needed)
  Fit 16" mirrors
  Gearbox oilchange
  Refit engine bars
  Work out where/how to secure spare wheels/jack/shovel/axe(s) etc.
  Fit aerial and radio
  

Other work to-do

• Get pump timing/valve clearance set
  Replace mismtached front door handles (painted white and wrong key..)
  Replace stuck heater valve
  

[Simon Baxter]

Heh.

Re: turbo pipe, only £18 from VW and they stock them, don't want to take any chances with wading do you (ask Clive!!)

Sounds like a very similar list to mine...

Work done.

Cold start cable handle. (Missing)
Big mirrors (new)
Full service. (needed it!)
Gearbox oil change. (minging)
Front diff oil change. (manky)
Clutch. (Slipping)
Free off stiff/sticking release arm.
Spigot shaft bearing. (rough)
Clutch slave cylinder. (rough)
New exhaust manifold to head gaskets. (blown, sheared stud)
New downpipe gasket. (blown)
Radius rod bushes (noisey)
Secure handbrake cables (insecure)
fitted interior light bulb (blown)
Fitted correct 10w rear side light bulbs
Fitted second hand OSR light cluster (smashed)
Fitted 50w reverse lights (trial, poss new product)
Brake and clutch pedal rubbers (missing/worn)
Cambelt and tensioner. (belt is shafted)
New wiperblades.
Pump timing. (just because)
New airbox to turbo pipe. (cracked)
Adjusted LDA to actually do something.
Fitted CB, and antenna.
Fitted new fuel flap and matched up key to ign.
Fitted re-nozzled injectors.
Repaired drivers door skin that had come adrift.
Tappets. (just because)
Front discs and pads (discs below minimum thickness)
brake fluid change (as black as you like!)
Fitted fresh strut to engine lid (old one knackered)
Fitted correct alternator pulley so the rev counter now reads correct!!


Work pending



Fit spare wheel to rear of cab.
Fit front fog lights.
Carry out headlamp wiring upgrades.
Fit viscous coupling (bit stiff)
Match up locks onto one key.
Replace rubber steering UJ's.

Thats 2 weeks of evenings and weekends there, end result - well, I did most of the lanes that we did on Syncro Suturday in about an hour and a half last night..
Rear diff lock that worked almost instantly normally decided to take a little while longer to work, but it performed admirably apart from that..
It did however exagerate some worn ball joints so some more genuine ones will be ordered monday..

Also, stainless steel spot/fog lamp bracket kits should be available early next week so I have some genuine fog lamps to fit too!
Not cheap, but as factory ones (steel bumpers) and will come with rivets etc..

[syncrodoug]

Must write a note to myself to make a list of things to do - I might make some progress then rather than keep changing my mind.
I've just unpicked the engine wiring loom from a Passat (AVB) so I can fit it to the TDI Golf engine - based on an ARL (150 horses and 310Nm of torque!).
I say its a based on a Golf engine but I have used a few bits from the Passat range.
Adapter plate should be back with me this week - Phil Moss of Ledbury is making a copy.
Another little problem will arise when I try to install it in the DOKA - I haven't enough height in my workshop to lift the back end to slide the engine in vertically so I decided to push it in on its side probably with the transaxle attached.
Then there's the engine mounts to fabricate...........

[syncroandy]

> Re: turbo pipe, only £18 from VW and they stock them, don't want to take any chances with wading do you (ask Clive!!)

Yeah, I did witness that episode, very educational.

My 'repair' makes it better than new. The end of the pipe can easily get crushed by the jubilee clip holding the rubber boot on. I made up a reinforcing collar out of thick brass strip, fitting snugly inside, sealed with silicone and pop-riveted in place.

[Simon Baxter]

> Re: turbo pipe, only £18 from VW and they stock them, don't want to take any chances with wading do you (ask Clive!!)

Yeah, I did witness that episode, very educational.

My 'repair' makes it better than new. The end of the pipe can easily get crushed by the jubilee clip holding the rubber boot on. I made up a reinforcing collar out of thick brass strip, fitting snugly inside, sealed with silicone and pop-riveted in place.

The £18 ones from VW have strength in place.

[syncroandy]

OK, mebbe I should order one just to find what Baxter is on about !

[Simon Baxter]

hhmmm, bits of silicone breaking free just before the turbo...


£18 is kinda insurance

[syncroandy]

Naah, it'll be fine, the silicone is on the outside to seal around the pop-rivet heads. Next time it's off I'll take a pic.

[syncroandy]

List updated...