TD engine rebuild

[jaded]

hello, have bought a TD engine to replace the non-turbo in my westy. will strip down the engine first but have only done bike engines before. anything special to look for, any must do´s or any good links?

[HarryMann]

Lots of good links..

Do a seerch in the Tech Archive and in here.. (use AAZ or JX or TD)

Also lots of stuff in the Wiki... just go to Diesel and read everything, some good parts lists and troques in there too

PAS. You heard it running, starting from cold? If so, why strip it down... maybe pop head off but, complete strip... ?

[mrhutch]

what engine code have you bought.. VW diesels have problems with the crank pulley, if you are doing a full strip down then replace timing belt and tensioner, along with new "proper" crank pulley bolt (brickwerks is the ONLY place to go for this)

I would / have already done..
new thermostat - AC one, opens at a lower temperature.. your cooling system probably has the thinner radiator so the cooling system will need all the help it can get if you are not replacing the rad

front mounted oil cooler

gauges to check what the oil pressure/temp is doing

thats only for starters.. enjoy the ride!

[HarryMann]

long with new "proper" crank pulley bolt (brickwerks is the ONLY place to go for this)

Well, I'm sure Simon sells them, but so do Volkswagen, which is where I got mine from ...

your cooling system probably has the thinner radiator so the cooling system will need all the help it can get if you are not replacing the rad

There are two rads available? Diesels were only built with one rad AFAIK, the same as the 2.1 WBXs...

[mrhutch]

yes, the TD and 2.1petty had thicker rads than the NA 1.6d

[jaded]

Wow, thanks for the quick replies!

engine was already on a pallet when i bought it, didn´t want to fit it and then find out it had problems.

is that ac as in Aircooled?

[mrhutch]

sorry no, as in air condition.. AC equipped vehicles had stats that opened earlier because of the extra load on the engine from a AC compressor

[HarryMann]

yes, the TD and 2.1petty had thicker rads than the NA 1.6d

OK, have now checked this out with ETKA, as its quite important

Up to 1985 the CS 1.6 NAs had the normal DG/DF radiator 068-121-253 A

At frame no. F 24-D-000-001 and onwards CS rads were the same as the new DJ and JX rads , the 'E' version, this was in the 1985 model year..

A year later, cowlings and fans changed too... the JX fan size jumped from the std. 300/200 Watt/ 305mm to 500 Watts/350 mm nominal dia. !!

The main other difference between the diesels is the TD floorpan having a wider duct behind the radiator cowl, the only explanation being that this is to improve flow and cooling. I imagine this floorpan was introduced in the 85 or maybe 86 model year and was not lightly undertaken... but is indicated solely as T-DIESEL in ETKA

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We obivously agree that the the heat rejetiion into the coolant of the diesels and particularly the TD diesels is a lot more than any of the T25 engines and should be born in mind.. Fortunately, quite a few report that putting diesels into the petrol body, doesn't usually create insuperable problems, but nevertheless, TD diesels do need that big fan which can come on when just cruising or hill-climbing...

[jaded]

thanks again!
pity as i already have an Aircooled one-
shouldn´t imagine they sold many aircons over here!

[HarryMann]

You have to decide on several things... as a priority.

Which TD engine have you bought and what ancillaries have come with it?

A 1.6TD (JX) from a T3, a 1.6 TD from another VW model or a 1.9TD from a Golf or Passat/Seat


===============

These areas you should focus on for reliability..

Exhaust manifold/ studs - quite special
Turbo (condition/placement (low or high)
Cylinder head (cracks,s erious or acceptable)
Main pulley-bolt/keyway (if 1.9 AAZ)
Pulley/alternator/pump belt arrangemenst (which one of many)
Pulley (JX vibration damper or AAZ one)
Clutch - suggest new
Type of sump gasket, plain or combined sump/ splash plate (requires longer screws)
OIl pump, using old strainer, but usually replace pump with larger gear version

Oil cooler - important, best up front
Gauges - Oil press/temp (maybe EGT if overfuleeling/overboosting)
Intercoolingoptions


TD requires sump modification for return oil flow, or acquire TD sump
1.9 TD is a taller engine than 1.6, hence lengthening of low turbo support bracket and oil return pipe too

LOts more considerations, so you really need to specifiy which engine you have acquired..

[jaded]

it´s a jx with just about everything still on it including clutch, gearbox and mounts.

[HarryMann]

Good, that solves most of your issues then..

Read through the list above, certainly pop the head off and see what everything looks like inside; there's some piccies of bad heads and eroded pistons in the Wiki under diesels https://club8090.co.uk/wiki/Ma ... el_engines

The pulley bolts don't tend to go on the JXs (and not having to remove it will be a godsend, can be a nightmare (seen 3 BIG men reduced to tears getting one off!)

IIf the pistns look OK and bore wear OK, I'd leave alone...

Definitely remake exhaust manifold head joint (warped/ usenew studs or nuts and must use those thick washers) and turbo to manifold (check manifold mating face isn't rough/warped cracked), see wiki photos in Turbo section

[jaded]

ok, thanks again for all the info.
will be disappearing into the garage soon