Injector pump & other ???

[RollModel]

I need some info on mating my 81 caddy body with a 85/86? Jetta TD motor. After a year + I finely have the body and motor in the same place and would like to get started on the project. Any help y'all can offer would be greatly appreciated. 1)My Injector pump needs rebuilding and I remember last year that someone on one of the VW Boards was well respected for his wizardry with diesel pumps - seems like he worked at a dealership or some place that specialized in VW diesel repair - anyone know how I can get in touch with him? While I have my head under the hood I think I'll try to stuff an IC in there as well- any ideas as to which one makes the neatist fit? I'm tired of 50hp, I want MORE. 2) Any and all hints and tips to make this a smooth and easy install are welcome - like what size exhaust and how to mate the manifold and pipe. 3) Will any 924 Porsche parts fit the caddy - my son has moved on to a JOB and a TDI, Thank God!, and I'm left with a 924 that needs a clutch - anyone need a 924? 4) I would like to replace the door panels, carpet, etc. and need a source. 5) The caddy trans code is FF, is this a 4 or a 5 speed? Thanks folks

[mortskeg]

RollModel- first off, welcome to the forum!
Sounds like you were lucky enough to find a rare TD engine to put into your pickup. I haven't had any of my pumps rebuilt, but the turbo diesel pump is turbo specific, so you do want to keep that pump with that engine (or another TD injection pump). Darth Garry, (http://www.vwcaddyforum.com/topic.asp?TOPIC_ID=3874) diesel master, has just had his 1.6 TD pump rebuilt by a local (to him) diesel specialist so you might be able to find someone close to you who can do this and calibrate the pump once it has been rebuilt.
The turbo has its own downpipe, and I don't know how this would mate up with the stock system. I'm sure that fabbing a slightly larger diameter system would be benifical. Garry should know more. Also Dr. C is running TD in his pickup IIRC.
Don't need a 924, thanks.
Check out california j-bugs/ TMI for your upholstery needs.
FF= 5spd.
Hope this helps, and again, welcome!:)

[Darth Garry]

Hey man welcome! I'm doing the same swap - N/A Diesel to a Turbo diesel, check out my pics on www.notinteresting.com if you feel like. Just go to "updates" and click on any topic that has "truckdoza" in the title, and you'll see activity on the truck. Not a lot of technical stuff, but a lot of images of how I did things.

Answer for #1 - HAVE IT REBUILT BY A PROFESSIONAL! There's a bazallion moving parts inside, and you need a few hundred thousand dollars worth of equipment to get it all working right again. I had my pump done at D&W Diesel and Electric (www.dwdiesel.com) They're real great guys who really know their stuff.

#2 - I haven't gotten to the exhaust yet, so I'm not sure what the story will be on that. Two other fabrication challanges you'll face will be to make a new mount for the fuel filter and for the turbo air box. The fuel filter I ended up mounting on the rain tray to make it easily accessible, and the air box I used a power steering resivoir mount which fits nicely into the mount on the passenger's side inner fender well, and a metal bracket that I made from 1/16" steel rod.

#4 - I am replacing the dash and complete interior with the interior from an MK1 Jetta. The stuff looks way better than the rabbit stuff, but fits all the same with some minor work to fabricate the dash mounts.

I hope this helps a bit!

Garry

[RollModel]

Thanks, Mortskeg & Darth for the info. Anybody have ideas on the IC? Looks like the challange will be getting a nice, neat and proper placement of the right size IC. I'm getting to old to do things over, so I'd like to get it right the first time. I'm sure I'll need y'alls imput on other parts of this project. Thanks again guys.

[Darth Garry]

If you aren't running AC the answer is simple, put it in front of the radiator where the condensor goes.

Garry

[RollModel]

Sorry Garry but I'm down here in South Alabama where the tempature AND the humidity are about the same 8 months out of the year - 90 to 100 - A/C is a must for me. I'm still looking for suppliers - besides junkyards - for things like bumper end caps, dash covers or good used ones that aren't cracked, and other plastic/rubber parts. Also, what types of shocks, motor/trans mounts, and suspension bushings, etc. do you guys prefer? I've got the trany out will replace/rebuild soon. Will the 200mm clutch work with the turbo motor - the Jetta had an auto and I've got a flywheel from a N/A motor that I plan to use. I'm going to remove the CV shafts and have them rebuilt and check the steering rack U/Js and anything else that I can get my hands on while the motor/trany is out. I guess I should replace the gearshift bushings and rubber boot while I'm at it. Thanks for your comments and ideas.

[Darth Garry]

Just to let you know, you will have to make some mods to the downpipe. I discovered that last weekend. I'm going to spring for the 2.25" techtonics kit while I'm at it though and upgrade the whole system.

I used the stock motor mounts, that were in good shape. Don't get polyurethane bushings, people say they're better, but I hear they squeak a lot, and they are stiffer so not preferable in the diesel. I don't think there is much difference between the 200 and the 210mm clutches. That should run fine.

You should check out missing linkz shift kit, I got the whole kit and it's AWESOME!

Garry

[RollModel]

Garry, are you going to intercool your turbo motor and if so which one are you going to use? I've got a Ford Probe I/C that I got from the junk yard where I got my caddy but I'm having a hard time visulizing the best place to mount it. With the A/C coil there's little room to route the intake and return lines. I may have to go with a diffent I/C - I/m not going to give up the A/C that's for sure! Who are some of the suppliers that you can recomend? I don't have a lot of time to surf the net and I'm not a geek - hell I still have dialup, so it takes a while to download. I need to get this project complete so I can get back to my Knucklehead project - to many irons in the fire! I did get the CV shafts out today and cleaned up the interior a little. Going the remove the carpet tomorrow and drop off the CV shafts to be remaned, and maybe try to replace the heatercore - I bought 3 or 4 that will fit with a little tweaking of the return lines for 5 bucks each and I know that is a weak item from my NA caddy experience. I may do the NA first to get an idea of what NOT to do on the Turbo! Thanks again for your info and if you can pass on any other tips like the exhaust, etc. they are most heartly welcome. leon

[Darth Garry]

I'm not intercooling as I couldn't find a decent, easy way to do it. I've read a lot of debate on the subject, and much research says that intercooling may only give modest gains in performance. I figured it wouldn't be worth the hassle and complication in my truck who's main purpose is to be a long distance cruising mobile.

Garry

[RollModel]

Yeah, D&E - key words! However, using info for website http://
www.nwlink.com/~vdb/vw/Engine/Engine_Swaps.html, Jan Vandenbrande, update Aug16, 1999 states: 1600 turbo diesel= 68bhp and 1600 turbo+intercooler = 90bhp. Is this anywhere near correct? If it's somewere in the ball park I'll stand on my head untill I come up with way to go from my 52hp NA to the 90hp I/C! I need all the HP I can get to stay out of the way of these logging trucks down here - they're like teenagers on dirtbikes-WFO and no fear! Do you know if the I/P needs to be tweeked when you add the I/C?

[Diesel]

Diesels need turbos and turbos need intercoolers. Not sure if the above figures are correct (ther're probably a touch optimistic,) but the trend should hold true. In theory you could run more fuel into the motor if the air coming in is more cold and dense, but I wouldn't sweat much about it. Might be worth fiddling with, though.