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[719MKV]

Hooray for the barter system!

Hooray indeed! if it wasn't for the barter system i would never get s*** done, im usually always broke haha.. Snoopy got a 16v, i get a cage, and i scored a full rear disc swap! Win, Win, WIN!!

[snoopy]

Win win for sure!  I wasn't able to get the cage material delivered this week ~ and working 9-10:30 (am and pm respectively) I wasn't able to go get it.  Besides, the weather tomorrow is looking pretty bleak.  Next weekend good for you?

Just a quick update, I assembled the dash.  Hard as heck to get a good picture down here in the basement ~ but here's what I've got.

No flash:


Flash:


I'm sure I'll have better pictures when its in the car and has normal lighting.

[719MKV]

looks good. I need a diff dash set-up...

[snoopy]

looks good. I need a diff dash set-up...

On what?  Your Rabbit?  Man, if you have a 'spare' late GTI dash, we can always lay it down on the sheet I have left and see if we can but something out with the plasma.

PS ~ I still want to pull your dash out when we do the cage on your GTI.  ~ just sayin'

[719MKV]

Lol i still want to go through the speaker holes, i think that'll look better. Im available whenever you are man. Just let me know!

[snoopy]

Lol i still want to go through the speaker holes, i think that'll look better. Im available whenever you are man. Just let me know!

The only worry I have is snaking the tube through.  Sooner the better for me. I'll see what I can do about having the tube here for next weekend.  Hopefully it'll be warmer.

[719MKV]

Hopefully it'll be warmer.

x 346,482,765!!!

[snoopy]

HEY!  CALL ME!  I have the metal, but looks like i get to work tomorrow.  I'd like to get started fairly early and at least get the main hoop done!

[snoopy]

Well, while I was away in California Victor (old one) finished putting the 'new' 9a into the car.  It smoked alot at first, but now its not (thank goodness).  However, the engine bay looks a little ragged.  Would like to get it cleaned up a bit.  Anyone want to help me with that?  I'd just like to have a pair of eyes that knows what they're looking at.  I think there are several vacuum leaks, misc wires, stuff like that I'd like to clean up and tuck away.  Get things running right (as it's running pretty rough now).

Anyone got some time?

[snoopy]

Well, lets update this thread with a few pictures.

First, I had a buddy from Germany on the lookout for a part for the car for quite some time.  He finally found one and sent me this picture about a month or two ago.  Anyone care to guess what it is?


Anyway, that box is now sitting next to me.  Still haven't opened it.  Probably should, but getting the car running properly is more important than opening boxes of stuff that won't get it on the road faster.

Moving on.  As I stated earlier, I picked up the car today and drove it home.


But I have to admit, the wiring in it was really irkin' me something fierce.  I had to do something about it.  So I started taking things apart to clean up some of the mess.


When I see this:

:facepalm:The thought comes to mind that this car will never be what I want it to be...and it makes me kinda sad.  Yet, I will not give up completely...

My desire was to have the engine harness put in and done cleanly.  This is not what I was looking for.  So I started tracing wires.  I had a lume that ran up the driver side inner fender, but instead of running the wires through the loom and out one spot near the radiator, the wires were literally draped across the engine compartment under the intake boot.  GRRRRrrrr.....  So I took them all off, lengthened them if needed, and loomed them up in the loom.

Here they are going back into the loom. The red and black ones that are capped off are the choke power and AC compressor wires that are not used in this car.


Once back in the loom you can see just the two wires going to the coil (tach and coil-power) sticking out.


The loom will take the wires passed the battery to the radiator.  From there the headlights and related wires separate from the engine harness.


I even wrapped the CIS injector hoses together with electrical tape and a zip-tie to keep them together.  Better than having spaghetti hoses in my opinion.


Here you can see that I wrapped the fan motor wires together (along with an alternator wire) with electrical tape.  Instead of using the electric fan circuit found in the harness, RS had built a simple harness going straight to the battery with an inline fuse.  Since I already had a fused wire for the fan, I deleted the new harness and used the car harness.

Below you can see the two body harness feed wires going to the hot terminal on the starter.  Those were also cut to size and taped together in like fashion to keep things neat.

Backing out a bit you can see how I ran the wires together from the loom next to the radiator to the starter and engine points in the general area.  Still needs some cleaning from this point.


Here it is after a little more cleaning.  I still had a few zip-ties to add after this shot, but you get the idea.  Definitely not the spaghetti that I had before.  Ultimately all the wires will be in a smaller loom that will cover the headlight/parking light wires as well, but that will be later.


Since I was running out of daylight, I wanted to get the car back together.  I figure it was running before I started, and I wanted it running after as well.  So I stopped where I was and put things back together to make sure it still ran.


It started again, so I closed everything up, cleaned all the wire-tie and snipped wire carcasses and went inside.  I certainly wish I had more time and someone who was comfortable with CIS injection.  That will be cleaned up next.  Once I'm certain the wiring is right, I'll start trying to figure out why it runs so rough. 

So till next weekend.:wave:

[719MKV]

no pics are working... and hit me up this week/end and i'll help tuck and such... sorry about today, been building my SRI for the rabbit and cleaning the garage and doing some prep work on the Jetta...

[snoopy]

Pix fixed.  Darn site!

Anywya, I have an appointment in Denver on Saturday till around 3pm.  Maybe after that will work.  UPS has been keeping me busy despite the Christmas holiday being over!

no pics are working... and hit me up this week/end and i'll help tuck and such... sorry about today, been building my SRI for the rabbit and cleaning the garage and doing some prep work on the Jetta...

[snoopy]

Time to update the thread.  But before I do that, I thought I'd share this:
http://www.dandcextreme.com/upload/jetta/jettamotorruns.avi
Its a video of how it ran after getting the 'Rocco' harness and injection put on it.

The gas is WAY old...so I wasn't to worried about how 'rough' it was running...but all the same.  While I was talking with a local VW guy (Dave) about his caddy (seen later) ~ I learned that he had removed the CIS-basic injection system and had installed a SDS (simple digital system) in its place.  Dave is about to go ITBs and re-worked head w/ cam on his 9a motor.  So I asked him: Still got the old basic system?

Him: "Ya"

Me:"How much do you want for it?"

Him: "Make me an offer"

Me:"Dude, I have no idea what they go for"

Him: "Give me $75 and its yours."

Me: "What's your paypal?!?!?"

So with any further adieu....anyon e want a fully intact Rocco engine harness, fuel distributor, complete with knock boxes, ignition circuit and all?


As you guys know, I'm a stickler for trying to keep things clean (though you wouldn't know that from looking in the interior yet).  So I have to say I was happy to see the effect of having the Rocco's motor harness out of the engine bay.


Having little experience with CIS (but getting more everyday), I 'arranged' to get Dave over to help install the CIS-basic system.  Here's a crappy picture of his caddy.


But the Jetta was sitting in the driveway ready for some lovin'.


The master approaches.


Once the Rocco fuel dissy was removed, we took the fuel supply line and put it in a 3 gallon can.  Since my fuel pump will remain on when the key is in the 'run' position, The first order of things was to get rid of the REALLY bad gas.

There was actually 3 gallons in the tank, so after the gas can was filled, I dumped the old fuel into my 15-passenger van's 33 gallon tank (which was almost full of good gas) to get rid of it.  Later we'll use some NEW premium gas to get this thing going.

While dealing with the fuel, Dave, dressed like a Dark CIS Jedi, got out his 'junmkyard' back of tools and started to work some magic.

That was the 450th picture on the build so far...boy I need to get a life!

Tackling one thing at a time, the CIS-basic fuel dissy went in, then the warm-up regulator...


Soon the motor was looking pretty good.  I was shocked at the lack of wires of the CIS-basic system....more like PLEASED!


Here's Dave relocating the warm-up reg to the side of the motor (vs. the front).


After that, and completely out of light, we cleaned up, and headed home.


The only thing we didn't do is: Install ignition circuit, get new gas and cycle it through the fuel system, and test fire.  That will come later.  The plan was, unless another ignition circuit presented itself, Dave would separate the circuit from my rocco harness in the comfort and warmth of his own home and bring it back over for installation.

More to come...

[snoopy]

Well, at the end of that last post Dave (and I) had only installed the injection system.  No spark yet.  He came over last weekend to finish the job.  He had taken my rocco harness home to separate out the ignition circuit, but decided that instead of cutting up a perfectly good engine harness, he'd just give me the one out of his Caddy (since he was going to coil-packs) on his SEM (standalone engime management) anyway.

He's keeping the rocco harness for the time being in case he needs to move the Caddy and the coil-packs aren't shooting properly.  But anyway ~ he came over this last weekend to put everything in and see if we could get the Jetta running properly.  After an extremely short time (like 15 minutes) the Jetta fired and roared to life.


http://www.dandcextreme.com/upload/jetta/jettaruns1.avi
http://www.dandcextreme.com/upload/jetta/jettaruns2.avi


After that, we tempted fate and got in for a drive around the block.  No video, but we did make it without any problems.  I only had 2 bolts per CV shaft so I didn't push it, but it had plenty of 'umph' and I look forward to getting it to 100% again.

Another buddy of ours has been tackling a turbo in his GTI so Dave had to run and help with that project.  And I was left knowing that my car was MUCH closer than ever before to running properly.  Besides, I was late to go paintballing with some youth with my church...so... .[COLOR="White"](What can you say when people needed shooting).[/COLOR]

Well, the last couple evenings (into the night) I've been working on doing what I can to clean up the engine bay as much as possible.  Re-re running wires.  Figuring out what needs finished and doing it....stuff like that.  Gratefully, I'm making progress, and will take some pictures later to document everything I've been doing.  Night one was installing more CV bolts, finding the wires left under the dash that need terminated, and then finding how to terminate them all the while testing the circuits to make sure they still worked (you never know). 

Night two (last night) I spend a ton of time back in the engine bay.  I installed a coolant temp sensor for the Autometer gauges and attempted to do the same on the oil-preasure.  I say attempted because I failed to be able to install the sender (which is big) into the small cramped space where it needed to go.  I'll take pictures later.  I also spent A TON of time re-relocating the hard fuel lines. Then hooking them up.  Then taking out the just installed ignition stuff from dave, only to clean it up, loom it better, and put it back in. 

Now that its light again.  I think I'll go see about taking some pictures.  With any luck, the car will still run too.  :laugh:

[snoopy]

More updates...this time, pictures.

Well, first ~ to get to the area I need to get too...I need to move the overflow.  Let me say...is there a way to permanently move this 'bottle' over here to the passenger fender?  I prefer not to have to do this every time.  Its messy :thumbdown:


That said.  After a few hours tinkering.  Here is what the driver side looks like now.


Which is a far cry better looking than before: 


Another shot...I've still got a few things to wrap up and clean up, but still....


Things did: 1) CV bolts.  I have a trans out of a 87 GLI so the metal straps didn't fit around the CVs, but at least the bolts are there now.


Tried to put in the oil pressure sender on the filter housing, but it keeps hitting the plastic thingy...which I think is the PCV hose.  Anybody got ideas what to do here?


By far the most time was spent moving the fuel feed/return lines around.  They were draped over the top of the motor which made everything hard to do...so I spent a bit moving them so that they pop up from under the brake master cylinder.


Here's a shot of the looming and taping I did.  Basically I'm messing with the main engine loom again.  The big changes were my two aux ground wires were put into the loom, and the coolant temp and oil pressure were taken out of it.  The taped up wires next to the loom are the brake-light switch wires (my Jetta has the switch on the master cylinder as seen) and the second set of wires is for the back-up lights. ~ which we'll talk about later.
 

I installed the coolant temp sensor off the head near the distributor.  When I took out the old item in this hole, coolant came out so I figured I'd use it for the new sender.
 

A bit of time was spent cleaning up the ignition wires....
 

Basically I wanted to loom them together in one loom.  Previously they were close, but a few wires needed their lengths to change to make it more neat.  So that's what was done. 
 
I also shortened the vacuum hose so that it could be 'grouped' with everything else.

[snoopy]

With that, there are only 3 wires left to mess with...


One is the biggest pain.  Its the back-up lights.  Sure, I can simply use a switch and turn them off and on as I please...but I prefer to install them to the trans so they light up when I go into reverse. 


However...this is the plug/thing I have in the trans. 

and I'm not sure at all how to hook up the wires to that.

As a back ground: the trans is out of an 87 Jetta GLI.  I just had it rebuilt and its an 020 w/ LSD and .7 diesel 5th gear.  Which prongs in the plug are responsible for the back up lights?  Can I get a better looking 'plug' out of a junk yard, bolt it on, and use the stock harness (the part that plugs in) to hook the wires too?  Why are there 4 wires?  Can anyone help me out here?


So there are a few questions I have for those who can lend a hand or give advice:
1) As stated above, what prongs in the plug are responsible for the back-up lights, and can I simply get a plug from the junkyard to ease hookup?

2) Anyone have ideas where I can install the oil pressure sender?  Got pictures?

3) Is there a way to move the coolant overflow/fill 'bottle' to the passenger side inner fender?

Thanks for any advice you can give.

[Smokestack]

I'll try and take a stab at answering some of your questions. The car is looking good though.

1) That plug was used in conjunction with the upshift indicator. I can't remember the pin out (been several years since I messed with one), but brokevw should have the info here.

2) For the sending unit you should be able to pick up a T at Lowes. I think it's a 1/4" NPT fitting, but you can take the sending unit with you to check. There's also a port in the back of the head around the corner from the distributor for the upper oil pressure switch (which probably isn't being used anymore in your case).

3) If you can route the hoses over to the other fender you can do it. A lot of people just delete them though (look at Jame's rabbit). I tend to like them over there because they hide the clutter coming out of the firewall and aren't really hard to move out of the way.

This going to be at the next GTG? Also, FYI a broken dipstick funnel is a vacuum leak. Last time I bought one from VW it was $2.

[snoopy]

Sold some parts the other day and that is bitter sweet. 

Bitter because I could have gotten everything I needed for the motor ~ but DIDN'T.

Sweet because I just eliminated a bunch of personal debt.:D

Man, I had a hard time figuring out what to do [sigh].  It was one of those moments when you realize ~ "hey, I can get the engine awesomeness that I want....RIGHT NOW!"  But at the same time your brain says:"Dude, didn't you want to pay off all your debt by July? ~ You know, this should really go towards that instead.  Besides, you've got a pretty rockin' motor in it already...just run that for a while..." 

At last, I knew what I should do...but man the temptation was SOOO THERE.  So finally, to rid myself of the devil on my shoulder, I told my wife about the funds becoming available and we talked about where they should be applied.   I, of course, informed her all about the moral dilemma I'd been toiling under ~ TWICE.  She emphasized for about a half second then brought me right back to reality. :laugh:

Anyway...I had to share that. 

Kinda like talking in 'group' I suppose. 

I feel better now. 

Carry on.

[719MKV]

Kinda like talking in 'group' I suppose. 

I feel better now. 

Carry on.

Hhahahaah I think we're in the wrong group then... I spend all my money on the cars then Im like WTF.

[snoopy]

Speaking of:
6 meters of 15oz. new WOOL....ordere d.


Delivery time frame: Late March ~ They have to weave it special for me.

I know...I know.  But now I'm outta money and can't get the motor parts I wanted.

[snoopy]

Well, after quite a bit of drama with the Jetta, I got it going! 

Man, what a pain.  But called the Insurance lady today and put the coverage back on it.  Even took it around the block.  First gear, hit the gas...both tires roasting ~ got LSD? (I do).  Then Heard the lite snap of a few blow and my gauges froze.  Changed out the fuse, added a few that I knew I blew removing the dash the last time (but didn't fix till it was all back together) and now I got most of my electrical back.  The car needs some serious tuning and tweeking, but it pulls pretty decent for having just come alive.

Just need to get the pin-out for that trans plug to make the reverse lights work, got the brake lights working good.  Blinkers and headlights all good.  Time to hook up the horns, then find why the gauges blew the fuse (prob just a routing issue),  clean/paint/reassemble the remainder of the dash.

[Smokestack]

...Just need to get the pin-out for that trans plug to make the reverse lights work...

Since you didn't look at the link I posted....



 

Looks like you're getting everything sorted out. Are you going to bring it out to a GTG anytime soon?

[snoopy]

Since you didn't look at the link I posted....

 

Holy crap.  Sorry man, I'm on Firefox and it doesn't change the color or underline links.  I totally missed it!  Thanks

Looks like you're getting everything sorted out.

Slowly but surely, yes.  I've been head deep in clearing out Scout stuff lately.  Trying my hardest to shut D&C down for good with everything settled.  So time with the Jetta is very limited.  Kinda sucks really, but eventually it'll be a cool little car that runs! 

I've actually asked for an 8hr tomorrow, meaning, at UPS you have to specifically request only working an 8 hour shift [you get two per month by the contract].  So hopefully they'll simply let me have the day off to keep working on the little monster.  Man, it'd sure be nice to finally get that road worthy and reliable after all this time!

Are you going to bring it out to a GTG anytime soon?

As soon as its to a point I can drive it without worry of leaving me stranded ~ DEFINITELY!  I actually look forward to it and wished it had happened by now, but you know how things go.

Right now, it is really hard starting.  It cranks easy, and if I spray starting fluid in it, it'll fire lickity-split.  The problem is that it only sort-a-fires just by itself.  What I do is hold the gas down to get air movement through the dissy, which keys the fuel to injectors, then after about 2 seconds full throttle, I take my foot off the gas and it fires up momentarily.  If I get it to rev, I can sort-a keep it running.  Once it warms, its better, but what I just described takes a few minutes to get it to run to a point I could drive.  Of course, once its in the RPM range, it'll rev like nobody's business.

My hope is that after a few gallons of fresh gas get through it, the engine will start acting better.  After pumping out the old gas, I put in 3 gallons of fresh premium mixed with a full can of seafoam into the tank.  I'm also going to flush the oil system and seafoam that and the intake system as well.  Right now I'm using the old fuel filter from James ~ purposefully.  It is pretty dirty, meaning when fuel leaks from its 'inlet' it is nowhere near clean, but I figure running a few gallons of seafoam'd fuel will loosen the crap in the system and put it through the filter.  I at least don't kill a new filter right off.  The plan is to put a few miles (like just the 3 gallons of gas) then refuel, re-filter and perform as major a tune-up as I can muster. 

Then go from there.

[Smokestack]

Generally hard starts and poor idle are from vacuum leaks. Check for cracks in the intake boots or leaks around shafts, adjustment screws, and injectors.

[snoopy]

Well.  Lets update this a little bit.

I did get the Jetta going finally.  The new gas helped a ton.  But the next problem was hard starting.  If I quirt Starting fluid in it, it'd fire up immediately, but short of that.  Well...lets just say i went through a can of starting fluid.

To be honest, there was no IAC/IAV (Idle Air Control/Valve) NOR was there the 5th Injector wiring from the system I got (apparently that's apart of the old body harness that I got rid of a bit ago). And here in Colorado, it gets 20 or lower at night, and we see 40-50 if we're lucky during the day.  So I posted a question about it, and got a universal "YOU NEED THE 5th INJECTOR" for my answer.

So I started trying to figure out how to make it work...again.


One morning while I was tossing this around in my head, I thought:"How am I going to key this thing and pulse it properly to give enough fuel when cold?"  Then I figured: "If I put a power and ground to it, I wonder if it'll squirt?!?"  So that's what I planned on doing. 

Victor (my Russian comrade from down the street) saw me out working and came over to see what I was doing.  I handed him the camera and said here take a picture of the injector while I hold a lead to it...instead, he snapped a picture of me. 

Yes, I'm old. 

Now to test the injector.  No power:


POWER!  Or as Jeremy Clarkson would say: Pow-waaaaarrrrrr!


Test successful.  Its time to re-install the injector and wire it!  Since I have a spare 9a in the garage, I pulled the fitting that mounts the injector of it, and using some vacuum caps, prep'd it for duty on the new motor.


Then I ran the 'power locks/windows' wire from the toggle on the dash through the firewall, along the engine loom....


...Up the fuel dissy, and along with the fuel lines to the 5th injector.


My buddy James just removed his CIS from his Rabbit, so I went over and grabbed the plug for the injector off his old stuff.  Connected everything, tied it away....and this is what it looked like.


Threw everything back together and waited for everything to get cold (so I can test it).

This picture brings me back to the thought: I HATE MY ENGINE BAY!  Sorry. But its not clean, organized properly, or pretty.  Its gross.  I hate it.  I wanted so much more from it ~ my last bay seemed much cleaner:


So I'm planning on building another motor for this car, then totally cleaning up the bay when I swap it.  For the time being, I think I'll find a good power-washer and give it a good hosing!