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Post by Volktales on Nov 4, 2017 18:20:13 GMT -8
Well here is the new project you have all been waiting for in all its glory... No it is not mine, but is always a VW that I had an interest in. The car is Reagh's 1969 VW 1600 sedan, commonly known as the Notchback. His L 60B Peru Green Deluxe has an interesting history and Reagh can tell that tale... This vehicle also is equipped with an automatic transmission, something that VW spelled out with chrome on the engine lid. So what does it need? It has not been in running condition for many years. When Reagh first got it, the fuel pump had failed and he took it to a VW "specialist" to repair it. Except they didn't seem to get past removing some parts and misplacing them... The original fuel injected engine is missing the throttle body/intake distributor, which is specific to this year and automatic transmission. I hope Reagh has a replacement in his stash! My job is to make this run again, which I am sure it will eventually... The original owner must have been a BIG fan of BCAA. There are at least ten stickers pasted throughout this car! Interior is quite decent, other then the usual split in the dashboard. Fortunately Reagh has a much better one in his stash which will be swapped out. Car has never had a radio fitted. Seats all have covers over the original material. Curious what condition they are in underneath... Car has 24,730 miles showing, which has surely been around once before. The biggest issue under the hood is that fuel tank. Talk about gross on the inside! You can see the rust inside the sender hole, even in this picture. The filler neck is full of flaky rust too. It is highly likely that this was the reason the car stopped running in the first place. Hopefully Reagh has a good spare tank in his stash, along with the missing fuel gauge sender (which was probably a rusty blob and thrown away earlier)... The front fenders have the usual Type III rot, and have been previously "repaired" before by bashing down the rust, and laying on the fibreglass and bondo. I guess these were the usual repairs on these cars because they all seem to be like this... This fender must have been really bad because it was already gone. There is the headlight bowl hanging from the wiring, that rotted completely off the fender! However the inner fender structure has survived quite well with less rust then my Fastback. Still Reagh needs some better fenders, and he has some not too bad spares. Except they turned out to be for an earlier model, and have different holes for the signal lights, and more importantly, no gas door! This is going to be a problem. I will donate my Fastback's old fenders, but they need rust repair too! Hopefully Reagh will find something, because the car is in nice enough shape otherwise and deserves to be done well. Now time for some more work...
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Post by Volktales on Nov 4, 2017 18:43:48 GMT -8
As previously mentioned, the first job was to change the oil. This sticker is likely the last one too. The insurance expired in February of 2002, and I bet the car saw few miles in its last years on the road. The oil was last done in 1999... Under the valve covers was not pretty. Dirty caked up surfaces don't make me happy. And the adjusters were ALL seized up too. Only thing to do is remove and clean everything. At least everything was not worn under all that sludge. It all cleaned up nicely and went back together without incident. Heat is your friend. My small propane torch came in handy. Each adjuster freed up nicely with a bit of heat. One adjuster was replaced due to a chewed up head, but the rest were all just fine. Once reassembled, the valves were all adjusted and then the plugs were pulled. Older NGK plugs were not worn. Next a battery was hooked up and the engine was cranked over (ignition and fuel systems disabled of course). It turned just fine and the oil pressure light went out soon. The compression was tested and found to range from 115- 125 PSI which is OK for this engine. Next up is to pull the tank and have some fun with the rotting fuel lines. The entire fuel system will be removed and cleaned. Luckily I have a lot of parts that came with my Fastback, so we should be OK there. Reagh has supplied another fuel pump which hopefully works. If it doesn't, this is not the end, because there is a specific Ford Ranger pump that apparently works just fine in this application. Who woulda thunkit???
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Post by Wongai on Nov 4, 2017 20:02:11 GMT -8
Thats killer. Really cool mini project! B
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Post by CrazyBrit on Nov 5, 2017 9:00:53 GMT -8
That looks like a nice little car. Let's see it on the road!
It will look really good alongside his DC.
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Post by PICTUP on Nov 5, 2017 18:30:26 GMT -8
A theme of green
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Post by Volktales on Nov 13, 2017 8:25:49 GMT -8
Been doing some more work on the Notchback. More pictures should be up tonight...
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Post by Volktales on Nov 13, 2017 19:48:42 GMT -8
It is much nicer working on something that is clean. Almost 50 years worth of dirt under the tank, so lets make that better. And better it now is. Used my favourite purple cleaner (SuperClean). Worked well although still some caked on ick on the front beam to deal with later. Note the wrong fuel pump installed, likely off a bus. And a bit too gross in the engine compartment too... Did you know there is green paint under all that dirt? Getting better. That electrical goody in the centre of the picture is the relay that controls the cold start jet. More on this later... At least now everything is clean. Even if it is not working yet! But look what Reagh found hiding in his garage! It is the missing intake air distributor! The very one from this car, too. Very happy he found it at last. That little spigot on the back is a one year only item. It is actually a cold start jet, that gives an extra shot of atomized fuel into the intake under certain conditions. This function was not originally designed into the Type 3 D-Jetronic fuel injection, and was added sometime in the 1969 model year. Reagh's car is a factory installation, whereas my Fastback is not equipped. This system was also available for retro-fitting as well. Continued...
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Post by Volktales on Nov 13, 2017 20:30:53 GMT -8
This diagram shows the parts that make up the cold start jet system. Note that item #16 is an electromagnetic solenoid that controls when fuel under pressure is allowed to spray through the cold start jet. Unfortunately this part is missing from Reagh's car, and likely has been missing for years prior to his ownership. In reality the cold start function for 1969 is not necessary under most conditions, and is only active at temperatures below -15 degrees Celsius. Newer versions where modified again and operated at much warmer temperatures... Keep in mind the Bosch injection system used on these cars was the first electronic system mass produced by any manufacture and many things were tweaked as development continued... Here is a picture of an actual valve, the same as #16 in the diagram above. Any of you with a parts stash have one of these lying around? Specific to 1969 models only, and also on retrofitted earlier models... Here is something rare to find these days. The original '"M-codes" printed on the fan shroud. This lettering is very delicate, and washes off easily. The numbers are: M236 S723 and M229/249. M236 is fuel injection equipped, S723 is unknown, M229 is cold start equipment set, M249 is automatic transmission. Sooo, now the question of fuel hose. If you spend any time on theSamba, then you know fuel hoses are all to problematic these days. The original style woven "German" hose does not seem to be holding up to Ethanol laced fuels very well. Also Type 3 injection systems run at relatively lower pressures then modern systems, so some people do not use injection rated lines. For this project I chose what is currently thought to be the best stuff, Gates Barricade hose which is rated for ethanol laced fuels and high pressure. Lordco now carries this stuff, but it is significantly more expensive. It better be good... As an aside, I was intending to buy a simple drip tray from Lordco. They did have one, and it was a very basic plastic rectangle with a small raised lip around the outer edge. Probably less then $1 in materials in its construction, and realistically would be a simple molding. So how much did Lordco want to charge for this item? The counter guy said "I think they are around $20". Ok that is stupid because the much more complex and larger drain pan/bucket was only $22. Then the counter guy looked up the real price. "Sorry it is actually $50", and he said it with a straight face too. Get real, Lordco. Although their part prices are relatively reasonable on many items, their "tool" pricing is just stupid... Who the hell would pay that much for a drip tray? Ever? Rant over for now...
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Post by tony on Nov 14, 2017 10:09:17 GMT -8
Nice and clean but doesn't work , kinda' reminds me of me , except for the clean part lol
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Post by Wongai on Nov 14, 2017 10:19:22 GMT -8
Those m codes are dang cool! Amazing that you guys found the intake air distributor. I imagine that was the a needle in the haystack situation. Good hunting!
Lordco is a last resort for me. Only desperation will bring me to Lordco. I worked right next door to the Lordco in Langford for years, but I would drive elsewhere to get my stuff. I do like that they have JET tools, but they are stupid expensive. And the level of disdain the Lordco counter staff has for their customers is not well concealed.
Appended rant over...
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Post by CrazyBrit on Nov 14, 2017 19:10:54 GMT -8
To be fair to Lordco, if no-one else has it, they generally do. I have found that what they sell is usually decent quality and the staff in the North Nanaimo location are always friendly and willing to help. I'd take them over Crappy Tire any day (even if I do buy some of my tools there because I'm cheap)
I need to get some of that purple clean stuff. I know there's yellow paint under the dirt on my Ghia😁
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Post by tony on Nov 14, 2017 19:30:47 GMT -8
Careful , that might be structural dirt!
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Post by CrazyBrit on Nov 14, 2017 21:46:10 GMT -8
Largely dirt on my Ghia thankfully!
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Post by Volktales on Nov 21, 2017 21:41:22 GMT -8
Sooo, didn't get all that much accomplished this week, but still going through the process of trying to fix stuff before giving up on it and buying new. First up was disassembling the fuel tank sender to see if it was salvageable. Thant tiny brass nut was well and truly seized to the central stud. Soaking in Moovit for days did nothing, so finally I had to heat it up with a mini blowtorch (originally found in one of my buses). This worked and revealed that the inside hair wire was intact, along with the contacts on the float assembly. You can barely see the hair wires next to the central stud in this picture. Like the sender in my Fastback, I will attempt to repair this one, as the new replacements are garbage quality as usual... This sender is not the original from Reagh's car, but one from an earlier 1964 model. These don't appear to be voltage specific, so it should work. Hopefully. Fuel pumps are another issue... The original from the car is missing, Reagh supplied the one on the left as a replacement. The others were spares supplied with my Fastback, although I am sure one of them is a spare that Reagh previously supplied me with at the time. So I rigged them up to a battery and tested them. The verdict was two were seized up, and two spun fine. Unfortunately none of them would pump any fluid... So, I had nothing to lose by taking things apart... Started with one of the seized up ones, just to have a look. It was obvious water had contaminated the fuel in this pump, thus ruining it. For fun i removed the rusted pump parts, and freed up the shaft with pliers. Electrically the motor ran after this, but the rust has made it impossible to put back in service. But what about the remaining two??? This picture shows the underside of the pump cover; the part that contains the three spigots on the pump. One spigot is suction from the tank, the center one is pressurized output to the injection system. The third port is a return spigot to the tank, that only functions as a pressure relief if the pressurized fuel can not flow to the injection system. This relief would stop the pump from stalling out and overheating. Anyway there is a spring loaded check valve, just visible as the shiny metal bit in the above picture towards the left side. It appears that this valve closes off the pressure output port when the pump is not running. Once running, the valve should open far enough to allow fuel to flow out the outlet. The valve was initially stuck from sitting, so the pump would run but not produce any pressure. The valve was carefully cleaned and tried again, but still the pump would not output... Part of this may be due to the fluid I was using. I was not going to try the pumps using gasoline in my basement, so used ATF just to see if I could get some kind of action. Maybe the viscosity is just too much for the pump to open the pressure valve correctly. I will have to try again later with gas, and see if things improve. If not, then i guess that Ford Ranger type pump is the next option... Also the injectors have been cleaned and tested, and should be able to function... Continuing on...
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Post by Volktales on Nov 26, 2017 22:16:29 GMT -8
No picture tonight, but a small update. I took the two running fuel pumps to work, where we had a jug of diesel fuel. I was told on theSamba, that diesel is thin enough that these pumps should be able to work with it. And it was true. The newish looking pump worked perfectly, putting out the required pressure with ease, and the check valve/bypass valve assembly worked properly. Too bad fuel leaked from the pump body where the electrical connectors were... . This would nicely explain why this new looking pump never remained in service... The other pump also worked, but the pressure was unstable, and the motor did not sound all that happy. One of those new Ford Ranger style pumps is on the way... I like leaving vintage VWs as original as possible, but sometimes you just can't... I am also starting to think that ALL of those spare parts that came with my Fastback, were all defective in some way...
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