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Hacked II: Getting a 1983 245 Back On the Road

ortho stice

Member
Joined
Feb 9, 2015
Location
Braddock, PA
The pump timing can't be that far off if it's running at all. Loosen the bolts and twist on it, hillbilly tuning style. That's actually how I did every VW 1.6l I ever worked on because I didn't have the dial and wasn't going to bother getting one (I was younger and much poorer).
 

fatcatbestcat

Professional Hack
Joined
Oct 1, 2019
Location
Mississauga, ON (Canada)
The pump timing can't be that far off if it's running at all. Loosen the bolts and twist on it, hillbilly tuning style. That's actually how I did every VW 1.6l I ever worked on because I didn't have the dial and wasn't going to bother getting one (I was younger and much poorer).
Yeah, that's what we tried. We pulled it out a little (from being all the way "in") and it did the same thing, but worse.
 

fatcatbestcat

Professional Hack
Joined
Oct 1, 2019
Location
Mississauga, ON (Canada)
I forget, do these have the advance lever in the cabin for cold starts?
Nothing in the cabin that I'm aware of, no. Again, I'm not super up-to-speed with diesels, but there's a cold start device on the side of the pump. It includes a lever that pushes against the throttle plate when cold. It's automatic, and to my knowledge there's no way to control it manually. We tried starting it with and without the cold start connected, and it didn't have much of an effect.

It's hard to explain. When the pedal is depressed all the way, the car runs at probably double idle speed, halfway depressed is idle, and anything less causes it to sputter and die.

IMG_20230206_143334938.png



There is one thing still nagging at me, though. For the most part, the throttle assembly was set up correctly (enough that it should at least idle)... but now I'm wondering if somehow I screwed up the throttle shaft on the pump. You see, the gas pedal in the cabin is connected by cable to the spool, which has an arm that pivots a plate, which is attached to the threaded shaft on the top of the pump.

1676001280913.png

It makes me wonder if it's possible that I moved the shaft a whole bunch before assembling it, thus only giving it like 20 degrees of travel, and in the wrong place. It's not too much work to take that all apart, so I might partially disassemble the throttle assembly and see if that's something.
 
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nordmaschine

forced instruction
Joined
Feb 12, 2012
Location
The Balkans, BiH
Yeah, I realized this a few days ago when timing the IP pump. Somehow it never occurred to me. I'm not used to dealing with motors with overhead cams, so I miss things like this, mkay?

At the very least this confirms my cam timing is good and that there's no way I put it in backwards... right?
Yep, no way to put it backwards.
OHV engines work the same way, still two crank rotations for one cam rotation.

Throttle shaft - yes, you could have missed the alignment. You should always mark the plate and the shaft before taking it off. You're probably not too far away, try putting it on one spline CCW. Also, it could be just the case of still having air in the system.

As for cold start - you can move the lever towards the front and hold it there or zip tie it...
 

fatcatbestcat

Professional Hack
Joined
Oct 1, 2019
Location
Mississauga, ON (Canada)
Throttle shaft - yes, you could have missed the alignment. You should always mark the plate and the shaft before taking it off. You're probably not too far away, try putting it on one spline CCW. Also, it could be just the case of still having air in the system.
The throttle shaft thing is only one nut to remove, so I guess it can't hurt to try and see if that helps. I took it apart probably close to a year ago, and am of course cursing my 1-year-ago self for not marking it.

EDIT: It was a little bit out of adjustment, and I tuned up the throttle as per the greenbook. Same result. Needs to be started with the throttle on the floor, and it doesn't stay running if you let off.

C´mon! You are almost there! Dont sell it. You can do this. Just add some patience :)
I hate to say it, but it's more or less a done deal at this point. The entire reason for my sudden change of pace and desire to get it back together in a (relatively, by my standards) short timeframe is because I was trying to sell it. I'll spare you the sob story, but I'm not in the best financial situation right now, and I would much rather have the money than a moneypit.

Buyer's remorse on my part? Definitely. I originally had plans to engine swap it, and I had actual heated shop space (with a lift!) lined up with a friend and it just didn't work out due to a number of complicating factors. Thus, I ended up in the same situation as the 144, working on a car that needed a lot more than I could give it in the cramped space I have. Sure, if the pump timing had been dead-nuts (or if it is indeed a throttle adjustment issue), it would run but the car still needs every bit of rubber on it replaced, and I don't think I can give it that. Even if I did somehow manage, then I'm left with what is at best a really slow weekend car that uses the most expensive fuel available at my local pumps.

I feel a lot better about pretty much breaking even and handing it off to someone who is both a lot more qualified than I am to deal with the D24, and someone who's more excited than I am about having a basically rust-free stick 245.
 
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OldCarNewTricks

Well-known member
Joined
Oct 23, 2016
Location
Oregon
The throttle shaft thing is only one nut to remove, so I guess it can't hurt to try and see if that helps. I took it apart probably close to a year ago, and am of course cursing my 1-year-ago self for not marking it.


I hate to say it, but it's more or less a done deal at this point. The entire reason for my sudden change of pace and desire to get it back together in a (relatively, by my standards) short timeframe is because I was trying to sell it. I'll spare you the sob story, but I'm not in the best financial situation right now, and I would much rather have the money than a moneypit.

Buyer's remorse on my part? Definitely. I originally had plans to engine swap it, and I had actual heated shop space (with a lift!) lined up with a friend and it just didn't work out due to a number of complicating factors. Thus, I ended up in the same situation as the 144, working on a car that needed a lot more than I could give it in the cramped space I have. Sure, if the pump timing had been dead-nuts (or if it is indeed a throttle adjustment issue), it would run but the car still needs every bit of rubber on it replaced, and I don't think I can give it that. Even if I did somehow manage, then I'm left with what is at best a really slow weekend car that uses the most expensive fuel available at my local pumps.

I feel a lot better about pretty much breaking even and handing it off to someone who is both a lot more qualified than I am to deal with the D24, and someone who's more excited than I am about having a basically rust-free stick 245.
Oh man, don't disparage yourself. Life and money are hard sometimes.

Great job getting it this far. What's great is that you learned some things from this project about application specific (D24) things, but I am sure also learned more about what you do/don't enjoy, as well. Do you think you will end up getting another brick in the future?
 

OldCarNewTricks

Well-known member
Joined
Oct 23, 2016
Location
Oregon
So there it is, the end. For real this time.

IMG_20230212_152402009_HDR.jpg

IMG_20230212_154759772_HDR.jpg


IMG_20230212_163501916_HDR.jpg

IMG_20230212_163758884.jpg


So there it is. The official end of Hacked II. I'm still hunting around for jobs, but if that goes "well", I might have something new to post about come the spring or the summer.

Thanks for reading so far.

Well, darn. You did do quite a bit to keep this car on the road. Good job.

Looking forward to seeing Hacked lll. Also, wish you the best on the hunt for a job.
 

fatcatbestcat

Professional Hack
Joined
Oct 1, 2019
Location
Mississauga, ON (Canada)
Well, darn. You did do quite a bit to keep this car on the road. Good job.
Not as much as I wanted to, sadly. I think my biggest accomplishment is that I got the timing on the engine so that it wouldn't explode. Otherwise I don't think I would have been able to sell it.

There probably will be some project car updates in the interim before I have a new project to work on. I'm actually headed up to the new owner's place in a week or two to give him a hand in getting the car to run right. The 144 is still around, though apparently parked in a field - so that story has gone full circle...
 

ortho stice

Member
Joined
Feb 9, 2015
Location
Braddock, PA
Yeah get it to run at his place! You have to drive one of these cars at least once!

Also, the first two projects I bought ('79 Rabbit diesel, '92 Cabriolet) I never got to drive for various reasons, so don't beat yourself up too much.
 

Broke4speed

Well-known member
Joined
Oct 5, 2009
Location
Marionville, Ontario, Canada
Yeah, the number of non-running project cars I've sold due to deciding it wasn't a great path to go down is not small. It's always a thing, and there's no shame in it. Everything you do stacks more knowledge away for the future, and future projects :). Just cause this one didn't pan out, doesn't mean the next one won't.
 

fatcatbestcat

Professional Hack
Joined
Oct 1, 2019
Location
Mississauga, ON (Canada)
Yeah, the number of non-running project cars I've sold due to deciding it wasn't a great path to go down is not small. It's always a thing, and there's no shame in it. Everything you do stacks more knowledge away for the future, and future projects :). Just cause this one didn't pan out, doesn't mean the next one won't.
I hope you're right... third time's the charm, right? I think I'm going to try for a redblock car next time.
 
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