This dives right into replacing a mechanical fuel injection system on a 1981 VW diesel Rabbit with a 1.6L engine. Bosch VE pump.
Installing pump, injectors, and fuel lines.
You should still use a service manual, this one is very good but hard to find: Volkswagen Rabbit/Scirocco/Jetta Service Manual, 1980-1984: Including Pickup Truck, Convertible, and GTI (Robert Bentley Complete Service Manuals)
This one is less good, but you can get it easy from amazon:VW Rabbit Diesel 1977 thru 1984 (Haynes Manuals)
Everything is in chronological order -- it starts with the fuel system already out.
A word about the motivation for this instruct able:Motivation:"assembly is the reverse of removal"
There are very good reference books for working on cars; Haynes, Chilton,
Bently. However they have a few drawbacks; the first is that
most of the photos are black and white and grainy. It is not their
fault, it is hard to take pictures inside the engine compartment or
under the transaxle. The second major drawback is the statement
"assembly is the reverse of removal". Most manuals are based an a
complete teardown of the vehicle. This is very useful if you want to
take a car apart peice by peice. However, once you take the car apart
and have peices all over the garage, spilling out into the drive way
and family room. You are generaly left with these instructions
"assembly is the reverse of removal." Even if you follow the
instructions backwards, line-by-line it is very difficult to get
everything back together. In my opinon these books should start with
a pile of parts and end with a completed vehicle.
So I have started this instructable with parts all over the place and
every bit of timing out of sync. Hopefully, when you hit the words
"assembly is the reverse of removal", you will find this instructable
and it will help yout out.Why repair a car from 1981?
55 miles per gallon, no modern emissions rules, cheap parts, and cheap
Why diesel? Well, check out the work being done by Rudy Behrens of
He is building living robotic systems that grow oil rich algea and
process it directly into usable diesel fuel.
Here is a nice article on the project: here
What else do you need to know?
Where to get parts:http://www.partsplaceinc.com/
-- These are VW specialist, every part has been perfect. Very good if you want to buy 'kits', such as all new hoses or a complete engine rebuild kit. They also carry many specialty tools and such. They are a 'real' store, so you can get them on the phone an they will be able to help, keep in mind that they are also minding the shop, so they might be busy with physical people.http://www.partsgeek.com/
-- Often have the best prices (not always though) good for pretty much anything for any car, but the descriptions are very brief so you need to be careful when ordering. Fast shipping.AutoZone
is okay, but prices are sometimes high and some parts ship slow, if one part is back-ordered or custom they delay the whole order. Of course there is probably one near by, so you can go there in person, cheap fluids - expensive tools. I like smaller stores better.
Local salvage yard -- In New England you will be about salvage cars tend to be around 10 years old.
Ebay -- I have not had good luck.
Amazon -- Look for deeply discounted professional tools. I used this and it worked: VW/Audi Bosch Diesel Fuel Injection Pump Timing Indicator Tool
Harbor Freight -- most of my car tools are from here, go to the store if you can. I like the color coded wrenches/sockets.
Home Depot -- not too useful.
Craigslist -- Look for someone who is getting rid of a garage full of VW parts, or a parts car.
Also -- The car I am working on is the former ' Clean Machine ' from Gordon Collage in Mass.
Also - I like this wrench set from Harbor Freight because I can remember the colors.... link