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Discussion Starter #1 (Edited)
Hi all, after many years and many other cars (both VW and other), I've gone back to a Mk1. In particular, an '81 Caddy.

I am a serial car rescuer. I have a history of buying derelict vehicles and working to refresh or restore them. I also have a lot of history in German cars, and water cooled VWs in particular.

I bought my first VW in 1979, a '78 Scirocco. My wife and I liked it so much that in June of '81 we traded it in to get a new one before the 2nd gen Scirocco arrived for '82. That was my first new car ever, a Cirrus Gray Scirocco S. We kept that car for 10 years.

It was replaced by a new '91 Jetta GLI 16v, as we needed a car with better back seat access for our growing son. We kept that one for 18 years, then gave it to our son after he graduated college. He still drives it today.

Other VWs over the years were an '86 GTI 8v, '90 Corrado G60, and a '10 Golf TDI. When the TDI buyback came, we bought an Audi A3 etron plugin hybrid to be the new daily driver.

My rescue projects over the years have been more varied. A '67 MGB basket case, gray market '81 BMW 323i, '71 240Z, '84 944, '73 914 2.0, '64 Toyota FJ40 soft top, and most recently a '72 911T. Only the 911 is still in my possession. The rest moved on to new owners when the projects were completed.

Anyway, on to the Caddy. I came across it recently. Born as a silver LX gas truck, it now has a 2.0 16v and 5 speed from a '92 Passat. Was parked a little over a year ago with an apparent fuel delivery issue. It sports a rather amateur Mars red paint job, but has a full round headlight conversion.

Not sure how far I'll take this yet, maybe just a quick repair to make it run, drive and do so safely. Or maybe I'll go full boat with a GTI-look refresh.

I'll post some pictures as soon...
 

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Thanks for sharing your project. For uploading photos, the easiest way is to download the Tapatalk app for your smartphone which allows you to upload photos straight from your phone. If you're old fashioned then I'm currently using www.imgur.com to host and hotlink photos, but there are a couple of other sites as well that still allow hotlinking.
 

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Discussion Starter #3 (Edited)
I'll look into using Tapatalk, although I dislike using my phone for forum posting, my fingers are too fat.
 

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If I'm writing a lengthy post, I'll type it up and post on the computer and then use Tapatalk to edit and insert photos. Or do it the other way, post photos from Tapatalk and then edit on PC to add text.
 

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Discussion Starter #6
Not thrilled with Tapatalk. Let's try this.

Examples of the prior projects, before and after:











 

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Discussion Starter #7
And the Caddy has made it to my garage now. As always, what I'm finding as I dig in a bit is a mixed bag. Some good, some... well, less good?

But I still think I can save it.









 

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Discussion Starter #10 (Edited)
The Land Cruiser was a major, frame-off project. Sold on BaT in late 2018 - https://bringatrailer.com/listing/1964-toyota-land-cruiser-fj40-4/

This could be almost as major, if I let it.

I could simply de-bug the functioning parts, make it run and drive safely and reasonably reliably. Then sell it to let the next owner do the cosmetics to suit themselves.

Or I could do some mild clean up of the basics, maybe a few improvements, and sell it as an improved but not super-great rat-rod type vehicle.

Or I could strip it down and and make it fairly nice...

Not sure where I'll go yet.

I've got the battery charger hooked up now, and started some cleaning under the hood. Wasn't ready to really start digging into the fuel delivery issue, so I took apart the tailgate latch because the tailgate was stuck. Some progress on that, tailgate is open now, and I'll probably get it back together tomorrow.

Some history - PO had owned the rig since 2008 at least, and the Passat 9A was already in it and running at that time. He used it as a daily driver for years, until it started having fuel-related problems. He mostly parked it in 2015 or so, occasionally tinkering with it to make it run right again. Mostly, he failed.

Last fall, he had it towed to a local shop to see if they could find and fix the problem. Of course, after sitting mostly unused for 4 years, things had deteriorated badly. He ended up spending over $3k at the shop, with some of the notable items including a rebuilt fuel distributor, and new ignition distributor, and O2 sensor.

After all that, the shop said it would run, but not especially well. They felt that the ECU may be faulty, due to how it was crudely mounted in a location unprotected from rain. The owner decided he'd spent as much as he could afford and brought it back home, where it has sat pretty much ever since.

That's where I'm at with it. I'm going to need to start stepping through the troubleshooting from the very beginning. For example, I don't hear the fuel pump priming the system when I turn on the key. So that's where I'll start.

This could be a not-to-difficult thing to get a handle on. Or it could be a long slog. Wish me luck.
 

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Check for spark,
No spark and no FP prime at key on just might be the knock box.
But I guess that also depends what fuel system is used on the Passat engine.

I have a 9a in my 2dr Jetta on cis-e and that one kicked my butt after it would not start earlier this year. I tested EVERYTHING 3x... Cause a buddy said I've never seen a knock box go bad. Welp, mine went...

That's not a shop I would ever recommend. Distributors are easily tested.
Fuel distributors too, bypass FP at relay and lift the flapper with an injector pulled.
 

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Discussion Starter #12 (Edited)
I'm not going to bad mouth the shop yet, they did test both the distributors before replacing them. The fuel distributor was described as, "Confirmed injectors are spraying fuel when fuel pump is on with metering plate at rest position. This is NOT intended operation. There should be no fuel flow. Suspect fuel distributor failure due to internal corrosion."

I plan to check for spark as soon as the battery is happy. (Only a year old, but moderately discharged.) The shop said spark was consistent after the dizzy was replaced due to an issue with the Hall sensor. I had this problem on the 9A in the '91 GLI I owned from new until 2007. So I don't doubt that, either.

Passat 9A is Motronic, similar to CIS-E, though.

Not familiar with the "knock box." Where would it normally be found, and what does it look like?
 

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I'm not the person to advise on Motronic systems. Sorry But I do think Motronic knock system is integrated in the ECU.

It's usually the shaft seal on the 16v distributor that leaks oil. I've learned to reseal them for $6 seal.

I used cis-e from a 16v scirocco to keep it looking clean and original for air box location etc. But I did make some mods for it to be fueled at the higher RPM on the larger displacement engine. WOT 12.5:1 AFR at redline. And the 83 Jetta used the same fuse box as the Rocco so it was basic plug and play.

The caddy uses a different fuse box. So you may have amateur wiring issues that showed up over time. Check grounds too. Just a thought... I don't know to what extent the swap was done. But having 2 wiring diagrams open and trying to figure out previous work will make the head hurt.
 

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Discussion Starter #14 (Edited)
LOL! Mine isn't even anywhere CLOSE to that nice looking under the hood.

But some initial progress today, have determined the fuel pump relay is bad. If I bypass the relay to make the pump run, it tries to start briefly when I crank it. Doesn't fire for very long, and I have to let the pump run a bit before it will try to fire again, so I suspect the fuel pressure is low.
 

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Discussion Starter #15
Some advice, please. Which fuel pump relay should I get for an '81 Caddy with a 9A in it? I see the original pump shown as 321.906.059 (possibly with a suffix C). The failed relay (which has the exact same 5 terminals) is 433.906.059. Is there any difference between the 321 and 433 parts? If so, do I want to match the chassis, or the swapped engine?
 

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Some advice, please. Which fuel pump relay should I get for an '81 Caddy with a 9A in it? I see the original pump shown as 321.906.059 (possibly with a suffix C). The failed relay (which has the exact same 5 terminals) is 433.906.059. Is there any difference between the 321 and 433 parts? If so, do I want to match the chassis, or the swapped engine?
the 321906059C has a 15-16A fuse mounted on top. The 433 does not. Both are the small 1/4in power pins. If you have the Passat fuse box it may have the slots for the wide pinned relays. Which might be 5/16 or 8mm wide, I forget off hand.

Check these PN's to see what I mean, 171937503A, 321906059D, 321906059E, 321906059F, 321906059G, 321906059H, 3300230, 443907385, 443907385B, 443907385C, 443955531, 447907385C, 5651803, 8D0951253A

See if this pic works...


Also the MK1 German Cars from 1983 used pretty much the same fuse box till 1991 as all the MK2 had. Which maybe the same as the passat too. So Something like a 1984 cabriolet FP relay might be what you need. Off the top of my head that PN MIGHT be 321906059D/E/F?
 

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Some advice, please. Which fuel pump relay should I get for an '81 Caddy with a 9A in it? I see the original pump shown as 321.906.059 (possibly with a suffix C). The failed relay (which has the exact same 5 terminals) is 433.906.059. Is there any difference between the 321 and 433 parts? If so, do I want to match the chassis, or the swapped engine?
Swapped engine, because of the rev limiter inside the fp relay.
 

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Discussion Starter #19
Some new stuff:

Fusebox is not Passat, but appears to be original to the truck after all. I was expecting a box with old style ceramic fuses, but this one (175.941.813) has new style fuses. As pictured:



Trigger signals at the relay panel terminals check out OK by the meter. Well, maybe not totally OK, but they exist. So I think the ECU is sending the trigger signals.

We'll know more late tomorrow. My local German part specialist will have me a new relay tomorrow.
 

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Yeah that the USA built cars fuse box.
Not a fan personally. But same as in my 81 rabbit D current project.
Depending how much of the original USA engine harness was used, there are Fuse links in the power feeds. Basically a section of wire designed to blow. You will see the black plastic blocks molded on the power wires where the fuse links are placed.

They corrode and deteriorate.
 
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