Back to work!

M

mickey

Guest
I've taken the next week off from work so I can make some serious progress on the EB project. It won't be entirely finished because I won't have the turbo, filter and intercooler problems resolved yet, but I hope to have the old engine extracted, dismantled and put away in storage and the transmission bolted to the new engine. I'll try to pull the exhaust system and do something illegal to the catalytic converter, too.

-mickey
 

Powder Hound

Top Post Dawg
Joined
Oct 25, 1999
Location
Under a Bridge, Crestview, FL, USA
TDI
'00 Golf 4dr White 5sp, '02 Jettachero 5sp, Wife's '03 NB Platinum Gray auto(!)
Something illegal to the cat. Hmm, so here it is, 4:15 in the morning (Sunday, no less: Yikes!) and I'm stuck at work. What kind of weird things would I come up with? The ASPCA would have me for sure!

Sounds like a quick and dirty hairball-ectomy is what any cat needs. Make sure that knife is long & sharp!!! (Or the chisel is long & sharp - you decide what tool is best!!)

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"I love the smell of [burning diesel] in the morning. It smells like ... victory!"
 

VeeDubTDI

Wanderluster, Traveler, TDIClub Enthusiast
Joined
Jul 2, 2000
Location
La Conner, WA
TDI
2018 Tesla Model 3: 217,000 miles
LOL! Just take a pole or something and stab it to death! My neighbor's Eagle had a rodded-out catalytic. Completely empty inside. It didn't pass emissions either. There's a surprise.


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2000 Yellow New Beetle 1.9 TDI 5-speed
1987 Diamond Blue Mercedes-Benz 190D 2.5 Turbo (sold, but considering re-purchase)
 
M

mickey

Guest
Getting closer...driveshafts have been disconnected. That was a major PITA. They use a cheezy 12 point INTERNAL bolt. A standard TORX socket works, but they're only 6-point and I stripped out half of the bolts and had to use a pair of Vice Grips to wrench them out, thoroughly mangling them in the process. (I've ordered a full set of 12 new ones, and located a 12-point "star" socket to install them)

Wednesday will be a long day of random disconnecting. I need to remove the A/C compressor and disconnect the alternator and starter. I need to remove various brackets down below that hold the power steering tubes, etc. There are still various bits of wiring harness clinging tenaciously to the block. The shift cables need to be removed. Clutch slave cylinder must come off. Then I need to do a little amateur carpentry and build a box to support the engine and transmission. I'll use my engine hoist to lower the whole thing onto the box, which itself will be sitting on a mover's dolly. Once it's all sitting on the ground my dad and I are going to rig up something to hold the front end of the Evil Beetle way up in the air so I can wheel the whole thing out of there. The engine hoist can lift the car up as high as I need (using the top of the strut towers as lifting points)...it's keeping it up there that's the problem since I need to move the hoist out of the way to roll the engine out. I may roto-hammer a pair of brackets into the garage floor and use them to anchor a pair of braces. Haven't quite finalized the details yet, but we'll figure it out. My dad actually wants to put casters on the bottom of the braces rather than anchoring them so they'll roll backward as the front of the car rises up. But personally I like the idea of having the braces anchored to the concrete slab.

Then there's still a lot of fabrication, etc, to do with the new engine. New G60 flywheel and 228mm VR6 clutch. Gulf coast filter kit. (Which I'll plumb with the engine removed. It'll be a lot easier that way.) Intercooler plumbing. (I'll mount the heat exchanger using exhaust manifold studs to hold the bracket, I think.)

Lots to do, but once the old engine is out I'll get to work on something FUN for a change. Putting together is always more fun than taking apart.

There's light at the end of the tunnel!

-mickey
 

diesel des

Veteran Member
Joined
Aug 19, 1999
Location
Belfast,NI
Mickey, make sure you tighten those drive shart botls well! I have messed this up a few times as it is suprising how tigh they are supposed to be. The usual result is a few vibrate out and then you sheare the rest. Make a real mess! I now use some thread lock.
 
M

mickey

Guest
Thanks for the tip. I won't be able to fit a torque wrench in those tight quarters, but I'll tighten the hell out of them.

-mickey
 

John C

Veteran Member
Joined
Dec 28, 1999
Location
Broomfield, CO USA
TDI
Jetta, 2001 Glactic Blue Peral - SOLD
Mickey,

Are you taking any pictures of your work? It would be interesting to see your progress in pictures.

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-65 Variant S (Squareback)
'81 Diesel Rabbit (deceased-mama's box of rocks)
$100 & $350 Beetles
33 years Diesel development
2001 Jetta GLS TDI Galactic Blue, Beige Interior, Alloys & Michelins
 
M

mickey

Guest
Nothing to see yet, but when the new clutch arrives I'll shoot a bunch of digital pics. I'll also post pics of my new Gulf Coast filter!


-mickey

p.s. It may take another couple of months, but you'll get to see a clutch upgrade, the innards of a TDI engine, a transaxle, a bypass filter installation, a VNT turbo disassembly and re-assembly with upgraded parts and an air-to-water intercooler setup...and all kinds of fun stuff! (Imagine how excited I am about all this.
)

[This message has been edited by mickey (edited December 15, 2000).]
 

John C

Veteran Member
Joined
Dec 28, 1999
Location
Broomfield, CO USA
TDI
Jetta, 2001 Glactic Blue Peral - SOLD
Great,

I'll be lurking.

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-65 Variant S (Squareback)
'81 Diesel Rabbit (deceased-mama's box of rocks)
$100 & $350 Beetles
33 years Diesel development
2001 Jetta GLS TDI Galactic Blue, Beige Interior, Alloys & Michelins
 

VeeDubTDI

Wanderluster, Traveler, TDIClub Enthusiast
Joined
Jul 2, 2000
Location
La Conner, WA
TDI
2018 Tesla Model 3: 217,000 miles
You're planning on doing those mods to the old engine, right?

How long before you get the new engine in? I hope everything works out well.

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Über-Beetle: UPsoluted 2000 Yellow New Beetle 1.9 TDI 5-speed
1987 Diamond Blue Mercedes-Benz 190D 2.5 Turbo (sold, but considering re-purchase)
 

Driv'n EZ

Veteran Member
Joined
Aug 22, 2000
Location
Soot Belchin, USA
Hey, lets start a pool on how long Mickey can go before he just HAS to do an engine modification on his new power plant.

What do you say, VeeDub? Can you start a thread. Winner gets to visit Florida and stay overnight at Ric's place. Second place gets two nights. Third ... three nights.
 

RJC

Well-known member
Joined
Nov 6, 2000
Location
Canada
The driveshaft bolts on the A2's are 8mm and require a torque of 33ft/lb, don't know if the new ones are the same. By using 3/8 drive, I can use a torque wrench on these.

Ron
 

NBKrissie

Veteran Member
Joined
Oct 22, 2000
Location
Chandler, AZ, USA
The first 8 words of this posting---absolutely inspirational. I wanna take a week off from work to spend with my NB too!Mickey, you're our role model and hero; quick everybody, link hands and we'll sing that hero part from "Wind Beneath My Wings!" Here's to ya, Mickey:

"Did you ever know that you're our heeeerooooo? You're everything we wish we could beeeeeeee? We can fly hiiiiiiigher than and eeeaaagle, 'cause you are the wind beneath our wheels"



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01 NB GLS TDI Techno-Blau
 
M

mickey

Guest
Personally, I'll feel a lot more confident when I start putting things together again. So far it's all been "taking apart." It's a depressing thing to see.

-mickey
 

diesel des

Veteran Member
Joined
Aug 19, 1999
Location
Belfast,NI
Dont worry mickey, when I was doing my engine conversion the car was off the road for 6 months. I thought at times it would never go back together, but it has and it kicks ass! Just think of how quickly you will be able to clime those hills with the big power moter
 
M

mickey

Guest
These mods are happening with the NEW engine, but so far I'm not modifying the inside of the engine at all. Just the bits that bolt onto it.

Though I do have that set of Raceware head bolts....

-mickey
 

vworks

Veteran Member
Joined
Jun 13, 2000
Location
Hudson, Quebec, Canada
Mickey, those socket-head bolts require a #10 or # 12 male tool aka "triplesquare" That is what Snap-On calls them. I have the whole set. If you do any work on German cars this set is a must.

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2000 Jetta TDI gls auto, Silver Arrow, UPsoluted, 16" NB wheels, Arctic Cat Y2K Thundercat.
 
M

mickey

Guest
Yeah, they're like 12-point TORX bolts. I got a set of sockets from Checker Auto for about ten bucks. ("Snap-on"...who needs 'em!)

I thought the bolts connecting the drive shafts to the transaxle were six-point TORX bolts and I ended up stripping half of them trying to get them out. (Ended up using Vice Grips.) Fortunately they're available from vwparts.com for a nominal fee. Those are a smaller size than the ones holding the flywheel on.

-mickey
 
M

mickey

Guest
Victory! The engine/transmission has been dropped out!

My brother and I fought like demons for a few hours today and lowered the old engine and transaxle as an assembly until they're resting on some chunks of lumber laid across the outriggers of the engine hoist. Next, we'll hook the hoist to the engine and transmission mounts still in the car and lift the front end of the car up another foot or two in the air. We'll prop it in that position, disconnect the hoist chains, then roll the hoist out with the engine and tranny still in place.

With the engine/transaxle out of the way we'll lower the Beetle back to the ground and roll it out into the driveway to free up room for the engine swap and assorted fabrication. I've got the clutch upgrade to complete, the turbo to bolt up (if it ever gets finished), the Gulf Coast filter to plumb and an intercooler system to install. I've also got to remove the new engine wiring harness from the new engine, which isn't compatible with my older ECU, and make sure all the various sensor plugs on the new engine will be compatible with my OLD harness. Some swapping may be necessary. Accessory mounting brackets and the starter motor need to be swapped.

And so on...and on .... and on....

I figured I'm looking at $2500 plus assorted bits for the modifications (turbo, clutch, intercooler, filter and possibly a complete 6 gauge VDO setup), in addition to the $3000 for the engine itself.

What fun!


-mickey
 

diesel des

Veteran Member
Joined
Aug 19, 1999
Location
Belfast,NI
Good to hear you are getting places now. Yes this engine tweeking is expensive! I hope that the drive shafts are still in your hubs when you moved the car as if not you will damage the wheel berrings! It takes the outer CW to be tight to hold the berring together. The best way to do it is to just pull the outer CV's from the shafts and put them back in the hub and tighted the nuts. I have a old pare of scrap CV's just for this.
 
M

mickey

Guest
OH! Thanks for the info! The shafts are still in the car. It only needs to roll about 15 feet. I'll do that with the shafts installed and dangling from strings that will allow them to rotate normally. Once the EB is parked in it's temporary junkyard I'll remove the shafts and re-pack the joints and bearings.

-mickey
 
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