Engine Swap Progression



-------------------- (Oct. 21, 1996)
Project TD update:
- Welded engine compartment brackets! Yes! I got the power steering reservoir bracket, the TD fuel filter bracket, and the air filter housing bracket all welded up. I even put on some paint so the welds don't rust.
- Made list of stuff to do for TD

Need to do:
- Pressure test oil to water cooler (The engine's coolant had oil in it when I first found the TD in the '84 Jetta)
- Go to dealer and get blow-up diagram of dipstick to engine block mounting (I can't seem to figure it out just by looking at the parts I have)
- Also get some parts: a few gaskets for cooling system and PCV filter (Yes, the turbo diesel has a PCV filter! I always hated it when I saw oil on my air filter - which leads me to my next item) an air filter, a fuel filter. Can't think of anything else.

-------------------- (Oct. 29, 1996)
Project TD update:
I started my engine swap!

I basically removed all the engine connections and peripherals. Took out the power steering pump, radiator, battery, alternator, water pump, intake manifold, etc... Disconnected shift linkage, water heater hoses, all electricals, clutch connection, speedo cable, driver's side driveaxle, etc...
-------------------- (Nov. 4, 1996)
Just ordered the magnetic drain plug, cam baffle, A pillar fairings, and VDO boost gauge kit. Should be here weds or thurs. Can't wait for decreased drag coeffecient and BOOST gauge! (I checked out the VDO gauge at Bow-wow it's REALLY sharp lookin'... my center console clock will be in the trash so fast)

Anyways here's the weekend update:

Sat. night - prepped motor mount for new rubber installation. Cleaned tranny (Geeze that took forever!) It STILL isn't all the way clean, but now at least you can see the magnesium through the grime. But for all purposes of mine it's friggin sparkling.

Anyways here's the part that pisses me off.

Took out the clutch push rod for inspection and to my horror saw evidence of a wasted bushing (brass metal globs braised onto the rod + chunks eaten out of the rod - or pitting) On other end of rod, there was evidence of pitting and some GRINDING! I guess this was someone's method of removing wasted bushing material from the rod. The thing is they removed a little of the rod too. I'm surprised there wasn't oil all over my clutch. The way it was installed this pitting / grinding area came in contact with the oil seal / bushing! Since there is only one bushing in the design this means the rod's orientation had been reversed at one point. (Or I should add *at least* one point.) Then I removed the push rod bushing and found evidence that it was installed by someone who tapped it in with a screwdriver! Huh? What's that? Brass is SOFTER than a screwdriver? Geeze! No wonder the brass bushing was all melted like candle wax over the pushrod. Someone had been abusing my tranny... I suspect 1. the previous owner of my car and 2. the place that did my clutch.

Anyways my plan is just to put in a new bushing and a new pushrod. To get the bushing out I had to remove the green and drive the bushing out with a 3/8" rod care of hardware store. Also had to remove clutch lever. I'll also replace pushrod oil seal, clutch lever oil seal, and mainshaft oil seal. I'll need a plan on how to install the pushrod bushing (special tool?)

Well I adjusted my tranny too (remember those little dust caps?) With the new setting I predict my gears will feel more distinct (no more slipping out of reverse!) Plus it should be a little easier to get over into fifth.

Anyways I also did some work on my '81 engine. I've actually never adjusted my lifters so I decided I might as well do it on my '81 for practice. I'm going to replace the timing belt too. One intake was out of spec (too little clearance) and all four exhaust's were out of spec (too little clearance too) Removed the tappets to measure them... It was tough making a tool to remove them. I have the tool that depresses the valve guides already. Ended up using a filed screwdriver to pop out the disks and a magnet to remove them. Did my calculations and figured out which tappets I need

-------------------- (Nov. 11, 1996)
Project TD update:
* TD exhaust system is different than normally-aspirated diesel exhaust system!
The turbo's spring clip ball joint connection is about 2 inches towards the rear of the car, and about 1 inch lower than the normally-aspirasted exhaust manifold end. Didn't notice this until After I installed the engine though. So right now the exhaust is "stuck" between the turbo's exhaust outlet and the front sway bar. I'll probably just hacksaw it off since I can't use it anyway.

* Guess I'll just have to go straight on with the techtonics! Until I can get the downpipe modified, I might just strap on the stock TD exhaust system to fire up that baby... (no muffler)

* We forgot to put in these little rubber buffers which go to each side of the motor mounts. So I used the crane and slipped them in there on mount at a time - took a little ingenuity but wasn't too tough. Also connected rear motor mount. For the rear (stripped) fastener, I just used multiple washers and didn't torque the nut up there to full specs since only about 1/2 of the nut was into good threads. I think it'll be fine - at least until I have to remove it again. I wonder if vw welded that into the body or if they made it removable... Time for a vw newsgroup post.

* I've decided to go to the new high-tech red-orange antifreeze (which VW and GM is using on their late-model cars.) Spent $35 for 2 gallons @ Brooks McKnight Chevrolet (VW is also using it on their 97's, but carter doesn't have it in stock.) I think the Chevy formula is almost identical to the VW formula, so I'll be fine. Anyway, this stuff is supposed to not wear out the water pump bearing. Plus it lasts four years (about twice as long as ethylene glycol?)

* Bolted on some stuff to engine and messed around with the wiring. Still have more wiring work to do and also bolt up waterpump + power steering pump. Also have to connect the drive axles.

* It's time to replace my speedo cable. The thing's always been fluttering, but when I was connecting stuff to the engine the cable housing cracked. Oops.

--------------------- (Nov. 17, 1996)
Got in some work last couple days on my favorite project:
* Installed radiator, Installed all the hoses, put in the new coolant - no leaks so far
* Installed the water pump, power steering pump, bracket, alternator, belts, timing belt covers...
* Started re-wrapping the wiring and routing it. Everything's hooked up, but it's not pretty yet. I'll finish the wire wrapping after I hear the engine run...
* Put in some Redline MTL in the tranny (hey - let me know if you need to change your tranny lube - I've got some extra bottles)
* I got the stuff from Autotech. The boost gauge hookup kit was used however (the bad had a hole in it and the tube fittings had dirt in them. So I went down to Eagle and got new solid brass fittings for <$4. The gauge looks beautiful! Still have to figure out how to hook up the A-pillar fairings. I'm pretty impressed in the quality of the A-pillar firings. I guess they mount with this black putty-type sticky stuff that came attached to them. It was too cold and wet for me to do anything like that though (Was it just on Mercer Island, or were we getting some SNOW?) Brrr... it was pretty cold out there...

To do list:
Still have to make the custom 2.0" downpipe (This guy who does the custom header work was on vacation. He'll be back this week)
Also have to re-pack the CV joints and install the driveaxles.
Everything in the engine compartment looks good so far! It's almost done... Assuming the downpipe turns out OK she'll be ready to go pretty darn soon.

-------------------- (Nov. 25, 1996)
Sunday's project report:

I Installed that Turbo Boost gauge...
had a hard time finding the right tap, but once I got the right one it cut into the aluminum like it was cheese
Seems like all the answers lie at Eagle hardware
Got a cool 90degree fitting too

Plumbing the pressure tube wasn't much of a problem - I just went through the firewall where my vacuum line went through.

Looks cool sittin' there

It's where the clock used to be (where your oil pressure is)

Also figured out how the A-pillar fairings mount
Cleaned the rubber it connects to
But it never stopped raining, so I didn't install them 'cause there's a couple adhesive - type pads which don't like water very much

4 day weekend coming up! Hopefully it'll be sunny!

-------------------- (Joke E-mail)
I'm done with my project TD!
I've put some pictures of it on the web page - check it out!>BR> http://www.klippan.se/sidecar/wille.html

-------------------- (Nov. 30, 1996)
Project TD update:
* Or course, the A-pillar fairings - they are installed and they look like they're meant to be there! They are slick, very slick. The black putty which came on the backs of them really grabs onto the body and also they have a plastic extension which slides under the window rubber so they're really on there - I guess they won't come flying off at speeds. They fit VERY well (made me happy) Maybe they'll give my top speed a boost...
* Found out my oil cooler was mounted upside down. Flipped it over (kinda messy when the cooling system is filled up to the brim)
* Installed the drive axles.
* Installed exhaust system. Got fed up with renting the spring-clip removal tool from Bow-Wow so I made one out of a monkey wrench. Also went down to B&B and got a little 2.0" section which has a slip fitting. Then went down to an exhaust place and had them weld it to a VW cat. converter fitting. So now I can slip the downpipe into the piece and bolt the piece to the TT system, which thinks my rigged downpipe is really a catalytic converter. A wire-brushed the tailpipe and I finally got it tucked up there the way it's supposed to be... it looks cool, and yet at first glance appears to be VW stock.
* Went to pressurize the oil system with my Techtonics Oil pump drill tool. (Just hooked it up the power drill and stuck it where the distributor / diesel vacuum pump goes.) After about half a minute it started getting hard to drill (guess the filter+cooler filled up finally) then about 30 secs later I heard something and noticed a HUGE puddle of oil under the car! Wow! I never thought so much oil could leak out of a car in such a short period of time. Anyways I traced down the leak to be coming from the cam pulley area. After removing the belt cover, I found the oil to be coming out of an oil galley plug which my buddy Tom the engine builder guy forgot to plug. I guess he's only a human and isn't perfect and maybe one of his assistants overlooked it or something. Anyways I'm going down there on monday when it's open to get the plug. I thought I was going to start it today, but I guess it won't be until next weekend...

Jake