New TDI Jetta Project/DD

[8v-of-fury]

All the work you mentioned will be stupid stupid easy with the engine removed.

DO IT FOR SURE, you will be able to tilt the engine back so you can clean out the intake ports as well and not get any down in the cylinder

[theman53]

Perhaps did your donor car have an intact glove box? I would buy it if you were not using it. I don't care what color it is.

BTW, good deal on this car again. My last post the guy is still clapping about it.

[BigVWman]

In the mkiv the brake pedal cluster is the same auto and manual, the clutch is a completely separate pedal. Really easy! The brake master is also the same. You will want to use the manual donors power steering line its routed different than the auto. If your intake looks anything like all of mine did you'll want to do the cleaning off the engine! Careful with the egr and solvents!

[wolfsburged]

Perhaps did your donor car have an intact glove box? I would buy it if you were not using it. I don't care what color it is.

BTW, good deal on this car again. My last post the guy is still clapping about it.

Nope, sorry. It was broken and moldy!

[wolfsburged]

In the mkiv the brake pedal cluster is the same auto and manual, the clutch is a completely separate pedal. Really easy! The brake master is also the same. You will want to use the manual donors power steering line its routed different than the auto. If your intake looks anything like all of mine did you'll want to do the cleaning off the engine! Careful with the egr and solvents!

I've done some reading and seen a lot of conversions done keeping the auto pedals, however the brake pedal is larger, and although it doesn't interfere with the clutch, I'd prefer the smaller pedal. Not sure whether I'll cut the auto down or swap pedals, but I have everything to do it either way.

[Baron VonZeppelin]

Must have been the original ATF - yowch.

Tranny dying is probably the only thing that saved the engine from imminent destruction.
Bet they would have driven it til The Belt snapped.
Its probably the original too.

Looking good under the hood.
Going to be a really nice one for you.

[8v-of-fury]

Must have been the original ATF - yowch.

Its good for the life of the vehicle isnt it..   Yup, till she pops lol.

[JessaBug]

Got an engine hoist over the weekend...the entire thing will definitely be coming out. Bumper and all is off already...Bill took the headlights out and got them all nice and polished up so they are clear again.

Haven't taken the timing belt cover off yet, but the serp belt was cracked pretty bad. It looked like this:

Oddly enough, that's the serp belt from my GTI at over 117k...TB job was done at 90k and the serp belt was bought as part of the kit but I get the sneaking suspicion the local shop didn't actually replace it...*sigh* I imagine the TB looks similar to that on the TDI though.

Got a lot of the parts ordered for the job. Hoping to get some progress in this weekend.

[wolfsburged]

Got the front bumper and core support off.

The headlights were a bit hazy so I decided to try the 3M headlight restoration kit that uses a drill. This is the product:
http://www.amazon.com/3M-39008-Headlight-Restoration-System/dp/B001AIZ5HY/
All I've got to say is that wow! Major difference and not too hard either.

Before:


First lamp done for reference:


And final product:


Clutch and flywheel, maintenance parts are in. Waiting on timing belt kit, should do some more work this weekend. Hurt my back on Sunday so gotta take it easy for a bit anyway...

[Baron VonZeppelin]

Nice Results on those lights WolfB ^5

Jessa you lost me on that serp belt somehow. lol
Is it off your GTI - or off the TDI ?

It looks like 60-80k on that belt.
Or it was velly elcheepoh

[JessaBug]

Its from my GTI...but the TDI's belt looked just like it. I think its an original belt at 117k. I know the shop that did the timing belt job...makes me not want to go there even more now since I can be pretty darn sure the alt belt wasn't changed on my car (2 years and less than 30k ago). Seeing the TDI belt at 114k looking the same also helped me think that its still original too.

[wolfsburged]

Progress today!


Rad support gone


Front end out, hooking up the new engine hoist/load leveler


Engine and auto trans is out


Going to do a little more cleaning and then the wiring mods in here


Good stopping point for today

Next up will be removing the auto trans from the engine, then pulling the intake and EGR to clean. I have a set of 4 new CV boots to repack the manual axles with. Then to drain and refill the manual trans, replace the seals, release bearing, etc.

[rallydiesel]

You'll have a nice car there when you're done. Good job!

[Baron VonZeppelin]

Progress today!

I look at that picture with all the fiddle faddle going everywhere -
makes me want to go hug and kiss and love up on my Mk1 & 2's so hard. LoL

It'll be a real creampuff deluxe when you and jess get done.
I'd do it too, if i sourced the kind of Buy-In you guys are sitting on.
This is pretty epic in the awesome category.
Groovy Man

 

[BigVWman]

With that engine out its easy to clean up what you couldn't get while it was in! Also cleaning up some of the old auto wiring should be easier with it out now!