Vanbcguy's M-TDI Build

[vanbcguy]

Too late now!

Sent from my HTC One XL using Tapatalk

[theman53]

you can always return it. I would if I had the chance, since you are towing.

[vanbcguy]

Cross border shipping would have me in about $300 by the time it was there and the replacement got here. Plus another couple hundred for the upgrade. I am TAPPED OUT right now.

For anyone contemplating a similar project, plan on spending a low end Kia to get it done....

Sent from my HTC One XL using Tapatalk

[CdnVWJunkie]

For anyone contemplating a similar project, plan on spending a low end Kia to get it done....

Isn't the case for any big project??   

[vanbcguy]

Dropped off my injectors and the HFLOX Warp 7 nozzles I managed to score at NW Injection on Wednesday. Price they came back with to set them up was a bit higher than I had anticipated but I got the nozzles for under $200 which pretty much makes it a wash.

It's been too frigging cold even for me to past couple of weeks - I have a carport that is enclosed on 3 sides which is fine when it's above freezing but it's impossible to heat. Still I am getting squirrely and want to get this DONE already.

My wife's wagon just puked its downpipe so that's another chunk of unexpected change. My 2013/2014 vehicular expenses are up to about a fully equipped 2014 Jetta TDI now, at least before I factor in a HPFP or two...

Sent from my HTC One XL using Tapatalk

[vanbcguy]

Started tearing in to Jezebel today. Pulled the lock carrier, rad, all my intercooler stuff, shift linkages, etc. Basically ready to yank the old drivetrain - just have the axles, the clutch cable and the cold start cable left.

Looking for an engine hoist now. Trying to decide if I should buy or rent one. Thinking I might just buy one and sell it afterwards.

Sent from my HTC One XL using Tapatalk

[bbob203]

Started tearing in to Jezebel today. Pulled the lock carrier, rad, all my intercooler stuff, shift linkages, etc. Basically ready to yank the old drivetrain - just have the axles, the clutch cable and the cold start cable left.

Looking for an engine hoist now. Trying to decide if I should buy or rent one. Thinking I might just buy one and sell it afterwards.

Sent from my HTC One XL using Tapatalk

Buy one off craigslist and sell it when your done you'll know what you will be able to resell it for! 

[vanbcguy]

Actually all the ones I've been able to find on CL here have been priced equal to or higher than a new one at KMS Tools with the exception of the odd really dodgy and/or broken one. So I bit the bullet and bought one yesterday.

Once I'm done my build I'll be able to use my trailer again too so I should be able to deliver it to someone. That should get me most of my money back.

Sent from my HTC One XL using Tapatalk

[vanbcguy]

Everything is unbolted and ready to yank!  Now it's time to clean up the shop so I have somewhere to PUT it and room to maneuver my lift around.



I was DREADING unbolting the axles after all the trials and tribulations I've seen around here.  Happily they unbolted quite easily with nothing more than my triple-square "allen key" set, no messing around.  Downpipe came off the turbo without much of a fuss too, that was the other one I wasn't looking forward too.  Gave it a good shot of PB Blaster on Sunday, came off no problem today.

There are some nice big holes in the back side of my transmission case for sure.  Didn't want to take my phone into Lower Greaseland under the car so I didn't snap any pictures today but I will once I have everything yanked.  Going to be going at it hard for the next few days, then I've got yet another trip for work. Bah.

[bbob203]

I love doing axles!

[vanbcguy]

Aaaaaand she's out!  My shiny new lift did great.  Had my buddy come by to help guide everything, worked awesome.  I was worried that I didn't have enough room in my "shop" but it worked out just fine.

Empty engine bay:




Engine on my new $69 cart:




And now of course the promised transmission carnage pictures!!  I've seen a few pics of self-machining-syndrome on 020s before but I think mine is pretty darn good.  The chunk missing from inside the bellhousing is HUGE!  No wonder it ripped the inspection plate off the bottom.  This transmission is DONE.  Can't see in the pics but the spider gears in the differential look pretty trashed.  The rivets that I can see through my fancy new inspection window are definitely sheared right off.

[rbremiller]

Buggered!

[vanbcguy]

Got a bit more done... Cut out the exhaust so I could pull the shifter as I'm switching to an 02J style one.  Put new motor mounts in.  Finished buttoning up the engine - just need to install the PS pump, glowplugs, injectors and the oil drain plug!

Injectors are rebuilt with HFLOX Warp-7 nozzles:



Ended up paying a bunch more for the rebuild than I was expecting, but I got a good price on the nozzles so I guess it's a wash. These look fantastic - they've been calibrated and everything so they should be working perfectly.  Sweet!

[vanbcguy]

Mounted up the PS pump today. Stupid belt is too short, gotta get a longer one.

Installed my injectors... Decided to swap the shorter delivery valves from my AHU pump as bending the lines to fit the longer Rover delivery valves wasn't seeming like it would work too well. Hopefully I didn't screw anything up there.

Measured out all the finer details of my turbo to firewall clearance. The vacuum can is going to be pretty tight - I put a few self tapping screws in with fender washers to keep the firewall insulation from getting torn up. I'm only measuring / calculating about a 1/4" of space, hopefully that's enough!



Sent from my HTC One XL using Tapatalk

[bbob203]

When I was total newbie I swapped delivery valves around with no idea what I was doing and never had any trouble as long as you do it 1 by 1.