VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => IDI Engine => Topic started by: JGWarner on February 20, 2011, 12:05:22 am
-
EDIT: This car is for sale as of August 2011. Drop me a line if you want it.
Yup, someone is crazy enough to do it. And he's me.
Posted on the VWvortex forums, where "Foxers" are (obviously) more common. What we call a VW Fox never got diesel in North America, and never got a Turbo anywhere!
http://forums.vwvortex.com/showthread.php?5186163-JGWarner-s-Turbo-Diesel-Fox (http://forums.vwvortex.com/showthread.php?5186163-JGWarner-s-Turbo-Diesel-Fox)
Enjoy.
-
Also, not that this is new to you but if you still have loads of dirty parts, a basin of vinegar mixed with dish soap (fairly high concentration of dish soap) or engine cleaner for the parts to soak really speeds things up.
You think letting them soak for a day is wasting time but it really helps the crud come off quickly and painlessly.
-
You see? You see why I wanted to join this forum so badly!? That's why. Right there.
Thanks for the info, I'll definitely reconsider the turbo's condition. I feel alot better. I thought the oil in the downpipe was a death sentence but the motor definitely shifted in transport as you suggest... In fact, it's probably got less play than that video shows!
-
I think you need some of this:
(http://i182.photobucket.com/albums/x82/tochtli83/laughcard-turdpolish-1.jpg)
-
Turd polish? Not sure how to take that, pal.
Thanks for the welcome, I guess. :-\
-
Two thumbs up from me for swapping in an engine that a car never came with! ;)
-
Two thumbs up from me for swapping in an engine that a car never came with! ;)
Thank you. You don't know how much I needed that just now.
-
Guess who's got an NOS (and NLA) oil-cooler water hose (the "T-ed" one)? Some place in GA did a closeout about 3 years ago, and I bought a few....
-
Does it come with a free can of turd polish? I'm running low. :P
-
Does it come with a free can of turd polish? I'm running low. :P
Use less polish and more buff, you are wasting too much of the precious stuff :D. Giver on the conversion, I want to get one of the quantum diesels so I can plug it into an iltis. I want to make it my hunting wagon, wheeling toy.
-
hey quantum, is it the old one piece design ?
The new ones suck and are 3 piece rubber with a plastic T
GB
-
hey quantum, is it the old one piece design ?
The new ones suck and are 3 piece rubber with a plastic T
GB
It's the old one-piece with a moulded seam. It doesn't look exactly like the one that came off my car: it looks like the seam is reinforced with ribs. But it's Genuine VW. Part number 068 121 053 R.
If you were planning on making silicone clones, I'd give you one if you promised to replace it with a silly-cone version. ;D
I don't think there's a HUGE market for them, but enough Quantum engines get reappointed to longitudinal applications that you might sell a few (I'm thinking of Suzukis mainly). There probably aren't enough actual Quantums left on the road to make a buck on them, but the motors live on...
-
There probably aren't enough actual Quantums left on the road to make a buck on them, but the motors live on...
They sure do. Interestingly, the Zuki kits out there usually come with a metal or plastic T to splice your own coolant hoses instead of the one piece factory hose. They also have a novel alternator mounting bracket solution I may resort to, since I'm deleting the A/C.
-
Hats off to you man ! Great build idea ! Diesel Fox Wagon is pure win in my books !
-
Hats off to you man ! Great build idea ! Diesel Fox Wagon is pure win in my books !
;D My sentiments exactly.
Remember, Diesel has been done in the Fox, but Turbodiesel has not. 1st evar in North America.
And the diesel BX cars in South America I believe are just NA motors with turbos attached, as opposed to a true TD swap.
I'm regularly updating the other thread at VWvortex. I'm saving the tough questions for you guys.
-
Alright, hard questions.
What is this white plug in the bottom of the water pump? The Fox WP does not have this.
(http://i187.photobucket.com/albums/x3/macwarnerbellows/waterplug.jpg)
Mine is cracked off, but I can't tell that it's going to be a problem. It was literally hanging in there by a shred of plastic, it broke off when I went to wipe oil off it.
Also, this is an MD code TD. From all my research that means this engine should have hydraulic lifters. These appear to be mech lifters. Thoughts?
(http://i187.photobucket.com/albums/x3/macwarnerbellows/mechorhydro.jpg)
(http://i187.photobucket.com/albums/x3/macwarnerbellows/mechorhydro2.jpg)
-
Same thing happened on the ME motors in 1985. They were still mechanical-lifters. Hydraulic came in late-1985.
On the Quantum, the MD was the last year of the TD in the Quantum. Starting in 1986, the only option was 1.8 gas or 5 cylinder. It's a bit of an oddball.
-
Sorry..TD fox wagon...total win in my books ! lol
I've found you can never trust what the info says... you never know if somebody has been in there before and replaced stuff... or if you happened to sumble apon a weird combo from factory between vin splits or something .
As for the port on the waterpump... not to sure !
-
Well, I guess I can't be too disappointed. I thought it was a CY when I bought it, which meant mech lifters and a K24. So the only difference with this MD is the Garret T3. You can't put a mech head on a hydro block, right? There'd be a huge leak where the second oil port goes. And this head was cast on 3/29/1985, so it fits the vintage. It must be factory. Bummer.
I should be more relieved that I might not have to rebuild my turbo, instead of whining about mech lifters!
-
check the faq...I could be wrong but there should be a what fits what cyl head/block thread. Maxfax maybe started it, I know he had one on the 11mm stuff, but I think he expanded it to all stuff.
You cannot directly bolt on a hydro head to a mech block, but you can use a hydro head on a mech block with the second oil hole plugged and some other work IIRC. Saurkraut put a 1.9L head on a 1.5 so it can be done.
-
Thanks, I'll check the FAQ.
Any wisdom to be had on the white plug under the water pump? I can't find it in the Quantum Bentley either.
-
Thanks, I'll check the FAQ.
Any wisdom to be had on the white plug under the water pump? I can't find it in the Quantum Bentley either.
It serves no purpose. Its like an inspection plug. When those old pumps start to leak, that's usually where it happens. Don't worry about it and/or just put on a new pump anyways.
-
Thanks. The pump on the Fox has half the mileage, will probably just swap that over. The entire cooling system is getting replaced in this swap, and A/C deleted. Should run a lot cooler.
-
Thanks. The pump on the Fox has half the mileage, will probably just swap that over. The entire cooling system is getting replaced in this swap, and A/C deleted. Should run a lot cooler.
don't delete the AC, you more then likely have junk built up between the A/C and when you pull them apart, you'll need to clean them out.
-
Eh? You mean between the radiator and the A/C condensor? Because I've got a new radiator too. VW had Fox rads on clearance last year for $39. Lucky me, unlucky anyone who needs one in a few years. I live in a moderate climate, I've been getting by without A/C.
On top of all that, the Fox is considered nose heavy as it is. This is all useless weight in front of the wheels.
-
yup, that's exactly where I mean. I live in a very mild zone, but I like my A/C. The fox is very motor forward, and maybe if you have the space bring it back a couple of inches. It'll make for a much better handling car.
-
Interesting idea... though the car handles fine right now for what it is. If this car saw track time I'd think about something like that. But I'm going diesel more for the fuel economy than the raw power...
Believe it or not the Fox was designed to be front heavy when empty. Under load of driver and passenger it actually balances out nicely. That's one way they kept the weight under 2,000lbs when it has an identical drivetrain to the heavier B chassis cars.
-
Updates to my thread (link in my signature)
The Fox has a metal fuel tank. That brings some challenges which I address in the thread.
Also got a 5M transmission, hoping it's tall 5th gear (0.600) will lend some good FE.
-
...kinda like waiting in traffic to go from San Fran to Oakland...
Yes there are lots of pics. 56k beware. Sig edited.
Wouldn't your new tank be just as zinc galvanized as the original?
It's in the thread... In short, the new tank is Ni-terne, NOT galv. Diesel safe.
It may be too much to read, but it's written for Foxers who are unfamiliar with the holy word of diesel. ::)
-
When you're ready to delete the cruise bracket and canister from the pump, let me know ;D
-
I wasn't commenting on the pictures. I was making a bit of a snobby (and possibly obscure) comment about slumming it on the Vortex. ;D
OH. Gotcha.
Yeah, I only have the main thread there because this forum wasn't allowing new member registration until a few days ago.
Also it's the only active Fox community around. Seriously, we're alot better than the average vortex crowd, I promise. It makes the transition to diesel very natural.
-
When you're ready to delete the cruise bracket and canister from the pump, let me know ;D
I already removed the bracket (wow it's heavy duty) and the rubber diaphragm off the IP. Still holds air.
Are you sure you want it? It's got a lil turd polish on it.
-
When you're ready to delete the cruise bracket and canister from the pump, let me know ;D
I already removed the bracket (wow it's heavy duty) and the rubber diaphragm off the IP. Still holds air.
Are you sure you want it? It's got a lil turd polish on it.
No need to polish it. I've got plenty here. I've got half a dozen turds in my yard right now. I buy it in the 5-gallon buckets.
-
It may be too much to read, but it's written for Foxers who are unfamiliar with the holy word of diesel. ::)
New convert zeal. ;D
-
No need to polish it. I've got plenty here. I've got half a dozen turds in my yard right now. I buy it in the 5-gallon buckets.
and I thought I was the only one who got it in 5 gallon pails. Although as of recent I've been eyeing up a 55 gallon drum.
-
No need to polish it. I've got plenty here. I've got half a dozen turds in my yard right now. I buy it in the 5-gallon buckets.
and I thought I was the only one who got it in 5 gallon pails. Although as of recent I've been eyeing up a 55 gallon drum.
Yeah, well I only polish them right before I start driving them. After that, they never get washed again. Seriously.
-
Thumbs up on your project from Moodus! ;D
-
Moodus! Holy crap, I've lived in CT all my life and you're the first person from Moodus I've ever met!
Updates in the 'tex thread, and I purchased some engine enamel today. Things are going to start looking spiffy.
-
Moodus! Holy crap, I've lived in CT all my life and you're the first person from Moodus I've ever met!
Updates in the 'tex thread, and I purchased some engine enamel today. Things are going to start looking spiffy.
Ever hear of Greg Zipidelli? (sp) ;)
I joke about it-if you have a pick up truck with a gun rack--you're from Moodus. If you have a Land rover with a 100 club badge on it, you're from East Haddam. ;D (same town pretty much)
Its like you never hear anyone worrying social climbing saying their from Rockville-they're from Vernon. 8)
-
My brother lives in Millington. Not technically a town, but a part of East Haddam that's about 3 minutes from Moodus. He's got a 1996 Green Passat with about 300k on it, and a 2001 Golf TDI with about 250k on it.
-
Updates in the Vortex thread, link in my sig. Paint is on the block. Teaser below:
(http://i187.photobucket.com/albums/x3/macwarnerbellows/painted4.jpg)
-
More updates in the vortex build thread (http://forums.vwvortex.com/showthread.php?5186163-JGWarner-s-Turbo-Diesel-Fox&p=71093145). Possible oil filter clearance issues?
(http://i187.photobucket.com/albums/x3/macwarnerbellows/oilkewler.jpg)
-
When I saw this I was expecting to see one of these...
http://www.wintonsworld.com/cars/a-cars-2006/2006-carpics/vw-fox-6-s.jpg
I don't suppose you guys get these over there?
-
When I saw this I was expecting to see one of these...
http://www.wintonsworld.com/cars/a-cars-2006/2006-carpics/vw-fox-6-s.jpg
I don't suppose you guys get these over there?
negative ghost rider.. we never got anything like that..
-
Only been out a few years, they replaced the Lupo. I don't recognise your Fox as anything we ever got. The new Fox doesn't seem to sell as well as the Lupo did though.
-
in mexico and south america they have alot of interesting vws
-
Yes they do, such as old style beetles (still in production I believe), and the "citigolf" which is a mk1, with the interior from Europe's Fox!
-
Yes they do, such as old style beetles (still in production I believe), and the "citigolf" which is a mk1, with the interior from Europe's Fox!
old style beetles god discontinued in the early 2000s. like 01 or 02 i believe.. no more old style beetles..
-
Yes they do, such as old style beetles (still in production I believe), and the "citigolf" which is a mk1, with the interior from Europe's Fox!
old style beetles god discontinued in the early 2000s. like 01 or 02 i believe.. no more old style beetles..
01 but you can order parts from Brazil still
-
Yes they do, such as old style beetles (still in production I believe), and the "citigolf" which is a mk1, with the interior from Europe's Fox!
old style beetles god discontinued in the early 2000s. like 01 or 02 i believe.. no more old style beetles..
01 but you can order parts from Brazil still
yea, thats it! i knew it was something like that..
-
I've just been on the VW latin american and brazilian sites and discovered some VW's I didn't even know existed! Like the Parati, Gol, SpaceFox, CrossFox, Bora (which was our saloon mk4 Golf, but I think it's their Passat), Voyage, Suran etc. Wouldn't it have made life eaiser for VW just to have shared all the models and names across the globe? I will admit the interior quality of some Latin American models looks very poor though!
-
I've just been on the VW latin american and brazilian sites and discovered some VW's I didn't even know existed! Like the Parati, Gol, SpaceFox, CrossFox, Bora (which was our saloon mk4 Golf, but I think it's their Passat), Voyage, Suran etc. Wouldn't it have made life eaiser for VW just to have shared all the models and names across the globe? I will admit the interior quality of some Latin American models looks very poor though!
the mexican/south american VWs are notorious for having cheaply built interiors, and wiring systems..
-
Yup, the Gol platform (Fox) was definitely built to a third-world standard... but we learn to love and live with it.
I would be careful not to lump Mexican and Brazilian build quality together. Brazil was/is MUCH better than Mexico, hands down. I know many of folks with worse electrical problems in A2s and A3s made in Mexico. This Fox of mine has had comparatively few wiring issues. I still think nothing compares with German quality, of course. And I'm more than glad to be replacing Brazilian parts with German ones.
Prospectus (copied from the vortex thread):
Still have to do the front and rear main seals and carrier gaskets, the cam seal, intermediate shaft seal and o-ring, check the oil pump gear lash (possibly also run a plastigauge under the bearing caps for peace of mind) then button up the oil pan, install the vac pump and seal, water pump and seals, thermostat and cover and seal, wire up the glowplugs, install injection pump and new fuel supply line, new heatshields for new injectors (that's a new wrinkle), fuel return lines, fuel hard lines, reference boost line from the intake to the LDA, install the exhaust manifold heat shields, the turbo and it's gasket (w00t!), the turbo hard oil supply line and soft oil drain line with their seals, install the crank sprocket and pulley, intermediate shaft pulley and water pump pulley, injection pump sprocket and cam sprocket, timing belt, set initial timing, sort out an acceptable alternator mounting and belt arrangement, front mount (another wrinkle), install the essential coolant hoses (some fox, some quantum), steal the oil deflector from the fox, install the pilot bearing, flywheeel, clutch, pressure plate and THEN start thinking about fitting this mess into it's new home!
That's not even mentioning stripping out the old motor AND transmission AND fuel system AND fuel tank and replacing it ALL, finding a place to wedge the new fuel filter, possibly cleaning/painting the engine bay, altering the bay wiring, building the glowplug system, routing the cold start cable, deleting A/C and EGR systems, swapping in a new radiator and coolant reservoir and all hoses and rad ducting cardboards, sorting out a downpipe and mating it to the existing exhaust, installing the intake filter and hoses, cleaning/draining/refilling/installing the 5speed transmission with it's new throwout bearing, starter bushing and 5speed linkage (with new bushings, of course!), new clutch cable, new mounts all round, the starter, AND finally working out the inevitable kinks and stuff I forgot along the way.
What the hell was I thinking when i started this??
I'm planning to take some time off work, maybe 4 days straddling a weekend (so 6 days total) to practically live at my uncle's garage to get the lion's share done. This diddling around for only a few hours at a time is costing me a fortune in gas, but I have no TIME!
-
Only been out a few years, they replaced the Lupo. I don't recognise your Fox as anything we ever got. The new Fox doesn't seem to sell as well as the Lupo did though.
I dunno about wagons-but I believe the euro equal to the Fox was the Audi 100.
-
I could tell so many stories about the ones i had. Seriously tough chassis, and could fix one blind.
-
Today: replaced front main seal and carrier gasket, rear main seal and carrier gasket, cam seal, intermediate shaft seal, checked oil pump gear lash for wear (it's like new, less than .007mm), installed freshly POR-15'd oil pan and it's new rubber gasket, painted a few random parts. My uncle very kindly dug up a place that could get my 155 bar injector nozzles and I ordered a set. turbinepowered will be rebuilding my injectors for me, since he's got a pop testing rig.
Changing those seals was a challenge without many (or at least the correct) special tools. The REAL trick is getting the smaller main crank sprocket off, since you have to lock the crankshaft somehow. That big bolt is held on with 150ft lbs of torque. The flywheel was off and the timing belt removed, so I was scratching my head. I know they make a special tool if the flywheel is in place (or you can attach the pressure plate and one transmission bolt then jam the flywheel with a wrench between them) but in this case I didn't have enough room to fit the flywheel with the motor on the stand and I can't get enough torque with the motor swinging around on the lift. I turned the motor upside down to do this job and my uncle came up with a handy solution. We jammed a hammer in the crankcase. It was a mini sledge hammer, just slipped the head under one of the crank lobes and let the handle jam across the bottom of the block (the oil pan gasket surface). No marred surfaces, no risk. Worked like a charm. To reinstall the bolt I just jammed it the other way.
I'll be back at it tomorrow night. I'm hoping by this time next week to have the gas motor out of the Fox! :o
-
Query for the assembled knowledge base:
I want to add an EGT gauge, should I bother with the 1/4" probe or splurge for a 1/8" probe? Is it really worth the faster response? Bear in mind this isn't a hi-po project, just looking for some peace of mind and a sight for fine tuning.
-
Thank you! I am sold on the smaller probe! Even 23 seconds seems slow.
Any preferred source for a small probe that works with VDO brand EGT gauges?
-
Do they make EGT probes smaller than 1/8 NPT? Less mass = faster response. Something like 10- 32 or 10- 24 would have much less mass. Can you get probes in those sizes?
-
Awesome information there libby, thanks!
Updates with pics soon in the vortex thread, link in my sig.
Here's a teaser:
(http://i187.photobucket.com/albums/x3/macwarnerbellows/gettingthere1.jpg)
-
Here's a video of the turbo shaft play.
http://www.youtube.com/embed/-yKPDm_9MBg
I think it will do just fine. Opinions?
-
its a bit playful, but really spins nicely, looks good to go imo
-
It wiggles, but has absolutely no blade-to-housing contact, and spins freely. No in-and-out movement at all along the axis of the shaft.
-
Just for a heads up...I just placed this EGT/gauge into my 1.6 NA/TD car.
EXTREMELY fast response.
http://cgi.ebay.com/ebaymotors/DIGITAL-EGT-THERMOMETER-PYROMETER-W-PROBE-NPT-Blue-/200512513757?pt=Motors_Car_Truck_Parts_Accessories&hash=item2eaf7a26dd#ht_1711wt_1165 (http://cgi.ebay.com/ebaymotors/DIGITAL-EGT-THERMOMETER-PYROMETER-W-PROBE-NPT-Blue-/200512513757?pt=Motors_Car_Truck_Parts_Accessories&hash=item2eaf7a26dd#ht_1711wt_1165)
-
Just for a heads up...I just placed this EGT/gauge into my 1.6 NA/TD car.
EXTREMELY fast response.
http://cgi.ebay.com/ebaymotors/DIGITAL-EGT-THERMOMETER-PYROMETER-W-PROBE-NPT-Blue-/200512513757?pt=Motors_Car_Truck_Parts_Accessories&hash=item2eaf7a26dd#ht_1711wt_1165 (http://cgi.ebay.com/ebaymotors/DIGITAL-EGT-THERMOMETER-PYROMETER-W-PROBE-NPT-Blue-/200512513757?pt=Motors_Car_Truck_Parts_Accessories&hash=item2eaf7a26dd#ht_1711wt_1165)
That's the same gauge I was planning on buying... Any way to make a video of temps climbing while you're at WOT?
-
Do they make EGT probes smaller than 1/8 NPT? Less mass = faster response. Something like 10- 32 or 10- 24 would have much less mass. Can you get probes in those sizes?
Many years agoI worked in a coal research establishment and one of my tasks was making up platinum/platinum-rhodium thermocouples up from fine wire, and ceramic sheathing. The fine wire would take the heat, as it needed oxy acetalene to fuse the wires togeather, but I'm not sure if you could callibrate the basic gauge meaningfully...
-
Wish I could get one of these 3" gauges:
(http://www.westach.com/gauge_images/3C86T14.jpg)
perhaps replace my gasser tach (which will no longer work with the diesel).
-
When you say it has extremely fast response, what testing have you done? Data points please.
Testing? Seriously....I'm not an engineer. I just build stuff in my garage. 16vT, 20vT, TDI, g60, TD currently a VR swap. Anyway...
What I mean by fast response is when I turn the key on...it's ambient temp(correct for cold engine), crank it up and response is fast. Rev it up and the numbers rise and fall FAST. Not 23 seconds...instantly. WOT pull will yield 1500 degrees and let off will pull it back to 700 in a second. So. 1500 to 700 in a second is pretty responsive if you ask me.
And the probe you show and say you like is identical to the one that came with my gauge.
-
That's the same gauge I was planning on buying... Any way to make a video of temps climbing while you're at WOT?
Yeah...I can make that happen. Tomorrow on the way home church I will make a video.
-
video as promised
http://www.youtube.com/watch?v=LZgxX1staok (http://www.youtube.com/watch?v=LZgxX1staok)
-
Wow, that's responsive. And gorgeous GTI, I hope my Fox TD sounds half that good.
1500F seems high, no?
-
video as promised
http://www.youtube.com/watch?v=LZgxX1staok (http://www.youtube.com/watch?v=LZgxX1staok)
Right on, thanks for posting!!
-
Updates in the vortex thread. Set my IP lift timing.
EDIT: This is a METRIC dial indicator, and the black tabs are set at the factory max/min values.
(http://i187.photobucket.com/albums/x3/macwarnerbellows/timing.jpg)
I err'd on the advanced side. Thoughts?
-
It should be between .037 and .043 ... I have no clue if you are way above or below. I would go with somewhere in the normal range.
-
Guessing that is at about 1.03mm? Should be fine! You can tweak it a bit from there to find the happiest mileage, etc.
-
It should be between .037 and .043 INCHES
Fixed it for you.
That's a metric dial indicator. The official spec is in metric: .93mm - 1.07mm, which roughly translates to your standard values. My setting would therefore be ~ .040".
Sorry for the confusion!
-
Lot's of updates in the vortex thread (http://forums.vwvortex.com/showthread.php?5186163-JGWarner-s-Turbo-Diesel-Fox/page5)
(http://i187.photobucket.com/albums/x3/macwarnerbellows/dday3.jpg)
-
fixed it, thanks.
-
Test fitting...
(http://i187.photobucket.com/albums/x3/macwarnerbellows/settledown.jpg)
(http://i187.photobucket.com/albums/x3/macwarnerbellows/clearances.jpg)
Anyone have the VW special tool for removing the pilot bearing? I'm stuck until it's remains are out. :-[
-
Scanned the last couple of pages of your thread on the Vortex and didn't see anything about the pilot bearing. I probably just missed it. What problem are you having? Is there one in the end of the crankshaft or something? Some Audi's have this issue depending on the transmission.
If by chance this is the problem, there is a special little tool that can be used to remove it. However, there is something else someone discovered to remove the bearing without the special tool. If I understand correctly, you can fill the hole and the area behind the bearing completely full of grease, and then used a shaft that's the same size as the hole in the bearing, and tap it in there with a hammer. This way the bearing is "hydraulicaly" removed from the hole.
-
Scanned the last couple of pages of your thread on the Vortex and didn't see anything about the pilot bearing. I probably just missed it. What problem are you having? Is there one in the end of the crankshaft or something? Some Audi's have this issue depending on the transmission.
If by chance this is the problem, there is a special little tool that can be used to remove it. However, there is something else someone discovered to remove the bearing without the special tool. If I understand correctly, you can fill the hole and the area behind the bearing completely full of grease, and then used a shaft that's the same size as the hole in the bearing, and tap it in there with a hammer. This way the bearing is "hydraulicaly" removed from the hole.
you dont tap it with a hammer, you smash it as hard as you can 99% of the time.. usually takes about 4-6 whacks to get it out..
-
You can get a loaner pilot bearing puller for free from chain stores. If worse comes to worst, you can cut the outer shell using a dremel.
does it have a big enough bore to get one jaw of a slide hammer in there? last pilot i removed, i had to use a slide hammer, and it still BARELY came out..
if you can get one jaw of a slide hammer in there, thread in a fairly large screw beside it to take up the slack, then pull it right out..
the one i had to pull was full of roller bearings, and the races disintegrated and the needles went everywhere.. it was a pain to get out..
-
the one i had to pull was full of roller bearings, and the races disintegrated and the needles went everywhere.. it was a pain to get out..
This.
I've also been told a pipe tap can help. I also dug up a pile of small chisels. I've got a few hours to chip away at it tonight, let's hope it gives in. Only the outer casing of the bearing is still in there, without much to grab on to. What the hell is it made of?? Titanium? I wish I'd left well enough alone.
Also the started bushing I ordered appears to be too small... is the diesel starter bushing a different size than the gasser one? Doesn't seem to make sense.
-
Productive night. (copied from the vortex thread)
Got the #$%&@ pilot bearing out:
(http://i187.photobucket.com/albums/x3/macwarnerbellows/killkillkill.jpg)
I resorted to chisels, drifts and a small sledge. No fun for either of us, but it eventually yielded to such persuasion...
Got the flywheel, clutch and pressure plate on. Good thing I went with the 5 speed, I didn't realize the new parts I got is for 210mm clutch, not the 4 speed 200mm. Unanticipated bonus. By the way, these were from a VW clearance deal last year, $10 each, genuine Sachs OEM. Don't you wish you owned an obsolete model VW wants to erase from their history??
(http://i187.photobucket.com/albums/x3/macwarnerbellows/clutchy.jpg)
I wanted to remove the oil filter to make installation easier (something I learned during the test-fitting) but she wouldn't budge. I nailed a screw driver through the brand new filter to torque it off. Oh well, I bought two but my cheap swamp yankee genes recoil at the thought of wasting $6...
(http://i187.photobucket.com/albums/x3/macwarnerbellows/soshesits.jpg)
So she sits until next Monday at soonest. My cousin is getting married this weekend, we'll all be busy with family n' sitch. All that's left is to drop the motor in, sock down a few bolts and she's goot to be towed back home, where I can button her up and get her running without driving 100 miles a day.
-
I guess you don't know the drift+grease trick to get the pilot bearing out...
:-X
-
I guess you don't know the drift+grease trick to get the pilot bearing out...
:-X
x2...I thought he had tried it, but I guess not.
-
I did not know about the drift+grease trick until AFTER I had already destroyed the innards of the bearing.
-
I did not know about the drift+grease trick until AFTER I had already destroyed the innards of the bearing.
SOMETIMES, not even the grease-drift method works.. i had a stubborn roller pilot in a 4.3 V6 chevy once.. it WOULD NOT come out.. it almost didnt even come out with the slide hammer i had, and it was a BIG slide hammer.
-
Yeah, this whole project has been a study in "Leave well enough f***ing ALONE!"
-
Yeah, this whole project has been a study in "Leave well enough f***ing ALONE!"
lol, atleast its gonna be a sweet car when you get it all done..
-
I've removed the thoroughly stuck race like that with a dremel in less than a minute.
i made due with what i had.. if i were in my own shop, it wouldnt have been stubborn at all..
-
I had real good luck recently using the paper and punch method to get some really stubborn cups out recently. Water and small strips of paper pounded in behind the pilot is cleaner and cheaper than grease and drift.
-
(copied from the vortex thread, more info there)
I snagged this uber-rare alternator bracket on eBay- only came on B2 diesels (VW Quantum and Audi 4000) that DID NOT come with A/C. A rare lack of options, meaning this is bona fide hensteeth.
(http://i187.photobucket.com/albums/x3/macwarnerbellows/rarealtbrac.jpg)
turbinepowered is still working on a bracket that ought to be superior, but this will be kept on hand as a backup/alternate option. It interferes with the snub mount, so it's not an easy fix my any means.
Anyway, on to today's accomplishments...
In she goes!
(http://i187.photobucket.com/albums/x3/macwarnerbellows/inthere1.jpg)
Several greasy hours of too much swearing, not enough beer, and plenty of scraped paint/knuckles later:
(http://i187.photobucket.com/albums/x3/macwarnerbellows/inthere2.jpg)
(http://i187.photobucket.com/albums/x3/macwarnerbellows/inthere.jpg)
Once it was down in, it fit quite nicely. Loads of room for the turbo, thanks to our friend "bang bang" Maxwell:
(http://i187.photobucket.com/albums/x3/macwarnerbellows/clearances2.jpg)
Perfect!
(http://i187.photobucket.com/albums/x3/macwarnerbellows/clearances1.jpg)
I'm particularly fond of how the turbo oil drain line snakes above the subframe and under the motor mount. Very slick.
(http://i187.photobucket.com/albums/x3/macwarnerbellows/clearances3.jpg)
So, the motor is in, and as people keep reminding me, this is a big deal. But I'm not really celebrating yet. We survived the battle, but there's still a war to be won. Lots of little things left before she can run, and I'm out of cash and time. We'll see how things shake out, but I doubt this will be drivable before September.
I need to thank my uncle here, without whose help today's escapade would have been impossible!
-
Circumstances forced me to sell this car. It sold on 8/26/11. :(