[Vwdiesel] Fresh Turbo Diesel

[Nate Wall]

Hello Everyone:

Well I've completed the TD engine swap in the '85 Jetta. All went
reasonanblly well, except it seemed to take forever! I started Friday
afternoon and finished up Tuesday night. Worst thing was the tranny mount
bolt head stripped out and the bolt was stuck. Ended up placing a 6-point 17
MM 3/8 drive socket on it w/ a huge cheater bar aqnd it let loose. The 1/2
inch drive 12-point 17 MM socet I first tried just slipped and rounded the
head right off. It was also impossible for me to remove the bushing inside
the tranny mainshaft. I used a big slide hammer (same I used for the starter
bushing) and managed to ding up the old bushing some. Bentley does not
mention how to get it out. I just gave up after 20 mins and put a new seal
in.

It runs great! Virtually smoke free and much quiter than the old motor. More
torque too. I took it for an 80 mile drive last night. The only concern I
have is at the 1,000 mile head retorque. Last night after the warm-up
retorque, one of the head bolts seemed to all of a sudden turn effortlessly
about mid-way through the 1/4 turn pull, but seemed to get tight again
towards the end of the pull. Perhaps I should leave this one alone.

Basically worked non-stop on it. I've posted 28 photos in the VW-Audi-Diesel
photo album, under "Nate's TD Swap". Check it out, see:

http://photos.groups.yahoo.com/group/audi-vw-diesels/lst?.dir=/Nate%27s+TD+Swap&.src=gr&.done=http%3a//photos.groups.yahoo.com/group/audi-vw-diesels/vwp%3f.dir=/Nate%2527s%2bTD%2bSwap%26.dnm=TD%2bSwap%2b031.jpg%26.src=gr

Comments:

1.  Rent an engine hoist. The fine folks at A-Plus rental delivered and
picked it up for an extra $33. I did not need to take the hood or front of
the car, or radiator off. Went right over the top, even w/ the A/C
compressor above the radiator.

2.  Keep a spare injection pump mainshaft seal handy and know how to change
it. (or arrange for the injection shop to change it). I found my seal was
beginning to leak, but the pump shaft was nice and tight. The pump shop was
closed Saturday. I bought a spare TD pump  w/ the engine, but its shaft had
more play in it, so I decided not to use it, AND Gary just happend to
include some pupm seals and gaskets, and a new shaft seal was in the goodie
bag. It was hell removing the old seal w/out damaging the sealing surfaces.
It was tight. I tore the crap out of it getting it out w/ two small
screwdrivers and a full-size seal puller (I wonder how the Bosch shop does
this). And the answer to that eternal question, "is there a main shaft pump
bushing?" There most certainly is, and it appeared totally unworn. The new
seal went right in. (See photos on Yahoo).

3. I mistakenly put the metal washer plate between the crankshaft and
pressure plate before torquing the new one-time-use bolts (should have gone
under the bolt heads). Since I also used hi-strength Loc-Tite, I left it
alone.

4. Get some Dust-off. First time I ever bought it. Its great for cleaning
crap out, or after using brake cleaner on stuff.

5. Make sure the drive axles are (wired) up in their proper location when
putting the motor back in. If not, once in, the axles will not lift up to
their flanges because the motor is in the way and the motor has to be lifted
again. How do know this? Hmmm.

--Nate