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PART TWO - ENGINE UPGRADE
Section V: MOUNTING THE TDI ENGINE
Once the vehicle's fuel and
wiring systems have been prepped you can now install the TDI engine.
Physically installing the engine.
| Step 1 |
1h00m |
- Attach the TDI engine to an engine
hoist and slide it into the transmission.
|
| Step 2 |
0h15m |
- Install the M12 nuts on the bottom
studs of the adapter plate.
- Shorten the original bolts for the
top two mounting holes and install.
|
| Step 3 |
1h00m |
- Install cross member and ensure
that the motor mounts are tight. This step involves
drilling new holes for the cross member to mount to the frame
of the van.
|
| Step 4 |
0h15m |
- Double Check that all mounting
bolts are tight and that the transmission bolts and nuts are
tight
- Remove Engine Hoist
|
|
2h30m |
Total time for preparing the fuel system.
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Installing the power steering system:
| Step 1 |
0h30m |
- Remove the original low pressure
line with the banjo fitting that went from the reservoir to the
pump.
- Install a new line from the
reservoir to the pump.
- Bend the banjo fitting that is on
the existing Vanagon high-pressure line so that it will fit at
the new mounting angle.
- Top up the system with fresh power
steering fluid.
|
Installing the electrical harness
| Step 1 |
0h15m |
- Install the pre modified
electrical harness in engine compartment.
|
| Step 2 |
0h30m |
- Secure engine ECU behind passenger
tail light.
|
| Step 3 |
1h00m |
- Attach electrical connections to
the engine, alternator and original Vanagon wires.
|
| Step 4 |
1h00m |
- Attach electrical connections to
the preinstalled cabling for pedals, additional gauges etc.
|
| Step 5 |
0h15m |
- Double check connections and
reconnect the battery
|
| Step 6 |
0h15m |
- Check for system functioning /
errors with VAG-COM
|
|
3h45m |
Total time for installing electrical
system
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Installing the exhaust
system
|
|
$45 |
AAZ / AHU Stainless
steel exhaust flange |
|
|
$35 |
Dynomax 2.5"
mandrel bent U pipe |
|
|
$50 |
Nice "turbo
muffler" |
|
|
$25 |
Brackets |
|
|
$15 |
Fancy exhaust tip |
|
|
$75 |
Labour at professional
exhaust shop. |
|
|
$245 |
Total exhaust cost |
Installing the coolant pipes
| Step 1 |
0h30m |
install bracket for Jetta III
coolant tank and mount tank. |
| Step 2 |
1h00m |
install coolant hoses |
| Step 3 |
0h30m |
fill coolant system with 50%
phosphate free antifreeze and 50% water. |
|
2h00m |
Total time for cooling system. |
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Installing the intake system
| Step 1 |
4h00m |
Mount intercooler by
driver side tail light, build aluminium intake system between
turbo - intercooler - intake manifold. Incorporate pressure
line to ECU and sensor for ECU. |
| Step 2 |
2h00m |
Install 8" fan for
intercooler and install wiring harness for fan |
| Step 3 |
1h00m |
build ABS plastic pipe
air filter box |
|
7h00m |
Total time for installing
intake system. |
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© 2004
David Marshall
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