2strokesmoke's (formerly JGWarner's) Turbo Diesel Fox

[JGWarner]

(EDIT 8/2011: this project car was sold to the illustrious 2strokesmoke, who will be completing the project. Thanks for all the support folks!)

My '88 Fox wagon will soon be receiving a heart transplant, from an '85 Quantum 1.6 Turbo Diesel. The motor only has 170k (minty by diesel standards) runs great, and was lovingly spared the wrecker's yard by one JohnBarleyCorn.

Why diesel? The Fox weighs about 800lbs less than a QTD, which was already capable of 40+mpg. 50mpg is not unheard of in the lighter TD Jetta and Golf of the era. Fuel economy is the primary benefit here, not screaming power numbers. The turbo will help, but we're still only talking around 70hp. Have no fear, diesel and gasser hp numbers have little comparison. The actual drivability should remain the same.

The patient:



The donor:



The organs in question:



Surgically removed by Dr. BarleyCorn!



Questions welcome. Updates to follow...

[reddfoxx]

[oRANGEJULIUS]

Sounds like a great swap! My old MKII jetta 1.6na diesel would regularly achieve 47-50mpg (mixed driving) with 380k on the clock; stout reliable motors for sure. Cant wait to see the MPG figures for the fox. Good luck with the swap!

[JGWarner]

Just ordered the first batch of parts from AutohausAZ:

1 0009871145 Fuel Hose/Line; Diesel Injector Overflow Line End Plug; Hose Plug
1 016141181 Clutch Release/Throwout Bearing; Guide Sleeve
3 026103085D Crankshaft Oil Seal; Front; 32x47x10mm
1 026115441A Oil Filter Gasket; Oil Filter Flange Gasket
1 026198025C Valve Cover Gasket Set; Rubber with Replacement Studs
4 028129589B Exhaust Manifold Gasket
1 068103051G Crankshaft Oil Seal; Rear Main/Crank Seal; 85x105x12mm
1 068109119E Timing Belt
1 068109243F Timing Belt Tensioner Pulley/Roller; Metal Roller
2 068115561B Oil Filter
1 068129717E Intake Manifold Gasket
4 068130219 Diesel Injector Heat Shield; At Base of Injector; 5mm Orifice
1 068130309 Fuel Hose/Line; Fuel Pipe from Filter to Pump
1 069129620 Air Filter
8 11621711954 8mm Copper Nut; Exhaust Manifold to Cylinder Head
1 2012 Anti-Seize Compound; 100 gram tube
1 3151193041 Clutch Release/Throwout Bearing
1 6050780581 Fuel Hose/Line; Braided Hose 3.2mm ID x 1.9mm Wall; Bulk
1 74010 Fuel Filter
1 811199339B Engine/Motor Mount; Front Anti-Torque Mount/Bushing
1 811399151B Manual Trans Transmission Mount
1 893199381B Engine/Motor Mount
1 893253115 Front Pipe Gasket; At Front Pipe/Wastegate
6 N90206103 Flywheel Bolt; 10x19.5x1mm
1 N90353501 Auxilliary/Intermediate Shaft Oil Seal; O-Ring Front Seal; 56x2mm; At Countershaft/Balanceshaft
1 W0133-1634877 Engine Mount

I really shopped around on these parts, AutohausAZ's prices are almost unbeatable. Everything is brand name, usually german manufacture (Mann, Bosch, etc) and free shipping on orders over $50. They even use OEM part numbers. Love AutohausAZ

Still more parts to be ordered, and some random stuff AZ doesn't stock.

Stay tuned.

[JGWarner]

Ordered a new fuel tank today (explanation to follow) from my FLAPS, of all places. Also ordered new radiator surround pieces from the local VW stealership, and they assure me there are plenty left, of all three sections. See my "Who's still got radiator cardboards?" thread.



#5: 305 121 291 1
#6: 305 121 329 4
#7: 305 121 281 1

Though, I had a funny moment when the VW parts guy said:"You know all these parts are obsolete, right??"
To which I replied: "My whole car is obsolete, pal."

Things are moving fast- the motor arrives tomorrow! I am headed now to my uncle's place to setup the engine lift. Wee.

[mike in SC]

Cool project. Keep us updated with pictures, please.

It ought to move along well with the TD, seeing as how it came with 81(!) hp when new.

[alaincopter]

Awesome, good luck with the swap! Couldn't have started with a better donor. Please take lots of pics, a well documented diesel swap is very inspiring

[JGWarner]

No worries, I intend to document this swap so thoroughly you might become UNinspired.

[darthaus]

There better be room in the garage for when I do my cat and downpipe!

[Veedubyoo]

It's filling up fast....to the point the 'Beloved' might have to go out!!

[JGWarner]

Things are moving fast! Pics below, as requested. The swap is taking place at my uncle's (AKA Veedubyoo).

By the way, this makes my uncle one indisputably cool dude. As for my cousin (darthaus) there's plenty of room for your VR6 A4. In the driveway.

The motor arrived this morning, born by JohnBarleyCorn's Quantum Syncro, seen below in all it's two tone glory:



I had to grab a money shot of the 5-cyl yumminess:



My uncle's driveway, full of VWs! In this shot, a BX wagon, B2 wagon syncro, my uncle's B4 wagon TDI, and buried in the snowbank beyond, his daughter's A4 sedan. All that was missing was my uncle's B5 wagon and his son's A4 sedan VR6! We dig dubs around here, can you tell?



My first glimpse of the 1.6 TD with it's 9Q trans still attached. Replete with black goop:



JohnBarleyCorn (Pete, in real life) and his friend Cameron were on the way through CT to pick up a motor in NY, and saved me the trip to Cape Cod by dropping off the TD on the way. The stars really aligned on this deal, it worked out great for everyone. Now I want one of those little trailers. Thanks again JBC!

The TD was promptly unloaded and came to rest in the workspace:



And the work began. First job was to remove the transmission. Edcon91 II is the lucky buyer for this trans. That's right, I'm not using the 9Q. I decided to use the PSA for the lower 5th gear RPM. I do alot of highway cruising for work, and the goal of this swap is drivable fuel economy.

This one's for you, Edcon:


Next came the pressure plate, clutch, flywheel, starter and it's wiring, then the fuel filter line, power steering bracket, A/C compressor and bracket, turbo and turbo drain line. All residual oil was drained from the motor. Here's how she currently sits:







Also, this label on the valve cover made me ROFL:



And incidentally, I've never seen a dog sleep so hard:



*PHEW* what a day! More tomorrow!

[doppelfaust]

More pics of the Citroën!

[turbinepowered]

More pics of the Citroën!

... Only a foxer!

And dude, that engine isn't oily at all. I came here expecting to see pictures of a totally sludged over engine.

Disappointed.

That's just six digits of mileage and no powerwashing in its history that you're seeing, not any kind of extraordinary slime.

I feel lied to.


It's also 6AM and I'm still up. Thus all the smilies.

[Veedubyoo]

More pics of the Citroën!

OK I'm impressed! Was wondering how long it would be before someone noticed what was in the background(and recognised it!)

[JGWarner]

Belongs to Veedubyoo. Loving mechanical restoration done, cosmetic underway. I've driven it on several occasions, she rides like a cloud on the breeze!

I'll let him fill in the details. It sure makes a nice background to work against.

[reddfoxx]

Cool! Glad things are getting going.

[Edcon91 II]

[QUOTE=JGWarner;69963541]

This one's for you, Edcon:


Can't wait until Saturday!

[Fusor2]

[QUOTE=JGWarner;69968379]
that citroen is a cool car, i would daily it for sure, drive her right into the ground! as i did with my peugeot diesel 504

[Veedubyoo]

[QUOTE=Fusor2;69971495]

that citroen is a cool car, i would daily it for sure, drive her right into the ground!

This man needs to be beaten early and often...

[doppelfaust]

I'm confused, what is needed for the cosmetic restoration? It looks prestine!

Sorry, I'll leave this out of your thread Jonathan.

Let me get this out of my system, I LOVE THAT CAR. I've always wanted to ride in one.

[JGWarner]

The camera is generous, sadly. It needs paint pretty badly and there's a few rust holes in the outer panels, though I understand she's physically sound. The roof is fiberglass. The trim isn't chrome, it's actually stainless steel, which is why it looks so damn good for it's age.

Come out to visit, Steve. I'm sure you'd get a ride in it.

TD content:

Not too much done today, mostly just moving stuff around and organization. I took a bunch of greasy parts home to clean. I've got the intake manifold soaking in my kitchen sink like a dirty pot.

I took tomorrow off work, so perhaps more will come off the motor. We'll see.

[JGWarner]

Today, off came the exhaust manifold, passenger side motor mount and bracket, both coolant flanges, vacuum pump, the stupid glowplug buss bar, cold start cable, oil filter, oil cooler, oil filter flange, oil/air separator, injection pump throttle cable bracket, cruise control bellows and bracket, all coolant hoses and the hardpipe. All bolts are being meticulously bagged and tagged. Lots of bolts were coated with anti-seize, so obviously someone cared enough to do something right for a change. Good sign, I hope.



She looks pretty bare now.





Hey look, a block heater...





Got a good look at the engine code. This in an MD, as opposed to a CY. That means hydraulic lifters, and that saves me some work.



Apparently these motors are pretty rare, only produced for 11 months from '84 to '85 and only available in the Quantum. It also means I have a Garret T3 turbo instead of the more usual K24. This caught me by surprise when I wiped away a thick layer of gunk to reveal the "AiResearch" logo... more on the turbo later.

Both the head and the intake manifold were cast on March 29, 1985. Nearly every part is marked "Germany" very clearly.



You could not ask for a more perfect space to work. I am deeply grateful to my uncle for letting me use his garage and many of his tools.

I brought home a pile of parts, and sorted through the box of random bits that came with the motor. I will most likely spend the next week scrubbing grease off metal.

[greggearhead]

Nice swap project!

Looking on doing any upgrades to the engine? Intercooler, water injection, etc? Just curious. Cant' wait to see the fuel economy result.

I laugh when people brag about their Prius or whatever. Old technology out there that cost a lot less can do as good (or if you look at the real big picture), much better!

[JGWarner]

I am planning to intercool down the road, but not right away. I want the motor in, clean and running first. I am deleting some things however- such as the EGR. Obviously I already ditched the A/C, cruise control and power steering that came with the QTD setup. The glowplug system will be custom and far better than stock.

The overpressure valve, which is just a backup for the wastegate, is also on the way out. That way I can eventually push the boost beyond the 10 PSI factory limit. The turbo will be freshly rebuilt anyway.

I don't plan to go crazy with mods, however. Fuel economy is the point of this swap, after all. That said- the beauty of diesel is that some power mods actually IMPROVE your FE.

[bigdaddykool99]

I am planning to intercool down the road, but not right away. I want the motor in, clean and running first. I am deleting some things however- such as the EGR. Obviously I already ditched the A/C, cruise control and power steering that came with the QTD setup. The glowplug system will be custom and far better than stock.

The overpressure valve, which is just a backup for the wastegate, is also on the way out. That way I can eventually push the boost beyond the 10 PSI factory limit. The turbo will be freshly rebuilt anyway.

I don't plan to go crazy with mods, however. Fuel economy is the point of this swap, after all. That said- the beauty of diesel is that some power mods actually IMPROVE your FE.

looks like you had a lot of fun

[JGWarner]

Intake manifold is finally clean. Wish I had taken "before" shots, it was nasty. I still need to make block-off plates for the EGR and over-pressure valve.





That's right. It's gonna be one of those swaps.

[Veedubyoo]

Wow!! Thats impressive...I saw it before...

[JGWarner]

That's why they call it Elbow Grease, right?

Sorry vortex, private joke.

[turbinepowered]

I demand more pictures of dirty engine parts made clean and fresh!

Also, I nominate this moment as a time to go crazy-nuts with a can of engine paint.

[JGWarner]

Chevy orange! bleh.

Yeah this block will be high temp POR-15, probably with matching valve cover and oil pan. Color? I dunno, probably just black. Suggestions?

Was swamped with work this week, but I'm still making the intake manifold's two block-off plates. They're coming along nicely.

[JGWarner]

Dirty parts.



The T3:



Sadly, the turbo has a bit of play in the shaft. When I removed the downpipe oil poured out the turbine end, not a good sign. I'll be sending it for a professional rebuild, unless a plum turbo falls into my lap.

[JGWarner]

I finished making the intake manifold block-off plates. Bye bye EGR and BOV...





Below is a testament to the power in "Purple Power" cleanser. This injection pump throttle cable bracket was painted black. It is no longer. That was after soaking for about 3 hours in half strength solution. Supposedly it pits aluminum in less time. I've only been using it on the steel/iron parts, but it works wonders.



Had an argument with the dealer about the stupid radiator ducting, they messed up my order a second time. More on that later.

Big box of "presents" arrived from AutohausAZ. Still more parts to be ordered, amazingly.

Should be a fun weekend! Let's see how quick I can get to painting the block.

[doppelfaust]

Those block off plates look like they came from the factory, nice work.

Obligatory pile of parts pic for Autohaus order is necessary, do it!

[Edcon91 II]

Impressive build so far! Keep it up. Keep it CLEAN!!

[JGWarner]

Who wants a solid 9Q ?

Edcon regrettably had to back out, he's got a deal cooking for a whole QTD, and I can't blame him. That means I can either use the 9Q, or sell it outright and buy Edcons PSA (we were going to trade plus cash, the 9Q being in demand) but this has me thinking about transmission options.

I got to talking with VW Fox (AKA THE Adam) and he mentioned if I really want a low 5th...

9Q 5th @ 65 mph = 3029 RPM
PSA 5th @ 65 mph = 2821 RPM
5M 5th @ 65 mph = 2489 RPM !!!

The 5M has the tallest 5th available in a longitudinal transmission- 0.600. Of course, good luck finding a 5M, they're pretty rare. Only came in early 1.7L B2s. Well what do you know? I just found an affordable 5M in NH. Might be picking it up this weekend! That makes this an even better deal than the one I had going with Edcon, so everybody wins.

And that means I can sell the 9Q outright. You're welcome, Foxers. This trans will make someone very happy!