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Old 05-06-2013, 05:22 PM   #256
Cogswell
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Thanks for the update, I'm enjoying following along on your build.


Mike
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The good thing is, your damn motor can't read. If it says oil on the container, it's pretty much OK to dump in there.... ED.
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Old 05-06-2013, 05:57 PM   #257
a1fa
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Oh.. Seat, and Skoda, how I miss you.. Those bolts get rusty quickly.
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Old 05-06-2013, 09:28 PM   #258
Xtremjeepn OP
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Quote:
Originally Posted by a1fa View Post
Those bolts get rusty quickly.
Not when you live in the high desert. Rust is nearly non existent in Colorado. The rust came from the vans previous life in New Jersey. So I'm eliminating what corrosion I can.
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Old 05-07-2013, 06:22 AM   #259
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Think I may actually make some notable progress today. It's been tricky to sneak out in the garage with a 13 week old daughter around.


Got a bit done yesterday. It's just been lots of cleaning, and not the type of cleaning that makes you go "wow, look at how clean that is". More the type of cleaning that makes you go "ugh, finally its clean enough to not cause problems!"


Here is an example of what I've been dealing with. There are a few things that must be swapped from the AXK Eurovan motor to the BDF Jetta motor. Things like the valve cover, oil pan, oil pickup tube, oil cooler, oil filler neck (start to see a pattern here?) I have to swap over a bunch of oil system parts from a motor that had an oil system problem. So everything must be cleaned to a fault to make sure to not contaminate the new engine.

Here is the underside of the valve covers. Note that the one on top has already been media blasted once and I've spent about 2 hours with various degreasers, even soaked it over night and lots of scrubbing.

I finally got it clean enough to see that the black plastic end piece was removable. (I wish I would have taken a picture of this when I started, you couldn't tell the black plastic end piece was a different material than the Aluminum cover. How crazy is that?

When I removed the cover I discovered a whole new valley of crud. Took quite awhile to get it clean enough to install.

The interior angles, hose mounts and oil filler mount are totally different on the Eurovan valve cover. Which is why it had to be reused.





There was no way that nasty old cover was going over this new valve train!




Once the parts were finally clean enough (no picture), I filled the motor with new Mobile One oil and pulled the oil pump drive and primed the pump with an air ratchet. Normally I'd do this a bit later in the process but the oil pump drive lives under one of the headers. Which means to access it you must have the intake and header off.




Then the valve cover was finally ready to go back on with as many new parts off the new cover as possible. (And a bunch of other stuff magically hopped onto the engine too)

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Xtremjeepn screwed with this post 05-07-2013 at 06:30 AM
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Old 05-07-2013, 04:04 PM   #260
RocketJohn
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Nice work!
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Old 05-07-2013, 04:41 PM   #261
Xtremjeepn OP
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Cool2

Well, I decided that since the stock Crack Pipe lasted 152k that there was little value in a $100 aftermarket one for me. So off to the dealer today to pick up a new factory one for $34!

Somehow the 15 mile trip to the dealer took 60 miles....




Then over the next 4 hours this happened!





When I did the timing chains I brand new O-ring for the thermostat housing. It's expanded to the point it doesn't fit. So that stopped me for the day. Once I get a new one there really isn't much left to do.

Need to reassemble the CV shaft and install the front of the van!

I also took the time today to add a nifty retrofit from my 1993 parts van!! Can any of you Eurovan experts identify it in the picture above?
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Old 05-07-2013, 04:45 PM   #262
MasterMarine
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I spy a transmission dipstick!

I snagged one from a van in the wrecking yard and put it in my 2002.
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Old 05-07-2013, 04:48 PM   #263
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Quote:
Originally Posted by MasterMarine View Post
I spy a transmission dipstick!

I snagged one from a van in the wrecking yard and put it in my 2002.

Very good

I took it from the 1993 that I stole the Poptop parts from. Just kinda forgot about it when I assembled everything last time!

Did you have to add your own mark to the dipstick? Or is the stock one right when warm?
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Old 05-07-2013, 04:56 PM   #264
MasterMarine
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I filled the transmission as you are supposed to (overfill, warm up to proper temp, drain out excess), then checked it one the stick at that temp. I made a note of where it was at. Then I warmed it up to proper operating temp and checked it again. I made a note of it then. Then I let it cool down overnight and started it up and checked it again. I then took all the info and made a label and stuck it on the radiator core supports so I can check it hot, cold or at the proper transmission measuring temperature.

I don't remember having to add any marks. TXpigeon on EVupdate sent me an email about there being more than one dipstick and tube used through the years. I will try to find it when I get home and post up the info.

MasterMarine screwed with this post 05-07-2013 at 07:08 PM Reason: spelling
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Old 05-07-2013, 05:10 PM   #265
Xtremjeepn OP
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Thanks
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Old 05-07-2013, 07:13 PM   #266
MasterMarine
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Here is the relevant portion of what he wrote to me:
Look to see if the dipstick stops at the end of the tube or about 1/4-3/8" in. There were a couple of lengths used and that's important for setting the level correctly. If it goes nearly to the end, the level is checked at 95-113°. If it's about 1/4-3/8" short, it should be checked at 140°. In either case the fluid should be half way between the dots. Once you've got that right, you may want to check it at a cold start and after a trip so you won't need to wait for an exact temperature in the future.

Even the overflow method depends on what year you have. If the overflow tube is green, then it's checked at 95-113(target 104). If it's black (longer), it's checked at 140. I didn't realize this until recently after I found out there were different length dipsticks. Have fun!

txpigeon
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Old 05-10-2013, 03:03 PM   #267
Xtremjeepn OP
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It runs!....now I'm off to have a margarita before assembling the rest of it!
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Old 05-10-2013, 07:02 PM   #268
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You and your ritas!
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Old 05-11-2013, 04:59 PM   #269
Xtremjeepn OP
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Talking

Well, I got distracted and did lower ball joints while I was in there today. But I did finally put it all together and take a drive. Runs SMOOTH. Gotta love the smell of assembly lube in a new engine!

Only drove for about a mile and only up to about 45 just to make sure it all worked. (And it was starting to rain)

Now it needs a bath and the fun parts can begin!

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Old 05-11-2013, 05:40 PM   #270
George Papadopolis
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love it!
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