The Toad's DG to AGG Gti Conversion

[badgerfax]

Joy and despair today.

Firstly the joy. The engine has come off the stand..... This was a small milestone but a milestone nonetheless.

My first job was to install a needle bearing in for the input shaft. For some reason I was expecting to have to remove one but this was not the case



My new bearings from BW. I have new input shaft needle bearing for the engine and a spigot shaft seal for the bell housing.



Fitting the new bearing was simply a case of tapping the bearing in squarely, firstly with a block of hardwood and finished off with a same diameter socket.



Now for the despair, and I really feel like pulling my hair out.

I fitted my supplied flywheel with no apparent problem. Inserted the supplied friction disk but the pressure plate is about 3mm from bolting to the flywheel. Either I have the wrong flywheel, disk or pressure plate.


This is where my lack of mechanical knowledge is evident as I am not sure what its supposed to be like when all the bits are correct.


This is the gap. around 3mm

[Aidan]

sorry to tell you but it looks like you fitted the spigot bearing the wrong way around, the face with the lettering on is the seal end and it faces the gearbox, the seal is to keep the clutch dust out of the bearing

[dave friday]

Regarding the clutch friction disc..have you fitted it the wrong way round?

[badgerfax]

sorry to tell you but it looks like you fitted the spigot bearing the wrong way around, the face with the lettering on is the seal end and it faces the gearbox, the seal is to keep the clutch dust out of the bearing

After the day I had yesterday i'm not surprised

Looks like BW will be getting another order

Thanks for the guidance Aidan

[badgerfax]

This evening I rectified my mistake with the input shaft bearing kindly pointed out by Aidan, I did contemplate doing this in October when the gearbox is going to be taken out for rebuild but I am glad that I did it with the engine out as it was harder than I expected.

I used the method posted by Ichyfeet As I don't have a slide hammer bearing puller thingy. I wanted to try the bread method but did not have a suitable size drift.



Lesson learnt: Block of wood needs to be approx 50mm thick. hole 25mm and the rawlbolt thread around 80mm. Did go through a few before I got it right.



Bearing take 2



Right way round this time

[300CE]

Keep up the good work Badger, great thread!

[badgerfax]

Keep up the good work Badger, great thread!

Cheers for the encouragement, Appreciate it

[badgerfax]

Well I'ts been a rather productive couple of days.

After my hiccup with the clutch that was basically down to my own inexperience. And the bearing that was down to my stupidity things have progressed.

I have given the newly acquired (Thanks Aidan) clutch bracket a scrub and paint.



And replaced the input shaft bearing in the bellhousing.


Then got greasy



Now then Enjoy a nice tipple, turn down the lights, maybe light some candles, stick Marvin Gaye's Lets get it on on the stereo.....





Actually it was more akin to teenagers fumbling about while the parents are down stairs but we got there in the end

[badgerfax]

Major milestone reached today, The engine is in the bus. Yippee.

Thanks to Elvis for the advice on fitting procedure, It worked really well and I managed to do it on my own, much to my wife's surprise
Main thing is to get the support bars in place and have trolley jack, lumps of wood and axle stands ready to support the gearbox.





Next job is to connect the drive shafts, the oil filler tube and throttle cable, hope to get on with it after work tomorrow.

[syncropatrick]

Glad to see the project pushing on.

[badgerfax]

Glad to see the project pushing on.

Cheers Patrick, Hows your build coming along?

[300CE]

All that hard work will definitely be worth it!

[syncropatrick]

Glad to see the project pushing on.

Cheers Patrick, Hows your build coming along?

Not at the moment. Rest of life has taken over for a couple of weeks. Should be starting up again on it this weekend.

[badgerfax]

Well it's felt like playing whack a mole at times this week, specifically with the clutch slave cylinder bracket arrangement. Changing from petrol bellhousing to diesel, you need a diesel slave cylinder bracket as the petrol bracket interferes with the starter motor.
I have fitted the new bracket (thanks Aidan) and now find that the pipe from flexi bracket to slave cylinder is too long
Solve one problem and another rears its head.

On a more productive note, I have 2 driveshafts with shiny new UJ,s,
The Chinese puzzle that are stainless water pipes are now routed and connected at the rad end (glad to get that out of the way...jeesh what a ball ache )
2 new heater hoses ran and connected at the matrix
The freshly painted oil filler neck is on.
And the first fill of oil has gone in....Yay


The exhaust pipe manifold needed a bit of a trim as it fouled the engine mount.

just cut the lobe off!

Here it is test fitted


The other hiccup I had today was with the Rjes throttle cable. The inner cable came with 2 different trunions, one at each end. When it came to cutting off the one I didn't need in order to thread it through the outer, the cable splayed a few times and I was concerned that I would not have enough. I ended up dripping wax on the cable and that seemed to help.

[badgerfax]

I have decided to try to fit an airbox on the near side, this is not, from the look of things now that the engine is in, going to be particularly easy as it's tight as a nuns knees.

I have seen pipes routed across the back of the engine to the off side where the original airbox was sited. I am concerned that the heat from the exhaust/engine and the length of the ducting is going to be a problem.

I would welcome suggestions regarding the air filter arrangement.

With that in mind I had a go at fitting my ECU this evening.
I have had conflicting advise on whether the ECU has to be isolated from the car body. Part of me wonders why, if there is a risk of shorting the casing, VW would have made the case with any metal on show?
So I have made some rubber pads and insulated screws just to be on the safe side.