8: WAITING FOR PARTS IS KILLING ME!!!
Project #1 TDI MKII
Today I drove up to Edmonton and picked up a starter for the car from
MrDave. I got back all excited and found that the stock M10x135mm bolts
don't go far enough to mount the front engine mount to it. Dammit, another
Well, I got bored waiting around for parts to arrive, so I started looking
at what I wanted to do with the intercooler tubing. The stock MKIV air
intake is on the driver's side. The I/C plumbing goes along the left side
with the I/C just under the passenger's light.
I'm looking to have the I/C right next to the passenger light if
possible. It may mean getting a smaller radiator though. I still want
to have the air intake on the passenger side so that I don't have to relocate
Here's a rough mock-in for measuring clearances.......
A little something that's been kicking around in the back yard for over
a year. Yep, it's a stock big bumper and it's got a rear buddy. Obviously
paint is part of the project....
And here's the clearance between the passenger shock tower and the engine.
I may have to do the VR6 "thumping" on the frame rail for the
V-Belt to clear. There's only about 1/4 inch clearance between the rail
and the pully and the mount was up by about 3 inches and in by about 1-1/2
Well, finally got the starter bolts last night and went to test fit the
engine into the bay. The pulley's for the serpentine belt are much wider
than the stock engine, so I can't get the rear mount hooked up. Looks
like I'm going to have to do the frame rail massaging after all.
Now, where did I put that sledgehammer?
Well, I didn't use the sledgehammer approach. I just used a ballbeen hammer
to flatten out the corregations on inside of the frame rail. I only need
just that much room. It's pretty damn strong stuff. I had to "convince"
it over quite a few blows.
What I did find that was disconcerting was that the turbo's Vacuum Diaphragm
is interfering with the rear mount's siding. I'm going to have to cut
it away, but it's awefully close.
I think when I get it all positioned just right so that the axles fit
in right, I may get a welder buddy to install the MKIV mounts. I won't
cross that bridge until the car is running.
Oh, a few more pics:
Here's the pics of the starter bolts. The very top one is the stock 135
mm MKII bolt to mount the starter and engine mount. It is just way too
damn short to even reach through the hole in the engine flange. The bottom
ones are the bolts I got from a local fastener place. They are 150 mm
and can get there, but are just a little too short.
The ones in the middle are my favorite. Why? Because they are my first
part towards an Audi RS6 (or S8 or Phaeton.. pick one). They are 160 mm
long and fit just right. For you swapper lunatics doing MKIV swaps into
MKII's here's the part number N 104 713 01 (M10 X 160mm).
A note, get the bottom one screwed in just to the edge of the motor mount's
threaded piece, then do the top one. The bottom one is really tight agains
the block and the bolt will actually follow the thread pattern of the
M12 bolt thread that's there for the stock MKIV starter bolt. It took
some swindling, but the front mount is on.
Here's my handy work with a hammer.
...and here's it in a way that you can actually see what was done. Two
corrugations were flattened and the third was tweaked just a little. The
worse clearance issues are closer to the firewall because the frame rails
narrow and also drop. With this in place, I've got a bout 1/2" clearance
between the serpentine belt and the frame rail.
And yes, I'll have to get longer coolant hoses because I had to clock
the oil cooler forward. I may clock it a full 180 degrees and just have
the coolant hoses reach around, just for radiator clearance issues.
OK, so over the weekend, I picked up some new Saw'z'all blades and today
I cut up the rear mount. Here's some pictures of it. As you can see, the
vacuum diaphragm is interfering with the side of the mount. If the mount
moves (which it does), it can bang easily against the diaphragm. This
worries me, but until I get some more research done on the clearance of
the MKIII mounts, VR6 mounts, and aftermarket mount clearances, I think
I'll just cut away a little more of the mount.
....pain in my ass!
Here's how tight the clearance on the rear mount is. I'm hoping that a
MKIII or VR6 mount would be shaped differently enough that the vacuum
diaphragm would have enough clearance for my comfort...The only problem
with that is that I need the subframe for it as well. More money, arrggghhhh!!!
A close up. This shows where I cut the mount and how close the two are.
As mentioned earlier, wiggling the mount causes it to tap against the
Here are some
better pictures of the situation. My thoughts are that the MKII 16V hydro
mount might give me the proper clearance that I'm looking for.
1992 Golf-TDI Swap (dubCanuck1)
1992 Golf-TDI Swap; The Swap Saga Strikes Back!