Build TDI-J70 - LJ70 TDI Swap (Erika)

[DirtSniffer]

The eagle has landed

Now I can pretend to drive and shift it again!

Need to work on the tcase shifter more, I spaced it out with 3 drain plug crush washers and it seems close but now that it's in the car it is slightly hitting the floor hole edge when all the way to the left.

 

[AirheadNut]

Looking good! Such a satisfying feeling to have the drivetrain actually installed in the vehicle.

 

[fjdiesel]

The eagle has landed

Now I can pretend to drive and shift it again!

View attachment 4166683

Need to work on the tcase shifter more, I spaced it out with 3 drain plug crush washers and it seems close but now that it's in the car it is slightly hitting the floor hole edge when all the way to the left.

Its been 10 hours. Is it running?

 

[sogncab]

Its been 10 hours. Is it running?

It's like watching old people screw around here.

 

[DirtSniffer]

Knocked off some low hanging fruit this morning. Added a 4th crush washer behind the tcase shifter and now all looks good. Put the boots on, bolted up the driveshafts (one cross threaded nut I need to replace, hopefully I remember), bolted on the speedo cable, greased and plugged in the trans wiring harness, and hooked up and bled the clutch slave. With the slave in the same spot as it was originally, I was able to just reuse the original slave hose.

Going to take some measurements and order a harness from fast forward, I am currently planning to mount the ECU on this flat spot below the wiper motor. I would then have a smaller car battery in front of it to run the engine and rest of the electronics, and then I'm thinking a large deep cycle in the front driver corner to run the winch and other accessories.

 

[DirtSniffer]

Was able to use the original heater core return hose. Switched up the supply side a bit, now need to make a 180 loop off the coolant flange output and neck down in size.

Looked at ordering a fast forward harness and now see they have a 10-12 week lead time. So I just placed an order for a SESH harness, at most 2-3 weeks if they do not have all of the connectors on hand. May need to modify it a bit, and may be a bit trickier to work out the dash signal wires, but I don't have time to wait for the fast forward harness.

Also threw in the radiator and core support so I can measure for an intercooler. I THINK I can fit one of these in there.

 

[AirheadNut]

You must have a rear heater? That hose routing is looking nice and clean.

I'm just now working on figuring out how to connect up all my various heater hoses. Was planning on getting some manifold/adapter type fittings 3D printed out of aluminum, but then discovered they're manufactured in China and subject to up to 75% tariff so now investigating different options. Thinking about doing a welded aluminum manifold with different sized ports.

 

[DirtSniffer]

You must have a rear heater? That hose routing is looking nice and clean.

I'm just now working on figuring out how to connect up all my various heater hoses. Was planning on getting some manifold/adapter type fittings 3D printed out of aluminum, but then discovered they're manufactured in China and subject to up to 75% tariff so now investigating different options. Thinking about doing a welded aluminum manifold with different sized ports.

Yes, I'm somewhat tempted to delete it but at the same time don't feel like taking stuff apart to do so. Lol.

That's a bummer on the 3D printed stuff, looks like a cool option but probably expensive to have done here.

 

[DirtSniffer]

Ordering radiator hose stuff and ran across this and had to share. T-bolt clamp with a built in steam port? lol

 

[DirtSniffer]

Ground down the welds from my patches on the inner fenders and bolted them back in temporarily. Need to drill a few holes and weld on a pedestal for the rear battery tray yet, and I'm also looking to fab up a new battery tray for the front as the plastic tray was broken and I want a little bigger battery anyways.

I've decided it will be easier to use the original 70 vacuum canister as it is already tucked away nicely and has a hard line over to the brake booster already. And, there is a switch for i assume is a warning light on the dash in it already. Just need to run a line from the vacuum pump over to it and add a T for the N75 valve. This also clears up some room to run the upper radiator hose through that spot.

It will be a bit tight, but I still think the ECU will fit behind the battery there.

Power steering. I am going to use the original 70 reservoir and low pressure return line as they are. I have removed the old high pressure line as I believe it is too small diameter to use as a supply line. I'm thinking I'll run a larger one through an inline cooler behind the low pressure line. Will then need a custom high pressure line made after I get a pump on there.

 

[jblueridge]

Yeah, vac can switch triggers warning on dash.

 

[Old Nick]

Really enjoying reading your thread. I got stalled on my swap for lack of time and cash. But, it's going to happen. Made me very happy to see that engine/transmission in your rig. I'm following along.