Alaskan 85 Weekender, 1.8T (AWM), 5 speed conversion

[tristessa]

[Wellington]

martinjnc; talent.
3 posts in 17 years, I bet you have a lot more you could share with us.

Some members I just sit back in awe at their abilities.

[martijnc1]

[akmush]

Thanks for posting martijnc1! I look forward to seeing more photos of your work.

Dealing with some final things with the motor on the stand and then my plan is to mate it up to the tranny. Getting close to pulling the waterboxer! Some questions for the 1.8T gurus-

Crank breather system- This junction used to go to a bleeder valve according to my Bentley. Do I need this or just plug it?

[akmush]

This is the stock set up for the pressure regulator valve. I noticed on many of andrew's pics he has silicone hose to the turbo intake and places the valve right next to the turbo intake. Fine to leave as is or is bumping into raised engine cover the issue?

[akmush]

I believe this is the Turbo cut off valve. Leave or remove?

[akmush]

And here is the original flywheel, clutch plate and pressure plate from the donor. I know I need new stretch bolts for the flywheel. Do I need to do anything else to the flywheel before install? How about a new clutch and pressure plate?

[tristessa]

That clutch disc is done, get a new one. Maybe, *maybe* look into converting to a single-mass flywheel (solid) instead of the DMF that's there, but I'll defer to those with mo betta experience on that front.

The "turbo cut off valve" is the diverter, and it's definitely needed if you like your turbo. Get a spare and toss in the glovebox or go to a rebuildable billet version -- I had one fail on a camping trip to Vancouver Island, and nobody in Victoria had a replacement on the shelf.

Move the pressure ergulator valve if it interferes with the engine lid, which I'd guess it does if Andrew is relocating them. AEB doesn't have it there, which could explain why it's only moved in some of his pics and not all of them.

You need the bleeder valve. TBH, you want to replicate the factory setup as much as possible aside from easily-done well-documented things that really only relate to emissions, like an SAI delete.

[xoo00oox]

[tristessa]

[xoo00oox]

This one is a 2004 Audi A4 1.8t engine, AMB code. You're right, it has the returnless fuel rail.

[vanagonjr]

[revolution337]

[tristessa]

[akmush]

I'm back! Can't believe I haven't posted since March 21, 2021

I'm susceptible to the "If it aint broke keep using it" philosophy. Last summer rolled around and the waterboxer while still slow, was reliable so I postponed. Some van highlights from last summer-

My first muffler welding project-

[akmush]

The van had been running hot for awhile so after checking thermostat I pulled the radiator. The scale confirmed my issue! Old radiator / replacement-

[akmush]

In June I was on the east coast and had a chance to visit with Vanagonjr and test drive the van! What a treat, now I have experienced the 1.8T and the lovely whrrrr of the turbo when it kicks in. Thanks for the test drive! Here I am feasting my eyes on the shifter linkage-

[akmush]

Two other projects to share from last summer- In Aug. I found a 1958 21' Chestnut Freighter Canoe. We moosehunt every fall in a sprawling area of wetlands northwest of Fairbanks and freighter canoes are our craft of choice. This beauty is fiberglass covering cedar ribs with an incredible weight capacity. I reinforced the transom, revarnished various parts and constructed seats.

[akmush]

And since COVID cooped me up at home pondering house projects, I decided to learn how to tile This took up much of my spare time this winter but is finally finished!

[akmush]

Now the reversed 1.8t is my primary focus (besides work).

Next steps-
1. Weld stub axles so the Passat tranny will work with my Vanagon CV's.

2. Install clutch and pressure plate and mate the engine and tranny on the floor dolley.

Stay tuned!