Got Some Goodies For The Jetta!!!

[Mr_Diesel]

I got a clutch kit... A friend of mine works at a local auto shop and he got it at cost!!! I saved about 100 bucks. This is a volkswagen factory made replacement, and should last me a good 75,000 miles (the way I drive it lol). I'm gonna start yanking the entire motor and tranny tomorrow so I can fix the oil leaks, clean up the engine bay and motor and everything.

1994 VW Jetta GL 2.0L 8V - $135.00

a. Clutch Assembly
b. Clutch Disc
c. Release Bearing
d. Alignment Tool

http://www.dubnetworks.net/images/clutch/IMG_1326.jpg
http://www.dubnetworks.net/images/clutch/IMG_1327.jpg
http://www.dubnetworks.net/images/clutch/IMG_1328.jpg
http://www.dubnetworks.net/images/clutch/IMG_1329.jpg
http://www.dubnetworks.net/images/clutch/IMG_1330.jpg

[jettadude]

nice, i gotta do a clutch soon

[GoodDayForADrive]

Looks good, but uh.. what's this doing in "Off Topic"?

[Mr_Diesel]

Looks good, but uh.. what's this doing in "Off Topic"?

LOL, I don't know... Wanna move it for me? lol...

I'm gonna start yanking the engine today.... Yikes!!! Never plucked an MkIII engine!

[jettadude]

moved

[GoodDayForADrive]

Looks good, but uh.. what's this doing in "Off Topic"?

LOL, I don't know... Wanna move it for me? lol...

I'm gonna start yanking the engine today.... Yikes!!! Never plucked an MkIII engine!

I can't, I'm not an admin.. have fun pulling that btw :lol:

Hey, while you're at it, do a write-up, so I can pull mine later :lol:

[Mr_Diesel]

Now you tell me.... I got the whole car tore apart, and I only have pictures of the last bit.

Note: I am pulling the entire engine to do this... Partly because there is a lot of oppertunistic work that needs to be done. Normally you would just drop the transmission to do the clutch, but I removed the entire engine, so I could fix the oil leaks, clean the grease off the engine and paint the engine bay. The intermediate shaft seal was toast... It was clear that it was gushing out of that seal. There is a high pressure oil feed that lubricates the IM shaft, and if that seal goes, you'd loose a lot of oil.

Differeneces between the MkII and MkIII engine removal are very miniscule. It is MUCH easier to remove the bumper, radiator support, and front subframe on MkIII. The MkIII bumper cover is fastened to the car with bolts... about 6 of them. This is A LOT better than the MkII where the bumper is usually held on by ghetto designed mounts on the side. The MkIII has these mounts, but after it's on, it's bolted to the car with 6 or 8 bolts...

I can see how it would be very very easy to swap an engine from a MkII into an MkIII chassis. The actual engine mounts are different, but the points where the engine mount bolts to the engine is the exact same as the MkII engines. 16V, 1.8L 8V, diesel or turbo diesel swaps from MkII would EASILLY mount into this chassis. If you have the VR6 or the TDI it would be considerablly harder because the transmissions are cable shift.

The entire wire harness for the car is all one big wad. All the wires that operate everything in the front of the car (horn, lights, turn signals, etc, all come off on one harness.

The MkIII, in short is a much better built MkII. They are similar in every aspect, but the way the vehicle is built is soooo much better. I personally think the MkIII is Volkswagens best chassis ever, now that I have had a chance to disect the entire thing.

Here is a list of the oppertunistic work I will be performing while the engine is out.

1. Deep clean and degrease the engine bay (mabey paint if it's bad)
2. Fix the IM shaft oil leak.
3. Replace Serpentine belt.
4. Replace V-Belt
5. Replace Timing Belt.
6. Degrease Engine
7. Replace H Block on AC
8. Replace all O rings on AC components.
9. Replace oxygen sensor
10. Degrease everything that is dirty


Here are some pictures of the project as it currently sits.

Here's the beast as it sits in the driveway by the garage:

http://www.dubnetworks.net/images/fixinclutch/IMG_1331.jpg

A Rear View of the engine and all the crap on the ground:

http://www.dubnetworks.net/images/fixinclutch/IMG_1332.jpg

Side View of the engine with all belts, tranny and IM shaft removed.

http://www.dubnetworks.net/images/fixinclutch/IMG_1333.jpg

New Clutch Plate Installed:

http://www.dubnetworks.net/images/fixinclutch/IMG_1334.jpg

Old clutch disc... WORN DOWN PAST THE RIVETS!!! 8O

http://www.dubnetworks.net/images/fixinclutch/IMG_1335.jpg

A crapload of old clutch dust that fell out of the flywheel when I took it off.

http://www.dubnetworks.net/images/fixinclutch/IMG_1336.jpg

All the crap I took off so I could pull the engine out of the front of the car instead of down through the bottom or up through the top.

http://www.dubnetworks.net/images/fixinclutch/IMG_1337.jpg

Oppertunistic replacements:

http://www.dubnetworks.net/images/fixinclutch/IMG_1339.jpg
http://www.dubnetworks.net/images/fixinclutch/IMG_1340.jpg

Outdoor mechanic's best friend: (damn bees)

http://www.dubnetworks.net/images/fixinclutch/IMG_1338.jpg

[GoodDayForADrive]

What's that weird thing bolted to the upper intake manifold in that last pic? That's not on mine, must be a weird OBD I thing..

[Mr_Diesel]

What's that weird thing bolted to the upper intake manifold in that last pic? That's not on mine, must be a weird OBD I thing..

It's a little hydraulic stop... If you let off the throttle really quickly this shishes down and absorbs the shock... It also makes the drop from a higher rpm to idle smoother. OBD I rules.

[GoodDayForADrive]

Hey I've been meaning to ask, and I don't wanna make a new thread, do you get a rattling sound from your 2.0? I always get this like rattling/buzzing sound while in low gears, usually only notice it when I'm in a neighborhood or something, going slowly.. What the hell is that noise? It's freaking annoying. Been there since I got the car, so I figure it's not harmful..

[Mr_Diesel]

Hey I've been meaning to ask, and I don't wanna make a new thread, do you get a rattling sound from your 2.0? I always get this like rattling/buzzing sound while in low gears, usually only notice it when I'm in a neighborhood or something, going slowly.. What the hell is that noise? It's freaking annoying. Been there since I got the car, so I figure it's not harmful..

Almost all 2.0L MkIII's have a heat shield over the exhaust manifold. They ALLLL rattle. Get your 13mm socket and take off that heat shield, and the rattle will be gone.... You really cant hurt anything by doing this, just make sure you wrap the oxygen sensor wires with electrical tape to protect them, and you should be okay...

Edit: I was looking at my friends OBD II 2.0L Jetta today... It didnt have that hydraulic stop either... And get this... IT DIDNT HAVE A FREAKING ISV!!! Do these engines not have an idle stabilization valve? Holy crap. Wierd.


Back on topic...

I finished up the clutch job today... It went really well. The clutch feels good. The timing on my jetta was off by 2 teeth.... This is why the torque was amazing, but the top end sucked bad... I fixed the timing, and it pulls all the way to redline now.... Much better power now.

I replaced the Cam shaft seal, the IM shaft seal, the crank shaft seal, the main seal, the valve cover gasket, and the oil pan gasket. NO MORE LEAKS!!!! I degreased and washed the engine bay and engine... The engine bay looks really clean now.

On a scale from 1-10, I would rate this as a 10. I will definatly consider having the shop do this the next time.... I did however, save about 370 bucks by doing it myself, and with that money I bought a 15 gallon upright air compressor, and a full set of pneumatic tools... (the impact wrench saved my life numerous times on this job... impact wrench makes a lot of the hard parts easy as pie, I highly reccomend getting one)

A rough estimate of the time it took to complete this job was 15 hours. The shade tree mechanic can expect this job to take about 15 hours if the entire engine is removed... It would probably take 7 hours to replace the clutch if you just removed the tranny, but like I say, there were lots of things I wanted to do to the engine that made it alot easier to do with the engine out of the car, so I just plucked the whole engine, and it took me about 15-16 hours to pluck the engine replace all the parts, and reinstall the engine.

While the engine was out, I decided to take off the battery, and the battery mount plate... There was A LOT of gunk under the plate. The kind of gunk that causes water to get trapped under there and start rusting shiz out. If you have an MkIII, I reccomend removing this plate and cleaning out all the dirt and leaves. I also put vaseline on all the areas that looked like it would being to rust... like all the bolt holes, and all the edges of the metal so it would help resist the standing water from the area.

They battery area always seems to have a problem with rust... I guess that white buildup on the battery terminals gets down in there and eats the paint off the area? I dunno, but the battery mount plate was starting to rust, so I sanded off all the rust and put about 4 coats of black primer on the plate to help with that.

Like I say, this was a very very very very very difficult job. It takes about 4 times as long to remove all the front end bits on an mkIII than a MkII. The removal/installation of this engine was a lot harder than a MkII removal/installation.

I am really sore and tired. This kicked my butt, but I saved a lot of money doing this myself.

I'll get some pictures in the morning.

[jettadude]

pics of the clean motor and engine bay!!!!!!!!!!

[Mr_Diesel]

pics of the clean motor and engine bay!!!!!!!!!!

Engine Before:

http://www.dubnetworks.net/images/fixinclutch/IMG_1333.jpg


Engine Bay After:

http://www.dubnetworks.net/images/cleanengine/IMG_1356.jpg

http://www.dubnetworks.net/images/cleanengine/IMG_1357.jpg

http://www.dubnetworks.net/images/cleanengine/IMG_1358.jpg

http://www.dubnetworks.net/images/cleanengine/IMG_1359.jpg

http://www.dubnetworks.net/images/cleanengine/IMG_1360.jpg

http://www.dubnetworks.net/images/cleanengine/IMG_1361.jpg

[jettadude]

thats freaking sick!!!!!!! great job!!! 8O

[GoodDayForADrive]

wow, cleanest 2.0 engine bay ever

[boehle]

i hate you...i wish mine would just stop leaking
page 2 owned bitchez

[SteveXs2]

That's one clean engine bay, awesome work on that. When you mentioned your timing it makes me think I should get mine checked too... I used to have good top-end but lately it seems like my low end torque has been good (ie; spinning tires when in 2nd gear) but my high end has cut out at around 4,500rpm from time to time.