Saturn TDI

[Craig]

Heres a thread from the Sixthsphere.com forums of what I've been up to.

http://www.sixthsphere.com/forum2/vi...=311131#311131

[cfg83]

Craig -

Originally Posted by Craig

Heres a thread from the Sixthsphere.com forums of what I've been up to.

http://www.sixthsphere.com/forum2/vi...=311131#311131

Wow!!!!

CarloSW2

[cfg83]

Craig -

Are you using the Saturn PCM (I'm thinking no)? You should take it to a Saturn dealer for an oil change ! Or maybe a VW dealer !?!?!?!?!

CarloSW2

[plastic torpedo]

Damn that is off the hook! What kind of power will it put down?
I know this isn't for performance, but it sure as hell looks like it will be faster than a normal 1.9L You guys could make a kit or something, I'm sure a lot of people will be interested in doing that mod. I know I would (for my next engine) if I had all the mounts and stuff!

[Jim Dunlop]

Wowie-wow! That is truly awesome! Keep us posted.

[Craig]

Thanks! This is one-of-a-kind at the moment; still have a ways to go with finalizing the motor mounts, axles, wiring, intercooler, coolant plumbing, ect. But it's going together surprisingly well...the TDI motor is a bit more compact in overall length, although the front mount and oil filter warranted cutting out the engine cradle crossmember for a new one. I'll keep you guys posted as things progress.

[quiksc2]

Argh. Stupid work. They have so many things blocked, we can't even do our job. I can get on here, but 6S is blocked...

[cfg83]

Craig -

Originally Posted by Craig

Thanks! This is one-of-a-kind at the moment; still have a ways to go with finalizing the motor mounts, axles, wiring, intercooler, coolant plumbing, ect. But it's going together surprisingly well...the TDI motor is a bit more compact in overall length, although the front mount and oil filter warranted cutting out the engine cradle crossmember for a new one. I'll keep you guys posted as things progress.

Since I'm not a member of sixthsphere (yet ), I can't read this :

Q&A Thread: http://www.sixthsphere.com/forum2/vi...=311143#311143

Soooooo, can you give me some more details? Which year/model VW did the engine come from? I want to know so I can compare the curb weight of what the TDI engine was pulling to what it will be pulling in the Saturn. But I'll bet you already did this calculation, yes?

CarloSW2

[Craig]

I'll go into more detail later (doing this from work), but the drivetrain is from a 1997 Jetta TDI. I looked at the shipping invoice, and it weighed 318 lbs, but that was with the pallet and axles, so I'm guessing closer to 290 lbs. There's a lot you can do with these things; a simple chip change will bump this up from 90hp/150lbs to 120hp/200lbs...there are some people out there getting 200+hp out of them with more radical tunes. I'll see if I can get some pictures posted here for those of you who are having problems with accessing the 6S site.

[madpogue]

Hmm, a 200 hp biodiesel with a spaceframe . Now I just gotta find an old waggin with a blown motor.

[cfg83]

Craig -

Originally Posted by Craig

I'll go into more detail later (doing this from work), but the drivetrain is from a 1997 Jetta TDI. I looked at the shipping invoice, and it weighed 318 lbs, but that was with the pallet and axles, so I'm guessing closer to 290 lbs. There's a lot you can do with these things; a simple chip change will bump this up from 90hp/150lbs to 120hp/200lbs...there are some people out there getting 200+hp out of them with more radical tunes. I'll see if I can get some pictures posted here for those of you who are having problems with accessing the 6S site.

Ok, then here are the specs :

1997 Volkswagen Jetta TDI Sedan Specifications
http://www.automotive.com/1997/101/v...ons/index.html

- Weights: curb weight (kg) 1,215

1215 kg = 2673 lbs

1995 Saturn S-Series Specifications
http://www.automotive.com/1995/12/sa...ons/index.html

- Weights: gross vehicle weight rating (kg) 1,429 and curb weight (kg) 1,070

1070 kg = 2354 lbs

Sooooo, 2673 - 2354 = 319 lbs lighter, but that is not taking into account the difference in weight of the engines. Also, I think the wagon may have weighed more than 2354 lbs.

CarloSW2

[geartooth94]

craig, how much did the engine run you? did you buy the trans. too ?

[Craig]

I got everything out of a Jetta that was being parted out (motor, trans, ECU, wiring, intercooler, various bits, ect) for $2300, plus another $350 to ship it from California to Maine. If you ever have to have something like this shipped, have it shipped to a business, such as your employer like I did with mine. It's cheaper that way, and I just had one of my coworkers bring it to my house in his truck.

A couple of things I've done so far: I made up a new piece to fit the Saturn clutch master cylinder with a 1/8" FPT so I can use it to work the Jetta clutch slave cylinder, and I blew the Saturn shifter apart so I can rework it for the Jetta shift pattern. I'll get some pictures of this up so you can get a visual of what I am talking about.

[sc2dave]

Originally Posted by quiksc2

Argh. Stupid work. They have so many things blocked, we can't even do our job. I can get on here, but 6S is blocked...

same here,supposedly i can only use it for business purposes,but i can get on hotmail,bank of america, ANCESTRY.COM.Why the hell would someone need to check on their ancestry at work?

[quiksc2]

Originally Posted by sc2dave

same here,supposedly i can only use it for business purposes,but i can get on hotmail,bank of america, ANCESTRY.COM.Why the hell would someone need to check on their ancestry at work?

I can't even get on Hotmail anymore. And I use my email for work purposes. It's how I stay in contact with all of my reps.

[bgates2b]

Gotta update the links for the new server Craig

[Craig]

Sorry to be so long in updating this...between work and school, I haven't had much time for anything else! But here is a link to the TDI Club forum that I just started a thread on http://forums.tdiclub.com/showthread.php?t=193909 that I hope you find useful. I've been working on the wiring harness and various mounting brackets, plus I have some pictures of the modified Saturn shifter I built to work with the VW transmission.

[Craig]

Haven't been to this site in awhile, saw this mentioned in another engine swap thread and couldn't resist bumping it up. Progress has been slow but steady...the wiring harness is "almost" done, I now have axles and a shift linkage, currently have the shifter back out of the car for a reverse lockout mechanism. Winter makes it a little hard to work on it, but I've been making a lot of little parts i.e. exhaust flanges and stuff like that.

[Cat Fuzz]

Dang, that metal fab work is giving me wood. I would love to be able to fab stuff like that.

[Craig]

Thanks! I can make lots of things, but the only thing I can't seem to make is money!

Seriously, though, if you really want to learn more about metal fabrication, check with your local high school or college about courses in welding, machining, ect. Another really good source is www.lindsaybks.com for some excellent books on these and many other topics. I'm forever takings courses or reading/researching textbooks, the internet, engineering publications, ect; I'm currently enrolled at Southern Maine Community College in their Integrated Manufacturing Technologies degree program...I'm working on the academics at the moment (Business, Calc, Physics, ect), can't wait to get into their machining program!

On the other hand, I wish I could cook...