Covid caddy project

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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

As usual the forum gets photos before the video drops.

A part 2 to the replacement of all mechanical auxiliaries sees the turbo, driveshafts, HPFP, rear shocks, firewall insulation, engine mounts, rear main seal and downpipe all being replaced. Along with a new clutch once the leaks finally stop, replacement control arm bushes to remove the urethane ones I'd previously fitted.

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Considering installing wing-nuts to hold the front on, given how often it's off.

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From here the bay needs a serious clear, it's been a moist cavern of oil and diesel for far too long.
It's a real credit to the guys here who smooth bays and do engine swaps it's a lot of work.

There's been a few parts arrive that aren't quite correct for the car, the downpipe has an O2 bung it doesn't need and it appears the turbo lines are wrong.
I'll be looking closer at the engine over the next few days to ensure it goes as smoothly as possible.

It won't be a 'slap together', and I expect the engine to be out of the car most of January. I have some stuff coming from Stanthevwcaddyman, and it'll be easier with the engine out.
How many is too many Volkswagens?
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

well day 2 of the Christmas fun, wasn't quite that. It was messy with plenty of expected issues along the way.

Removed everything from the rear of the engine.

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It then had the gearbox removed, and the back of the block and head scrubbed.

The coked intake manifold was one of the reasons for the engine removal.
Still not sure how best to handle this, thinking of having a cylinder head shop 'hot tank' the manifold
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The main reason for this chaos other than turbo replacement was the issues caused by this leaky boy.
I had previously re sealed the original pump, but 3 weeks post my last clutch replacement it let go again.
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As you can see it made a moist mess of the clutch I'd installed not that long ago.
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This has prevented anything over 50% throttle for roughly a year now.

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The mush is diesel and clutch fibre. Yummy.

After whipping off the sump,
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Pleased to find all is in order there, and surprisingly clean for it's age.

The coolant system on the car hasn't faired as well,

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A previous owner has attacked a lot of fittings with glue.
luckily I'm changing the heater box and core out.


Hopefully get the new rear main seal installed tomorrow, that's probably the only part of this overhaul I'm nervous about.
Need to pick up a few missing gaskets and seals from Volkswagen pending their parts department is open.
How many is too many Volkswagens?
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

Another day, and good progress.

Today's task had me nervous.

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While it all looks good, we wont know for sure until it's all reassembled, running and not leaking

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Let's hope this clutch lasts longer than the last one I installed

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Gave the gearbox a clean

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Along with the auxiliaries bracket, and oil filter housing in an effort to brighten them.

While I have further preparation to do, the reassembly will be unfortunately held up by some missing gaskets and parts.
How many is too many Volkswagens?
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

Four days into this chaos now.

Started by pulling back all the wiring.

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Then went about removing the brake booster to facilitate the replacement of the firewall insulation

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Then hit the bay hard scrubbing with degreaser.

Enjoy some before/afters

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I spent about 20 minutes hand polishing one half of the bay and got a good shine.

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Hopefully tomorrow I can pick up some well colour matched paint and tidy up a few areas before dropping the steering rack/subframe to install the firewall insulation.
How many is too many Volkswagens?
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

Apologies, I forgot to update this thread last night.

After completing the hand polishing of thre engine bay.

Confirmed paint work was required.
Old outrigger holes were finally welded up, and the previously hidden selections now exposed by the mk4 front end prepared to be colour matched.


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From primer into 2 stage colour and clear.

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From there I went insulation wrestling

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And for good measure test fitted the upper tray and upper insulation

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Hopefully tomorrow my missing gaskets are arriving tomorrow, this should facilitate my engine and gearbox being fully reassembled.

I have a few other items to attend to before that can be reinstalled in the freshly cleaned bay but progress is moving move than it has in a long while.
How many is too many Volkswagens?
stu_b
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Posts: 933
Joined: Sat Mar 18, 2023 5:28 am
Engine size/power: 1.6 CR TDI (75bhp)

Re: Covid caddy project

Post by stu_b »

Kudos to you my friend
May 2025 see this beauty back on the road without any idiots trying to kiss you (crash into you)
Hope the Xmas holidays are seeing good progress
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

Thanks. I figured we get all the bad luck out of the way before I paint the van.
I'd be far more upset the other way around

Yesterday saw the engine bay completed with the AC lines cleaned and installed. They're not as bright as everything around them. But replacements weren't in the budget

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I turned my attention to completing the engine and gearbox work.

The intake manifold all cleaned inside and out

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It looks pretty nice with the new turbo mounted up

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That was a whole ordeal. The parts supplier going off my VIN failed to provide the correct turbo lines and gaskets. Vw to the rescue.

Today I replaced the timing belt and water pump, this completing the intended mechanical work.

Everything is now ready and waiting for the car to go back together.

In preparation of the duel zone climate install, this happened tonight

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You can see here how badly the mk3 heater box mates to the the mk4 dashboard without the correct heaterbox adaptor

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So one benefit will be resolving this leak.

Today I fitted a new heater core and pollen filter to the new heater box assembly. Hopefully get it in position tomorrow.

I did check, the mk4 dashboard has provisions for the duel zone temp sensors, with rubber blanks installed

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Looking forward to my new seats and some tech installed, coupled with hopefully some smoother driving
How many is too many Volkswagens?
CaddyMountain
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Joined: Mon Jul 15, 2024 4:08 pm
Engine size/power: 2.0 CR TDI (83bhp)

Re: Covid caddy project

Post by CaddyMountain »

Great work! It is big project! Almost a restoration :)
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

It's basically becoming a restoration.
Hopefully it equates to a car that's good to drive for another few hundred thousand kilometers.

It's 40°c today, so it's cooking in the shed.
I got the crash bar out and the old heater box assembly

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It would appear my timing was good as the old heater core had started leaking

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I've swapped the required items such as the heater box drains across to the new one.

Once it drops below 30°c at around 10pm I'll weigh up fitting the new heater box.

Not sure if it's best to wait for Stan to provide the loom before I go to that trouble
How many is too many Volkswagens?
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

In case anyone was curious

Last night I decided to put the new heaterbox in

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No leftover hardware at the end either.

Caddy ducting retained, finally have the correct Mk4 top duct installed, new drain installed too.
Once the new wiring is in place we should be good to rock and roll
How many is too many Volkswagens?
kobat79
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Joined: Fri Aug 11, 2023 11:27 am
Engine size/power: 1.9 TDI (104bhp)
Location: Co. Louth, Ireland

Re: Covid caddy project

Post by kobat79 »

That's an incredible amount of work and great attention to detail buddy. Nice job. Thanks for documenting it in such great detail for the forum, too. It's much appreciated.

Sent from my SM-A546B using Tapatalk

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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

Thank you.
I'm not sure how useful it'll be to anyone, other than scaring members off doing similar things.

Some tech has arrived, at the convincing of Stan.
Instead of the mk6 golf panel I had intended a mk7 style unit is in play

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And something I've wanted to do for some time and posted in the other section of the forum about it.

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Some factory Mk4 fogs
And to accompany them a highline ccem.

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This is to enable "static turning light using fog lights" a feature my wife's previous Tiguan had that I quite liked.

Figured while I had the dash out it was worth installing.

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I'm now at the point, once I have the required looms the whole thing can go back together inside and out.
Hopefully happens shortly.
How many is too many Volkswagens?
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

Not a lot to report on while parts are being waited on.

Stan has been a total tease as usual sending photos through of his work.

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My fog light grills finally arrived from Europe

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Still considering coating the lenses for a french/yellow look

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And now we're back to waiting.
How many is too many Volkswagens?
FishermansFriend
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Location: Ireland Dublin

Re: Covid caddy project

Post by FishermansFriend »

That's a lot of work and parts, fair play to you. The van is in good hands. Everything nicely documented.
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fishynos72
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Posts: 319
Joined: Mon Aug 24, 2020 10:12 am
Engine size/power: 1.9 TDI (104bhp)

Re: Covid caddy project

Post by fishynos72 »

FishermansFriend wrote: Sun Feb 02, 2025 9:53 am That's a lot of work and parts, fair play to you. The van is in good hands. Everything nicely documented.
Thank you, high praise from you,
Ive seen your build thread.

How are your brakes?
How many is too many Volkswagens?
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