Ecomodding the TDI Beetle

[arcosine]

2000 TDI Beetle 5 speed, red.

I bought this for $500. Oil was pouring out of the exhaust, about 1 quart in 5 min.

I will remove and inspect the turbo to see if I can rebuild it (kit is $55) and clean the carbon out of the intake manifold.

The exhaust is broken in two just after the converter, it will need to be welded back.

Tires and struts are good, no uneven wear. 205/55R16

197,600 miles.

Id like to fit the SWB bike inside. That would need a boat tail. I should get twice the mpg as the Honda odyssey (25-26 hwy last fillup) driving to and from events.

I'll explore EGR mods, belly pan, fender skirts and 5th gear swap.

The idea is to use another beetle hatch to attach the boat tail and it would lift up for access.

[arcosine]

I got the turbo and intake manifold out yesterday. I undid the lower motor mount and was able to push the engine forward enough to drop the turbo with exhaust manifold out the bottom. Once out, I was able to access the stripped allen head on the intake.

Turbo is shot, compressor wheel rubbed the housing, not rebuildable. I can get a new one on Craigslist for $500. He also has a set of .656:1 fifth gears() for $250.

EGR and intake were half clogged with carbon sludge. Cleaned them out mechanically, then gasoline solvent, then water with lots of Dawn detergent. Built a fire and boiled it and then the presser washer on it. Bare metal inside now. Intake ports need cleaning too, but rain today. I'll order the turbo when funds are in my pay pal.

Dreaming:

[Daox]

Ah the joys of working on the ALH engine. I remember swapping one out on my sisters 03 Jetta TDI. Not an over abundance of room.

[Dave's Civic Duty]

Originally Posted by Daox

Ah the joys of working on the ALH engine. I remember swapping one out on my sisters 03 Jetta TDI. Not an over abundance of room.

Hi Doax, a few months back I hit something on the freeway at night, by the time I saw it in my headlights, boom! Lucky I have a Panzer Plate so I didn’t destroy the oil pan. I’ll be following your posts. Good luck, love my 2000 TDI 5speed Beetle. In the Summer I can easily get 52MPG. Wanted to run a blend of Biodiesel, but since it’s available at the pump just driving my dream car!
Dave

[freebeard]

So what's new? The photochop glosses over the area between the fender and quarter window. Beetles and Porsches share the general shape.

It needs to show plan taper in the cabin.

[COcyclist]

I just did an intake cleaning at 125,000 miles. Yuck, what a messy job.

[razordave]

Hard to imagine he still has a $500 car 5 years later.. I've done it many times but I've also never claimed to be sane.

I'm loving mine even if I don't seem to be making any real progress, it still does better than my crx did

I love adding all the old oil bottle contents to the fuel tank.