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Old 10-17-2018, 08:05 AM   #1 (permalink)
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Ecomodding the TDI Beetle

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.


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Last edited by arcosine; 10-17-2018 at 08:39 AM..
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Old 10-19-2018, 02:56 PM   #2 (permalink)
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Join Date: Nov 2010
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sc1 - '98 saturn sc1
Team Saturn
90 day: 43.17 mpg (US)

Airplane Bike - '11 home built Carp line Tour

rans - '97 rans tailwind

tractor - '66 International Cub cadet 129

2002 Space Odyssey - '02 Honda Odyssey EX-L
90 day: 28.25 mpg (US)

red bug - '00 VW beetle TDI

big tractor - '66 ford 3400

red vw - '00 VW new beetle TDI
90 day: 58.42 mpg (US)
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Thanked 291 Times in 196 Posts
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:
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Last edited by arcosine; 10-19-2018 at 03:04 PM..
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Old 10-19-2018, 03:01 PM   #3 (permalink)
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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.
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Old 08-08-2019, 09:13 AM   #4 (permalink)
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Quote:
Originally Posted by Daox View Post
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 didnít destroy the oil pan. Iíll 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 itís available at the pump just driving my dream car!
Dave

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