The Official VR6 Engine Swap (Page 14/73)
bmwguru FEB 19, 06:44 PM
Here is an update of where I stand with this swap. I ran into a problem today. When I pulled the mock-up transmission off the engine, I found a hairline crack in the lower timing cover. So, I have to order one from VW, hopefully I'll have it in a few days.
So, the timing covers have been removed and we are kind of stuck until I get another cover.


I'm not sure if I mentioned this, but I have decided to mount the engine to the cradle and not the space frame. When it was mounted to the space frame, I had too much movement out of the engine using the VW mounts. It can be done easily, but I am looking for rubber left on the road and little slop in the drivetrain. So, I finally have mounts made to use the stock transmission mounting points and made a mount for the engine. The cradle needed a slight mod done to it which took about 15 minutes. There was a little trimming needed near the rear mount to give adequate clearance for the VW transmission. Also, the stock engine mount bracket had to be removed to clear the oil pan. I am mounting the engine to the cradle's frame rail slightly forward of the control arm. No cutting or grinding is needed anywhere else for this swap. Here is a pic of the trimming needed near the rear transmission mount.


Otherwise, the engine is ready to go in the car for the final time. It has only been in and out maybe ten times for proper fitting, and reorganizing myself to mount it differently. Once I have the timing cover and reassemble the engine it should be iinstalled within a few hours.
Here is a pic of me fabricating one of the jigs for the mounts. Basically, I could do the next VR6 swap in a lot less time now that I have the formula. All the mounts are made by hand out of 3/16" steel. Welded and reinforced. That was time consuming to cut the steel, notch it, weld it and make it look pretty. If I still had access to a CNC machine, it would have been better IMO, but I am finally happy with the current results.

[This message has been edited by bmwguru (edited 03-04-2008).]

bmwguru FEB 20, 09:46 PM
Allrighty,
We got the timing cover and reassembled the engine. The transmission is bolted on and the engine is ready for install. In the pics you can see the engine mounted to the cradle. I ran a little behind today and didn't get to put it in. Hopefully, I'll have some free time tomorrow or Friday.
Once the engine is in, it will be on to the wiring and drive axles.
Dave
FieroJimmy FEB 20, 10:10 PM
Just a thought, but you may want to throw some spindles on there, and measure for your axles before you get it in the car.

Unless you're planning on just sending the whole car out for them.
bmwguru FEB 21, 04:20 PM
I was going to measure the axles out of the car, but the struts camber angle would need to be precise. The VW inner joints don't have as much movement as the GM. The difference is a few inches.
Anyway, here is where we leave off for the week. The engine is in and mounted. The upper intake manifold is off so that the wiring can be done. Normally on the VR6 the intake comes off for everything. I had to make it accessible for repairs without tilting the cradle. So, it looks like that won't be an issue. Everything has more than enough space and it looks like there is more room to work on the engine than in the Jetta.
Here are the pics.
darkhorizon FEB 21, 04:40 PM
I can measure axles within a 1/2 inch with the suspension out of the car, the amount that it can be off is very small, and its quite obvious about where the suspension sits.
bmwguru FEB 21, 05:55 PM
I was originally going to measure the axles out of the car, but there really is no hinderance measuring them in the car. I want to make sure to get the full travel of the axle as well. In the car is the way to go for that. There is a lot more room than expected in the engine bay....just enough for a turbo...
Anyway the axles and wiring, as well as the fly by wire throttle configuration are the next step.
Dave
darkhorizon FEB 22, 01:56 AM
I made sure I measured with the axle seated in the trans, and had the outer removed, and I went from there.

What are you going to do about the outers? I have seen people in the past just use the donar car's knuckle and wheel bearings, its not all that hard of a swap if you do a coil over setup.
bmwguru FEB 22, 06:53 AM
The easiest way to do the axles is to have the driveshaft shop make a set. I was going to use the VW knuckle, but then I'd have to make another set of coil overs with the VW strut. The problem with that is the VW axles are not the correct lengths. It is just easier to measure and make a phone call and wait for the little brown truck to show up.
Dave
Erik FEB 22, 06:59 AM

quote
Originally posted by bmwguru:

The easiest way to do the axles is to have the driveshaft shop make a set. I was going to use the VW knuckle, but then I'd have to make another set of coil overs with the VW strut. The problem with that is the VW axles are not the correct lengths. It is just easier to measure and make a phone call and wait for the little brown truck to show up.
Dave

we like little brown trucks with big parts
Ravant FEB 23, 03:40 PM
Now to ask a question.

What are the chances of any of the new DSG's fitting this engine in a swap of this nature?