The Official VR6 Engine Swap (Page 16/73)
Austrian Import FEB 24, 02:01 AM

quote
Originally posted by FieroJimmy:


The shift pattern problem he's talking about comes from the shifter cables approaching the trans from the "wrong" side of the engine. In the Jetta, the cables come from the rear of the mounted driveline, but in the Fiero, the cables come from the front. The result is the shift pattern is inverted (In this case, reverse would be where it is in the 5-speed Fiero, but 1st would be where 4th is.)

From looking at the pictures you've posted, I can't tell just how the cables are oriented on the trans, but it could be an issue to deal with.

Either you could get custom cables long enough to wrap around the engine bay and approach the driveline like it did in the Jetta, or it may be possible to re-work the linkage on the trans to allow the shift forks to move in the right direction.



Great posts. Thanks Dave. Love the pictures. That engine really looks happy in there.

I was wondering the same thing FieroJimmy was, myself.
Most swap threads I've studied, people tend to redesign the linkage somehow and add metal brackets to fix that issue. (either on the shifter side, or the tranny side)
My question: - I'm still learning - Wouldn't it be cheaper/easier/faster to just get longer cables that have enough slack to go around, so that they face from the right side?
Aren't these shifter cables just the exact equivalent as the shifter cables on mountainbikes (meaning a metal wire, inside a flexible sleve)? - Just thicker wires? (just making sure they don't kink anywhere as a precaution)

[This message has been edited by Austrian Import (edited 02-24-2008).]

bmwguru FEB 24, 09:38 AM
The trans cable issue has already been worked out. I'll post details when I get to that part of the swap....with pictures
Austrian Import FEB 24, 02:52 PM

quote
Originally posted by bmwguru:

The trans cable issue has already been worked out. I'll post details when I get to that part of the swap....with pictures



Thanks. There is no such thing as too many pictures
We loooove pictures
Richjk21 MAR 01, 11:44 AM
Bump - any progress ?
bmwguru MAR 01, 11:50 AM
I've been busy with customer's cars all week long....I'm leaving the house in an hour to go to work on the VR6 for about six hours today...I should have some decent progress by tonight.
...and yes, Max....I'll post some pics....lol.
Dave

[This message has been edited by bmwguru (edited 03-01-2008).]

bmwguru MAR 01, 07:36 PM
ok, I wanted to make a correction. I previously stated that the engine mounts were made from 1/8" steel....oops. It was supposed to say 3/16" steel. 1/8" is a little thin in my opinion.
As of now, the rear suspension has been reinstalled. The fuel system is 100% completed and the cooling system is about 50% done. I spent today going over a lot of the wiring harness details, plumbing the fuel lines and installing the upper intake manifold for the final time as well as the rear suspension install and I ordered some more performance goodies for the VR6.
The good news about this swap was when I discovered that if I use a clutch slave cylinder from a 1996 GTI 02A. The 02J slave has a push in type of hose whereas the 02a has the threaded hole with the same threads as the Fiero. The only issue is that the clutch line must be lengthened by about 7 inches to reach the VW slave....no biggie.
I'm hoping to have the cooling system completed with the OE red VW coolant by the end of the week.



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

Saxman MAR 06, 08:55 PM
Bump for the latest - and so I can keep track. This one fell off my tracker.
bmwguru MAR 07, 06:05 PM
I have been working on the swap this week, but I haven't had much time for posting about it. I've been a little excited about my other car getting finished.
Anyway, here are the goodies that I am doing this week....
First off, the clutch line had to be lengthed. That was pretty easy using Rodney Dickman's clutch line repair kit. It gave me the extra length needed to reach the VW clutch slave. Ironically, the VW clutch slave's thread size is the same as the Fiero. I may need to repace the VW clutch master, but we'll see if the Fiero master can work the proper ratio with the slave to operate the clutch.

Also, the VW has issues with breaking the PLASTIC shift selector arm. I have no clue why thy made them out of plastic, but I get cars towed in all the time that can only be shifted into third and fourth. The best is when they drive them in and it needs a clutch and the arm. Anyway, I update to the aluminum arm. Gruvenparts.com is the best place to find this part. Here is a pic of the aluminum arm and the factory plastic. The aluminum arm also has less throw, which is nice.

Aside from that, I've been working on the cooling system. I want a lot of the system to use metal piping rather than rubber hose. The problem with the VR6 is that the upper and lower radiator hoses come off the same thermostat housing on the driver's side of the car. So, I welded up some pipe from exhaust J-bends. Ground the welds smooth and then pressure tested them. Once done, I painted it and used insulated clamps from summit racing to secure the pipe against the firewall.

Those clamps are nice. I secured the fuel lines, clutch line and just about anything that is hanging loose with them. It really cleans up the engine bay.
The other issue I ran into is the expansion tank. I made a securing bracket and I am going to locate it under the driver's side engine vent. It has to be at the highest point because it is also part of the cooling system under pressure. It is a pressurized overflow tank.
Other than that, it is coming along. The axles should be in my hands by the end of next week. Hopefully by then the cooling system will be completed and then on to the shifter cables. I'm going to leave the wiring modifications and ECU programming to the end because there is really no parts needed to do that....just peace and quiet.
Dave
bmwguru MAR 07, 06:14 PM
I also forgot to mention that the factory throttle body does not fit with the stock Fiero trunk. So, I really wanted to run the fly by wire throttle, so thanks to German engineering, I turned the throttle body 90 degrees and bolted it up. No more clearance issues. the calibration is done during routine servicing called "Basic Settings". That is when the tech takes the VW laptop and sets the throttle valve and automatic transmission kickdown. I normally reset the throttle adaptation during routing services for all my customers.

[This message has been edited by bmwguru (edited 03-07-2008).]

Vonov MAR 17, 03:19 AM
Having just purchased a 12V VR6 MkII Jetta, I now understand VERY well why you want to put one in a Fiero. These motors have the sexiest sound, very reminiscent of the old 911 Porsche, and pull strong all the way thru the the power band. I can only imagine what the 24V motor you're planning will be like. Yowzah, yowzah, yowzah!!!
You're gonna need to schedule a flight physical...

I see one other HUGE advantage to this setup---FINALLY!!! A V-configuration motor in a Fiero that is as easy to change the plugs on as a four-cylinder engine...

[This message has been edited by Vonov (edited 03-17-2008).]