NEED INFO: VR6 24v, 6 speed Swap into a 98 NB

[JMPELLEGRINO]

Hey.. yes another VR6 swap questions.

The problem is that there is too much information and too many opinions that are posted. Can some one give me advise on what I should do in my case.


My wife has blown our 1998 VW Beetle 2.0 auto. It only had 46,568 miles on it.

I purchased a 2003 VR6 GTI 24v Motor with a 6 speed Tranny. I have bought the complete engine, tranny, wiring harness, ecu, hoses, shift assembly, pedal assembly, Clutch cable and anything that looked important off of the fire wall and fenders.

Questions...

Will it fit?
Did I get all parts that I need?
Do I need the cluster?
Do I need the Ignition Module and Keys?
I have it on the cradle... will it bolt right up?
What kind of Exhaust Modifications will I need?
What type of wiring issues am I going to have?

I also have a new universal turbo system, should I install it now?

Here are the specs..


- T3/T4 63 Trim, A/R 50 V-Band Turbo Charger w/Internal Wastegate(8 PSI)
- Manual Boost Controller
- FMIC (Intercooler) Core Size 21"x6"x2.5" w/ 2.5" Inlet & Outlet
- 2.5" FMIC Alumminum Piping w/ Silicon Hoses and Clamps
- Complete Oil Return Kit
- GReddy Type-RS BOV
- 2.5" Aluminum BOV Adapter Pipe


Thank you all for your comment and advise...

Most of the links are not working anymore... and Pictures of previous installs would be great...


jmpellegrino@comcast.net

[Deserion]

Honestly, you will probably have better luck with your questions on the Vortex.

[FarrisK]

My wife has blown our 1998 VW Beetle 2.0 auto. It only had 46,568 miles on it.

...how did she manage to do that?

[Toad]

from what i've heard and seen, a 24v vr6 is already a really tight fit in a beetle engine bay. the fact that you have a turbo one means your gonna need extra space. i wish you luck. i would love to see it.

[LouEvilMetal]

theres a 12v beetle in louisville sounds sick

[VR6]

Hi JMPELLEGRINO

I do have a VR6 in my beetle (99 ex 2.0 stick)
so I can give you some first hand advise.

My recommendations is not to put the turbo in just yet.
You need to get this bug going first.

Biggest problem I see is the immobilizer due to the I think 7 digit code Beetle vs. 11 digit code 2003 CANBUS model.
If you really want to get this going get the keys locks and cluster or you have to do some serious sw hacking.
I'm not 100% sure on the 2003 vr6 - does it have DBW?
You will also need a support block from the dogbone to the tranny and the left and right motor mounts (I think)
I can take some pics from my car for you if you like.
You will also need the catalytic converter and I recommend to 2.5" or you can use your stock.

When you are done you will have a blast :D

I will be on the road for a couple of days so response time will be slow.

[karn_porsche]

You will need the cluster and ignition key. You can make the beetle cluster work with it but you need to know how to do by VAG com. You will need the exhaust system for VR6. If the donor car is GTI so it would fit New beetle hanger. Like VR6 said above that leave the turbo behind for a while. You will need to know how the engine runs and the room to set up the turbo. Also, don't forget the suspension. The lower springs or stock springs for beetle only work well with 4cycles or 1.8T not VR6. The Engine and transmission mounts are important. If you want plan for turbo in the future, get the VF engineering mounts for VR6. If not, stay with VR6 stock engine mounts which are strong enough.

The turbo set up is another story that you will have to design how you want your car looks, stock or agressive looking. HPA water intercooler set up is a good choice but you have to remove the battery. The front intercooler take the air directly but front bumper has to be cut or you have to get aftermarket or Turbo S bumper to get more air.

I'm doing the swap soon and also plan to set up turbo in the future. I use the lupo cluster which are similar to RSI and R32 motor with GLI 6 speeds tranny. My car is converted from automatic too.:D

[NaplesTurboS]

Where did you get the motor and all those parts?

[karn_porsche]

Where did you get the motor and all those parts?

I don't know if you ask him or me:rolleyes:, but I got the wrecked R32s from insurance company auction (my friend auctioned for me).

[JMPELLEGRINO]

Wow,

Thanks guys, for stepping here. I pleased to say that I actually have things covered, from what it sounds like. However the motor mount thing... I just figure out. My motor is sitting crooked. I posted pick below. There was an add in Craigslist that had a part out from a 03 GTI with 23k miles that was rolled. The only damage that the Motor suffered was a cracked Intake manifold. I replaced that. I made sure to vacuum out the Intake ports. Wow am I glad I did that. Chunks of the plastic manifold came up. AS FAR AS BEING A TIGHT FIT... oh yes it is! But there is actually a lot of room from the exhaust manifold down. You at leas have a 1ft deep x 2ft wide x by 2 feet down back there. There is enough room for a Twin Turbo set up. Here i8s the list of the parts I took.

Motor and tranny
Down pipe with converter and 02 sensors
ECM and Wiring Harness
Interior Harness
Cluster, Ignition Module and Key
Peddle Assembly, Clutch assembly
Clutch Hydrolic Hose and shifter assembly

Everything above was $4,000. Not including the other things needed.

I will wait on the turbo stuff for now. I need to purchase the Half shafts and MAF. I plan on relocating the Battery to the rear. I really need to budget stuff now. I will be purchasing 4 RSI kits from UK within the month.

Anyways, I am stuck at the moment with the wiring. I'm not sure if I completely take out thold one, cause has the ABS, Headlights and other interior stuff. Should I leave the old harness powered up but only remove the the engine parts. Because my car was an automatic, how do I hook up the Clutch switch... things like that are the stuff i am facing now. Beside the motor being crooked. Enjoy the up to date pics...


http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0046.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0050.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0044.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0052.jpg

NOW FOR THE SHOT OF WHERE YOU CAN SEE IT IS CROOKED...


http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0055.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0054.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0058.jpg

[JMPELLEGRINO]

Wow,

Thanks guys, for stepping here. I pleased to say that I actually have things covered, from what it sounds like. However the motor mount thing... I just figure out. My motor is sitting crooked. I posted pick below. There was an add in Craigslist that had a part out from a 03 GTI with 23k miles that was rolled. The only damage that the Motor suffered was a cracked Intake manifold. I replaced that. I made sure to vacuum out the Intake ports. Wow am I glad I did that. Chunks of the plastic manifold came up. Here i8s the list of the parts I took.

Motor and tranny
Down pipe with converter and 02 sensors
ECM and Wiring Harness
Interior Harness
Cluster, Ignition Module and Key
Peddle Assembly, Clutch assembly
Clutch Hydrolic Hose and shifter assembly

I need to purchase the Half shafts and MAF. I plan on relocating the Battery to the rear.

Anyways, I am stuck at the moment with the wiring. I'm not sure if I completely take out thold one, cause has the ABS, Headlights and other interior stuff. Should I leave the old harness powered up but only remove the the engine parts. Because my car was an automatic, how do I hook up the Clutch switch... things like that are the stuff i am facing now. Beside the motor being crooked. Enjoy the up to date pics...


http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0046.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0050.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0044.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0052.jpg

NOW FOR THE SHOT OF WHERE YOU CAN SEE IT IS CROOKED...


http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0055.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0054.jpg

http://i37.photobucket.com/albums/e85/jmpellegrino/0_IMAG0058.jpg

[VR6]

Just to show you how my motor mounts looks like, here some Pictures.
What tranny are you using O2A ? or O2J ? or O2M ?

Left


http://img902.mytextgraphics.com/photolava/2008/09/26/motormountl-4bzu9qaxn.jpeg

Right


http://img701.mytextgraphics.com/photolava/2008/09/26/motormountr-4bzuafioz.jpeg

Bone


http://img109.mytextgraphics.com/photolava/2008/09/26/dogbone-4bzuariwk.jpeg

[JMPELLEGRINO]

I guess the BONE is the problem. I'm getting the GTI mount today... so that problem should be solved. Now if someone can jump in for some wiring problems...


:cool:

[VR6]

what's the wiring problem?

BTW I think the bone is the same on all MKIV's - do you have the support bracket that's attached to the transmission?

[JMPELLEGRINO]

I got the Motor mount on the passenger side.... it is different... i'll post pics.

okay...

My beetle was an automatic. So I purchased the Interior harness as well so I can get the switches for all of the clutch stuff. Anyways, so I am not sure if I should yank out the interior harness of the beetle or just leave it hooked up, with power for all the other stuff. Or is just adding the clutch switch and wiring enough.

Since I have the GTI Cluster, I was going to use both the motor harness and the interior harness ....


WELL ****! I don't know what to do!:confused: I'll get my head straight take pics and post my thoughts...

[karn_porsche]

I talked to my buddy yesterday about your concern. He said the 98 beetle will have the totally different wires from later models. You may have to use all wiring from GTI since the battery connecting pins are different. I can't remember how many pins of each have.

[JMPELLEGRINO]

Does the stuff for the Air and Heater stay??? Air bag sensors?? Or do I just worry about connecting what on the harness?:confused:

[karn_porsche]

What style of A/C came with the donor car? If it was 3 knobs like beetle. You should be fine. The airbag sensor plugs are different but you can just spice and connect to the original wire of airbag plug on the beetle.