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From: one thousand, five hundred miles north of Ft. Lauderdale for the summer.
Originally Posted by JJR512
[I]have yet to find..... complete detailed parts list that says exactly what to use and where to get it.
944V8 basic hybrid parts list...
engine mounting/clutch/bell housing/driveline hybridization
*XSCHOP or TPC modified crossmember
*XSCHOP or TPC spacers
*TPC bumpsteer kit
*XSCHOP or TPC motor mounts w/ urethane bushings
C5 corvette bell housing *XSChop 944V8 C5 adapter plate (close tolerance mating of GM bellhousing to Porsche driveline).
*XSChop 944V8 pilot bearing adapter with bearing
*Spec 944V8 stage 2~3 clutch and pressure plate
flywheel (aluminum, preferably) and bolts
hydraulic slave throw out bearing
clutch master
starter/cable.
oil filter/oil cooling *TPC oil pan w/pickup
gasket/bolts
oil cooler (Z06 or Setrab)
fabricate mounting bracket
AN10 oil filter kit (Jegs, Summit, Lingenfelter, TPC ect)
cooler lines (AN10 should be good on a street car)
H20 cooling and heat
fab high capy duel pass radiator or source (from TPC or Renegade).
high output Fans w/ fabbed shrouds (TPC)
fabricate support Bracket
radiator hoses (TPC or Renegade have the part numbers)
thermostat/housing
heater control valve
fab upper and lower Heater hoses, vacuum line
brake prep
1998-2004 Ford Mustang hydroboost master w/lines. [ BMW hydroboost can also be used]...
fabricate mounting Plate
exhaust
(TPC or Renegade) ceramic long tubes or other compatible modified headers
fabricate y-pipe
resonator 3~3.5" inlet 5"x15" Borla
fabricate s-pipe
Muffler 3~3.5" inlet 15"X9"X5" Vibrant or Magnaflow
engine and serpentine setup
F-body water pump
LS1 crank pully and [lF-body Camaro '98~02 LS1 serpentine setup]:
belt tensioner
AC idler pulley
PS pump and bracket
alternator and bracket
belts
LS1/6 intake w/ fuel rails and injectors
intake gasket
manual 92mm+ throttle body
throttle cable
air intake boots, tubing, cone filter
bare bones wiring harness mated to Porsche 944
ECU/programmed
coil harnesses (2)
coils and mounting hardware.
install new injector O-rings *944V8 VSS bracket & sensor
MAF sensor
MAP sensor
IAC sensor
O2 sensors
EGR valve
PCV valve
TPS sensor
oil pressure sensor
water temp sensor
sparkplug wires, sparkplugs.
AC (street 944)
F-body/LS1 compressor
your oem condenser
fabricate AC lines or source from TPC or Renegade
F-body AC bracket
Last edited by odurandina; Sep 9, 2014 at 01:04 PM.
944 engine is not VW design. It was relatively clean sheet design and brilliant at that.
On the other side VW (audi/skoda/seat) started from relatively simple 4 cylinder engine (EA827) , that was junk to begin with, but they worked somehow since they were simple.
Then they took that engine and complicate it to the point where you have two thermostats, water heated electronic throttle body, forced vacuum sump, intake over spark plugs, so spark replacement takes 4 hours, etc.
The result of this added mess is an engine that consumes the same amount of fuel as EA827 from 1972, is unreliable and since there is so many different versions of the same engine it is really hard to find an engine that is exact match even though there are few of these junk engines behind every corner.
Case in point could be my girlfriend's 2002 audi a3 1.6. One of two thermostats seized, so engine literally cooked itself, but since the other one worked fine, temperature gauge never saw it and was happy to report normal temperature. I wouldn't believe it if it wasn't me driving it at the time it happened.
I found new same type (AVU) 80.000km engine from a wreck to replace it, but even though all numbers suggest it is exact same engine, it is not. One has camshaft sensor in the head, the other behind timing belt pulley.
All in all, the car is very nice in itself, but engine is one of the biggest POS Ive ever dealt with.
Bosch stuff is really hit or miss. I do try and replace with Bosch items, but sometimes shake my head at how early they fail. Everyone has different experiences, but I put almost 200k miles on a 2000 jeep grand cherokee, 150k on my 2500HD chevy, have about 100k on my wrangler, and have never replaced an alternator/starter/ or anything else electronic for that matter. My dad had to finally replace the alternator on his expedition at 145k miles, and he was so pissed that he sold the truck because it was going to hell. I told him, Dad, Porsche guys replace their alternators about every 40k miles. I make my living by working on Porsches, but I drive American vehicles so I don't have to ever work on my own cars. Change the oil and other general consumable items and that is about it. If you need play by play instructions, then tackling an engine swap isn't for you. Yes, all the information is there, you have to dig a little. People are going to use slightly different stuff on each build, there is no 1 way to do it.
With all due respect Doc, what are your daily drivers? Kinda curious if you are comparing apples to apples.
Regards.
With all due respect Doc, what are your daily drivers? Kinda curious if you are comparing apples to apples.
Regards.
2002 jeep wrangler with 100k miles (My plow vehicle)
Just sold my 2002 2500hd with 150k+ on the clock. Owned since 45k.
2006 Jetta TDI: Actually has been a decent car. Owned since 120k, 155k miles now. Fried some radio electronics but that is about it.
Just sold our 2000 Grand cherokee with 175k miles on it. Owned since new.
And the maintenance I had to do on those, lol:
2500hd: Both front wheel hubs. A fog light bulb. (brakes, tires, oil changes, etc as standard fair)
2000 JGC: driver window regulator. fuel pump. Rear wheel bearing seals. (brakes, tires, waterpump/hoses/thermostat, oil changes, etc as standard and preventative maintenance)
Wrangler: oil changes. turn signal switch.
And as you know with Porsches. I have $17k in receipts on my 964 done in the last 2 years. I won't even begin to add up the 944.
From: one thousand, five hundred miles north of Ft. Lauderdale for the summer.
Originally Posted by JJR512
have yet to find a single set of all-encompassing instructions with every single step explicitly detailed...
and you won't....
the sequence of chassis, suspension, engine and electronics parts removal, ensuing prep, fabricating, mating and installing of all the hybrid and secondary support parts listed above isn't set in stone.... you could ask the 3 main shops who've done the swaps in significant numbers to help you draw up a squeaky-clean recipe.... but,
if you we're to ask Scott Mann [Renegade Hybrids], Mike Gokey [German Performance], XSChop, Eric Hill [TPC], or a handful of others for the best order of stated above, your request would most likely be met with reticence.... I suppose you could offer them an all-expenses paid weekend for wrench and wifey at Turtle Bay resort on Oahu....
or we'd could just leave it with – why would they?
Last edited by odurandina; Nov 14, 2014 at 02:29 PM.
2002 jeep wrangler with 100k miles (My plow vehicle)
Just sold my 2002 2500hd with 150k+ on the clock. Owned since 45k.
2006 Jetta TDI: Actually has been a decent car. Owned since 120k, 155k miles now. Fried some radio electronics but that is about it.
Just sold our 2000 Grand cherokee with 175k miles on it. Owned since new.
And the maintenance I had to do on those, lol:
2500hd: Both front wheel hubs. A fog light bulb. (brakes, tires, oil changes, etc as standard fair)
2000 JGC: driver window regulator. fuel pump. Rear wheel bearing seals. (brakes, tires, waterpump/hoses/thermostat, oil changes, etc as standard and preventative maintenance)
Wrangler: oil changes. turn signal switch.
And as you know with Porsches. I have $17k in receipts on my 964 done in the last 2 years. I won't even begin to add up the 944.
Thanks Doc, just what I thought. The cars you are comparing are decades apart, so its really apples to oranges. My experience is of cars from the 80's and 90's. I always found issues with electronics on American cars when the cars were only a few yrs old. I am sure they have gotten better now. Actually most of the American cars from the same era are no longer on the road.
Thanks Doc, just what I thought. The cars you are comparing are decades apart, so its really apples to oranges. My experience is of cars from the 80's and 90's. I always found issues with electronics on American cars when the cars were only a few yrs old. I am sure they have gotten better now. Actually most of the American cars from the same era are no longer on the road.
I'm not though, I am comparing the bosch electronics of todays boxsters, 996s, 997's.
Forgot to say the jetta did leave me stranded in the middle of nebraska in 8 below zero weather one time. That was a fun walk.
I see a lot of picking on Bosch going on, especially in reference to German cars. Isn't Bosch an OEM supplier for a lot of auto makers worldwide? Haven't they been for years in the past? Fuel injectors, O2 sensors, starters, alternators, various sensors and meters, computers...for decades, hasn't a lot of that stuff been either made or designed by Bosch, regardless of what country the car maker is from?
I see a lot of picking on Bosch going on, especially in reference to German cars. Isn't Bosch an OEM supplier for a lot of auto makers worldwide? Haven't they been for years in the past? Fuel injectors, O2 sensors, starters, alternators, various sensors and meters, computers...for decades, hasn't a lot of that stuff been either made or designed by Bosch, regardless of what country the car maker is from?
How about the innovators for most of the ignition and fueling technology.
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if it ends w/ Hooters girls (Waco) in the hot tub, then, ok... 
