The first thing I'm going to tackle is the fuel system. The problem is that the entire system has had gas sitting in it for almost 20 years. Gas, when sitting for a long period of time turns int a varnish that coats the inside of everything. This varnish can flake off and clog the fuel system. So, first I need to determine how bad things are.
Task To Do List
- [Done] Determine if there is any liquid left in the tank. There was.
- [Done] If needed, drain the tank of any residual fuel. 20 year old gas really stinks!
- [Done] Pull up the rear carpet and pull out the sending unit. Using a flashlight determine the amount of varnish left in the tank. Yes, lots of it.
- [Done] If the tank looks like it's in bad shape remove the transmission and then remove the tank. Crap! Its filled with tons of crap. Gotta drop the tranny.
- [In Progress] Remove Transmission. See sub-section A. It's not as easy as it seems. ;-)
- Remove fuel tank.
- Bring the tank in for redo.
- Begin cleaning and removing parts of the fuel system to the rear of the 924.
Tools/Parts Needed List
- [Done] Pump for removing any remaining fuel.
- [Done] 5 gallon fuel tank for old fuel.
Sub-section A: Transmission Removal
- Tools Needed
- Sockets and Wrenches (19mm, 17mm, 13mm, 10mm).
- VW CV joint allen key, also known as a 12 point 8 mm allen key, or a 8mm triple square.
- 5mm or a 6mm allen key.
- Step by Step
- Undo the CV bolts. These are the hardest and most likely to strip, I would recommend replacing them with NEW factory style units and they can be obtained from local VW dealer. Once off bag the ends of the CV joint and use a coat hanger to get them out of the way.
- Look in the larger bellhousing area at the front of the tranny (where it meets the torque tube) and you will see the coupler which has the two 5mm (or 6mm) allen key bolts, you will have to turn it 180 deg to be able to access the second, remove both bolts entirely and slide the coupler off so that it is only on one of the shafts and not joining the two together.
- Go to the top of the tranny and find the two wires for your backup lights and unplug them
- On top of the tranny there will be a rubber boot at the end of the shifter linkage. Under the boot you will find one bolt (13mm) with a safety wire through it. Remove the wire and then the bolt, (it would help to put the car in 4th gear before doing this), once the bolt is removed whack the shift lever forward into third, this may take a couple of tries but the goal is to get the shift rod off the selector lever on the tranny.
- Undo the 4-6 bolts holding the tranny to the torque tube, once these are removed and you will now need a jack, or your chest, and take the weight of the tranny off of the mounts and undo the two mount bolts and then lower the tranny
Fuel Tank Removal
- Tools Needed
- TBD...
- Step by Step
- TBD...
Chapter 3 Status: In Progress
