Starter fo 2.2 Subaru in '73 Superbeetle ?????

[panel]

Looks like this is a good p/n 357972771 if anyone else is looking to get one etc.

[vw1970]

Just another confirmation that this starter works for a Type 1 trans with a ej25. I used a rotary burr and it took a 5 mins and a few test fits but it fit great and was able to use the big dumb 17mm nuts that held the stock VW starter.
You can see the template i made and how much i had to remove. Hope this helps the next guy!
IMG_20230830_173636 by Travis L, on Flickr
IMG_20230830_175650 by Travis L, on Flickr
IMG_20230830_180219 by Travis L, on Flickr
IMG_20230830_180102 by Travis L, on Flickr
IMG_20230830_180100 by Travis L, on Flickr

[Kafer_Mike]

FYI for others looking to do same TDI starter swap... https://dunebuggywarehouse.com/products ... gItlPD_BwE

[Piledriver]

That plate would adapt a manual tdi starter: the automatic starter throw is correct without a spacer. The manual version has a longer nose.

Do make sure to get the 9 tooth gear version.

The manual tdi starters are easier to find, but that plate basically doubles the up front cost, but then you dont have to mod the starter.

[Bruce.m]

Got a typical parts house version on my beetle.
Works well. The fit is a bit tight as the solenoid is above the main body so close to the parcel shelf. I also needed a longer bolt and gearbox stud.

[Gerrelt]

I also needed a stronger starter, because I am converting my beetle to a Subaru EJ20.
Thanks to this thread I managed to make the TDI starter fit, and it works great!

This is how I did it:

I bought a generic starter from the autoparts website I normally use.
The starter I searched for was for VW parts number 020911024A.
It turned out to be a starter for, among other models, a VW New Beetle (9C1, 1C1) 1.9 TDI, years 07-2005 to 09-2010.
Be aware that you need the 9 tooth model!
Because I am in Europe, I had several brands to choose from. The one I bought was around 90 euros.

Here it is compared to the standard (1600) vw beetle one:


The round part that enters the gearbox is exactly the same, just as the cog depth.



The only differences are the mounting holes and the solenoid position.

I made a template using the standard starter:


Overlayed on the new starter, you can see how to widen the holes:


I used a 12mm drillbit to widen the holes:


While test-fitting I disovered that the lower mounting stud attached to the gearbox was too short to put a nut on it.
Also, there was probably not enough room to spin the nut.

So I removed the stud (with the double-nut-trick), and used a M10x40mm allen bolt instead.

On the other side, the engine bolt, I used a M10x120mm allen bolt.

The bolt was a little bit too long, so I added a 10 mm spacer.
The bolt threads into the adapter plate, and I didn't want it to extend too much behind the plate.
For a VW beetle engine, you will probably need a different length bolt, as there will be a nut on the other side.

Because the holes are now pretty wide, I made some small custom plates for the bolts to go through:



My beetle has the rear parcel tray removed, so there is more then enough space for the solenoid.
But I think it will fit with the parcel tray in place too. Allthough the solenoid will be much closer to the parcel tray.

After mounting the starter I did some test starts, and it works great!
The engine is not running yet, but the starter sounded strong, with good speed.