specialed1995
Well-known member
Since the weather is turning colder I've had some spare time to start working on this project again.
I extracted the broken bolt that snapped off many months ago after soaking it in penetrating oil several times and working it in with the air chisel. It finally broke loose and came out turning it with a pair of pliers.
I also removed the factory belt tensioner and sawed off the boss that it goes through on the front to make room for the new tensioner mount I need to fabricate. As I said before I’m using jimbote’s setup which retains the A/C compressor but deletes the power steering pump. I’ll have to do some calculations and figure up exact how everything needs to be.
I removed the side motor mount as well (the one right in front of the turbo), as I’ll be fabricating mounts similar to CFM’s designs and won’t be needing it. Will probably end up selling any leftover VW parts I end up removing on this conversion.
The intake manifold was very gunged up after 335k miles so I removed it to get it ready to clean. I plan on soaking it in diesel fuel and scrubbing it with a brush etc. to loosen and remove the carbon. There’s also a bit built up inside the cylinder head, so I’ll rotate the engine around until the intake valve for the cylinder I’m cleaning is closed, and clean and scrub the port with a brush and blow it out with compressed air, plugging the other open ports of course. If anybody has any tips or suggestions about doing this please let me know.
I’m going through the wiring harness now and labeling all the connectors to see what I need to keep and what can be gotten rid of, and I’ve run into some trouble. The 24 pin connector that goes to the engine wiring harness won’t come unplugged, and I need to get it unplugged to replace the glow plug wiring harness, as it has dry rotted and fallen apart.
What’s the trick to undoing this connector? I slid the plastic ring that goes over the rubber seal back, but try as I might it wouldn’t come apart. I could see no locking tabs anywhere so I suck a flathead screwdriver around the base and lightly pried on it thinking it was stuck. I didn’t want to pry too hard and break it so I stopped and decided to ask for some help. If anybody could offer a tip on how to unplug it I’d be grateful!
More work on this project is coming after the holidays!
I extracted the broken bolt that snapped off many months ago after soaking it in penetrating oil several times and working it in with the air chisel. It finally broke loose and came out turning it with a pair of pliers.
I also removed the factory belt tensioner and sawed off the boss that it goes through on the front to make room for the new tensioner mount I need to fabricate. As I said before I’m using jimbote’s setup which retains the A/C compressor but deletes the power steering pump. I’ll have to do some calculations and figure up exact how everything needs to be.
I removed the side motor mount as well (the one right in front of the turbo), as I’ll be fabricating mounts similar to CFM’s designs and won’t be needing it. Will probably end up selling any leftover VW parts I end up removing on this conversion.
The intake manifold was very gunged up after 335k miles so I removed it to get it ready to clean. I plan on soaking it in diesel fuel and scrubbing it with a brush etc. to loosen and remove the carbon. There’s also a bit built up inside the cylinder head, so I’ll rotate the engine around until the intake valve for the cylinder I’m cleaning is closed, and clean and scrub the port with a brush and blow it out with compressed air, plugging the other open ports of course. If anybody has any tips or suggestions about doing this please let me know.
I’m going through the wiring harness now and labeling all the connectors to see what I need to keep and what can be gotten rid of, and I’ve run into some trouble. The 24 pin connector that goes to the engine wiring harness won’t come unplugged, and I need to get it unplugged to replace the glow plug wiring harness, as it has dry rotted and fallen apart.
What’s the trick to undoing this connector? I slid the plastic ring that goes over the rubber seal back, but try as I might it wouldn’t come apart. I could see no locking tabs anywhere so I suck a flathead screwdriver around the base and lightly pried on it thinking it was stuck. I didn’t want to pry too hard and break it so I stopped and decided to ask for some help. If anybody could offer a tip on how to unplug it I’d be grateful!
More work on this project is coming after the holidays!