Josh_WA
Veteran Member
- Joined
- May 8, 2015
- Location
- Mountlake Terrace WA
- TDI
- 2014 Jetta TDI, 1993 Eurovan Weekender TDI(AHU) converted 2/2016, 93 Eurovan MV TDI(1z)(sold!)
weekend progress
I've sorted out all the coolant plumbing now. I didn't however tie in the coolant circulator from the 2.5 setup. I can still tie it in later, but I haven't figured out the electrics of it yet, so I'm trying to keep it simple for the moment. Feel free to chime in on whether it with will be detrimental to leave out. I'd like to swap out a poly hose splicer I ended up using for a metal/brass one though. I'm finding that I'm not very good at stopping to take too many pictures now that I'm as far as I am into this.
One thing that I didn't notice from other build threads I've read is integrating the AC compressor into the existing system. The EV AC compressor doesn't mount properly on the bracker (could be modified), but then doesn't align properly as well to the ribbed belt. I thought about trying to change the clutch pulleys until someone advised me to just enlarge the AHU AC compressor to fit the EV AC piping. I didn't take measurements but it was about 2mm additional that I had to open the holes. You just need to remove the end cap on the compressor and drill/grind it out.
the rear of the two unmodified compressors.
[url=https://flic.kr/p/Vk59Vo][/URL]
Didn't get a shot of it done, but here is the AHU compressor with the EV AC hoses now plugged into it.
[url=https://flic.kr/p/VnLdox][/URL]
Finished up the engine side of the fuel delivery. After all that time keeping the original short supply lines on the engine, I finally removed them for some shorter hoses to mate up to where I located the fuel filter. It physically fits well in the location, and was able to put together a mount from the EV fuel filter mount to get it to stay in place. I'm using the Jetta fuel lines from the donor car and they are really long. Enough that it can reach to this spot.
Here's the where I put the fuel filter sans the remaining fuel lines.
[url=https://flic.kr/p/Vk59LL][/URL]
[url=https://flic.kr/p/Vk59Lq][/URL]
I went ahead and pulled my wiring through the firewall to get that part going. I've got a few things to tidy up in the engine bay still, but was eager to see what I had after my initial wire work I had done a few months back. I'm definitely not missing any connectors, but I see that there are a few connectors that I probably was afraid to snip out initially. I'll snip those back after the engine is up and running properly.
plenty of room to get the cabling through. I'll end up pulling it back out later to get it properly covered though.
[url=https://flic.kr/p/Vk59Ey][/URL]
Just a shot of the cable through to the other side.
[url=https://flic.kr/p/Vk57Mq][/URL]
Here's what I've left myself to sort out before I start the engine:
-exhaust downpipe through where I'll remove or hollow out the cat
-upper coolant hose
-intercooler piping and location (i've got a good idea. Hope it pans out)
-mount EGR and N75 somewhere
-coolant/oil/brake fluid/transmission fluid
What I have to sort out prior to driving. Not including all reassembly of front end or dash.
-Accelerator pedal
-clutch and brake switches
-Align axle to transmission extension
I've sorted out all the coolant plumbing now. I didn't however tie in the coolant circulator from the 2.5 setup. I can still tie it in later, but I haven't figured out the electrics of it yet, so I'm trying to keep it simple for the moment. Feel free to chime in on whether it with will be detrimental to leave out. I'd like to swap out a poly hose splicer I ended up using for a metal/brass one though. I'm finding that I'm not very good at stopping to take too many pictures now that I'm as far as I am into this.
One thing that I didn't notice from other build threads I've read is integrating the AC compressor into the existing system. The EV AC compressor doesn't mount properly on the bracker (could be modified), but then doesn't align properly as well to the ribbed belt. I thought about trying to change the clutch pulleys until someone advised me to just enlarge the AHU AC compressor to fit the EV AC piping. I didn't take measurements but it was about 2mm additional that I had to open the holes. You just need to remove the end cap on the compressor and drill/grind it out.
the rear of the two unmodified compressors.
[url=https://flic.kr/p/Vk59Vo][/URL]
Didn't get a shot of it done, but here is the AHU compressor with the EV AC hoses now plugged into it.
[url=https://flic.kr/p/VnLdox][/URL]
Finished up the engine side of the fuel delivery. After all that time keeping the original short supply lines on the engine, I finally removed them for some shorter hoses to mate up to where I located the fuel filter. It physically fits well in the location, and was able to put together a mount from the EV fuel filter mount to get it to stay in place. I'm using the Jetta fuel lines from the donor car and they are really long. Enough that it can reach to this spot.
Here's the where I put the fuel filter sans the remaining fuel lines.
[url=https://flic.kr/p/Vk59LL][/URL]
[url=https://flic.kr/p/Vk59Lq][/URL]
I went ahead and pulled my wiring through the firewall to get that part going. I've got a few things to tidy up in the engine bay still, but was eager to see what I had after my initial wire work I had done a few months back. I'm definitely not missing any connectors, but I see that there are a few connectors that I probably was afraid to snip out initially. I'll snip those back after the engine is up and running properly.
plenty of room to get the cabling through. I'll end up pulling it back out later to get it properly covered though.
[url=https://flic.kr/p/Vk59Ey][/URL]
Just a shot of the cable through to the other side.
[url=https://flic.kr/p/Vk57Mq][/URL]
Here's what I've left myself to sort out before I start the engine:
-exhaust downpipe through where I'll remove or hollow out the cat
-upper coolant hose
-intercooler piping and location (i've got a good idea. Hope it pans out)
-mount EGR and N75 somewhere
-coolant/oil/brake fluid/transmission fluid
What I have to sort out prior to driving. Not including all reassembly of front end or dash.
-Accelerator pedal
-clutch and brake switches
-Align axle to transmission extension
Last edited: