Monday, February 14, 2011

'99 EVC VR6 to TDI conv. & auto to manual trans conv.: Day 3.5

Another day in the shop.  As always, Monday delivered its requisite surprises, but luckily most of the day was spared any big heartaches--so long as you don't consider this lovely nest a heartache:

TDI wiring harness being integrated into T4.
 I love the smell of solder in the morning--it smells like Victory!!  (sorry, couldn't resist!!)
Out with the old, in with the new.  This is the VR6 harness that was removed.

TDI harness being finallized, ECU installed in stock T4 location.

 Rebuilt injection pump installed on engine.  Oil filter flange install being prepped (green gasket).

  Oil filter flange installed.
 New VW oil cooler installed; new VW turbo oil supply pipe installed; new VW crankcase breather tube installed; new VW water pump installed.
Slowly but surely it's all coming together.

 Torquing crankshaft bolt: 78ft/lbs + 90*.
 For this we bring out the big guns since we need a torque multiplier.  The big tool is used to hold the crank stationary while the TTY bolt is being stretched 90*.

R side 4-cyl T4 engine bracket installed;alternator/AC compressor bracket installed.
 Our special AHU A3/B4 silicone hose.
Another shot of the silicone engine hoses.  These are about 2-3x thicker and substantially more robust than the stock OEM hoses for this application.  Of course they cost about 4-5x more, but the OEM ones are very prone to failure over time due to oil/fuel leaks--and they are a PITA to swap out.

1 comment:

  1. My dad recommended this blog and she was totally right keep up the fantastic work!

    Exhaust Shops