MEGASQUIRT IN JAMAICA........my family car turned project

[justvwpower]

i recent sold my bachelor ride (mk3 2.0l modified 2 dr) for a family car which it turned out to be a b3 passat wagon ...but in keeping to the code of the garage ...nothing drives stock ....it has blown up in2 a project now i'm in trouble with the wife ....WHATEVER .
Its a 2l 16v w/ automatic, and passats are an uncharted territory for me as i'm a golf connoisseur....but being that there are a lot of similarities i dove right in ......
First thing to go was the V-belt system as i nearly lost a finger in the alternator and the serpentine system looks cleaner....and thats where the trouble started... i only had acess to the mk3 serpentine system but when bolted up to the 16v (cuz the timing sprocket is thicker) the crank pulley was in line with the W/P and the P/S pulleys ..... hmmmm after consulting vortex to get some ideas and seeing ISSAM,s thread on ABF pulleys i said y not go 1 further ...AN ALL IN 1 SERPENTINE SYSTEM...so i set out 2 do just that

[justvwpower]

first of alll..... want to get rid of this ......BADLY
and also this

[justvwpower]

mk3 crank shaft pulley fitted

[junn]

pics of the wagon in hand plis

[justvwpower]

[/IMG]i;m afraid it doesnt look too good .... but i'lll post pix

i'll get interior pix 2morrow

[justvwpower]

here is what i have done so far regarding the all in one serpentine setup

(sorry bout the date on the pix forgot to set the camera)

[justvwpower]

i had to fab th water pump pulley from an 1.8t aeb audi clutch fan pulley

the 3 holes didn't match up with the 3 hole w/p setup so i lathed out the center and put the v-belt pulley center in there plus is was the right offset after much trial & error

i tried the clutch water pump pulley that came on the 16v but its offset was too deep

in the long run i came up with this

[justvwpower]

thanx to the inspiration of the clutch delete pulley by Issam and bahnbrenner i have my waterpump pulley
now the next problem i have now is to make the p/s pulley
so this is how it looks so far

[justvwpower]

the problem with the p/s pulley is the most of the serp pulleys made for the p/s dont have an offset .... just like the stock pulley (v-belt) so i needed a pully to go in towards the pump assembly... i tried a G 60 supercharger pulley by lathing out the center

the offset was good but the diameter of the pulley made the pulley rub against the p/s pump housing i needed something bigger so the other options were....

and

but these had the same nonoffset feature and worst of all they were too big ...so big that with the pump fully adjusted outwards the belt would still cudn;t go in between the w/p and the p.s pulleys
so much for the vr6 route i needed a smaller pulley that can go over the pump assy and still be small enuff to allow belt placement
off to the junkyard 2morrow because my yard is out of options

[justvwpower]

the big pulleys were from a 1.6 mk4 bora and a 2.0 jetta mk4 (same car duh!!!!)
as the terminator wud say.....
i'LL BE BACK!!!!

[justvwpower]

heres what it al boils down to



BUG UPS &SHOUT OUTS to denis @ efituning (this is not his address) he can be found here http://www.efi4tuning.com/ he has been great in service and it is believed to be the 1st megasquirt in Jamaica
but also nuff props to the folks in MEGASQUIRT land who has helped with their experiences & trials & errors can hardly wait to get this thing running

[junn]

nice what rad are you going to use? or the air compressor clears the stock rad?

[ellocolindo]

big thanks to you for looking at a scrapyard solution to the elusive serpentine belt set-up in the 16v engine WITH a/c AND p/s on the same belt.
i am planning to boost my 9a and turn it to serpentine belt.
when it comes to the compressor. what are you doing for hte a/c lines that attach to the compressor?
the fittings between the original v-belt and the mk3 serpentine compressors are different.
i have thought of 2 choices.
try and swap compressor puleys and clutches; a lot of guessing on the aligment and so on; or try to see if i can swap the tail sections of the compressors themselves to accomodate the original lines.
if neither one work out i will have to have custom lines made.

[justvwpower]

to answer both questions....i'm using a mk2 golf gti radiator cuz its shorter and i can install my euro oil cooler beside it ...i also have the choice of using the g60 radiator also cools just as good.... bout the A/C compressor i had made an adaptor to use the b3 A/C line but then i found the mk3 lines in the junk yard... i can tell u how to build the adaptor... first u have to get a /get someone with a TIG Welder its easy to make wish if i cud sell them (jus kidding)

[justvwpower]

!!!!YaYYY !!!! i found the right pulley but 1st some corrections to the build.... i opted for a mk1 radiator and i changed the p/s to a mk3 type that is actually smaller than the passat (the pulley flange is further away from the pump body) so i can use more offset pulley wise
pics to come later have to get wrenching

[ellocolindo]

" the need is the mother of all inventions"
please let us now once everything is lined up what parts you have used.
thanks again for the contribution to the forums

[justvwpower]

thanx for the encouragement .....its the least i can do to fuel thethe spirit of "VagWrenching"
well here are some more pix
this is the look with the mk1 radiator installed still thinking bout the g60 to get rid of the long hose run

while looking for the pulley i started to yank the Motronic loom trying to figger our what wires i need a dwhat i dont so am doing it surgically ...want the car to still look OEM btw the wife thinks i'm doing serious repairs on it wud be my arse if she found out its another project

[justvwpower]

next to be installed is my faithful euro oil cooler

and thanks to some info i found a close pulley its from a toyota 4a-ge 20v W/P pully
and thats from almost choosing A/C pulleys that wud have taken extensive mods and fabbing the w/p pully is a 1/16"shy of my correct offset and it goes over the p/s pump (very little filing to be dun)and the right offset will be had when i make the holes to bolt it to the p/s here it is with the g60 pully i was trying to use 1st (g60 is smaller)

[jamaicawagon]

while looking for the pulley i started to yank the Motronic loom trying to figger our what wires i need a dwhat i dont so am doing it surgically ...want the car to still look OEM btw the wife thinks i'm doing serious repairs on it wud be my arse if she found out its another project


Exactly where in "Spain" are you. I am going to chat your business to wifey unless I get to collect a "smalls" ...okay Daaaddddyyy.

[justvwpower]

today i went tie the chinist to make the pully for the p/s using the w/p pulley from a toyota 20v, remember
the offset is out by 1/8 i chose to use the pulley center from the clutch pulley from the pl engine (jus knock out the center


then using the lathe to cut out its center

then cutting the center of the main pulley


proceed to make an index so that we can locate both centers accurately




holding the the canters after making the index

the index is not so biig just .005

tacking it in place and checking concentricity

putting on a bead and ......balancing

time for a rest

[justvwpower]

yup finally reach home.....now for the moment of truth


with this offset i know the pully is gonna rub a little so i dressed the pump a little


dressed
area

a li'l off the top also

viola!!!!!


dont 4get to put ur adjustment all the way out



had some time left to install my euro oil cooler

you are welcome to try this at home
not responsible for los of limb injuries ... the whole kit n kaboodle of bad stuff that can happen
i know it looks ghetto but hey ... this is jamaica.... i haven't started mi powdercoating bizniz as yet
at a later date but please powdercoat to let them look good
now to get the belt ... i'll post the belt number whn i locate it .....
i was thinking of running an underdrive crank pulley .... let me know what u'all think bout that... i need to kno b4 i buy the belt ..so post your ideas
@jamaica wagon send me a pm and we'll talk
I'LL BE BACK !!!!!

[justvwpower]

sorry for the delay folks as it rainy season here ....evry day it start in the morning and ends at late evening..... so no work dun as soon as its over ....
I'LL BE BACK !!!!!!!!!!!! STAY TUNED SAME V A G TIME SAME V A G PLACE

[sin bar]

awesome!

[ellocolindo]

hey man; i want you to make one for my and give me a price please. shipping to canada.
once you have figured out the correct belt.

waiting on you and your brain to find a solution

[justvwpower]

bear with me folks ....still the rainy season ...can't work in squally showers

[justvwpower]

bout the pulley ..... u cud ask Issam to make the pulleys for u u can reach him@ ....iabed@inaengineering.com i will give u the dimensions for both the W/P & the P/S pulleys as soon as the weather permits.hopefully tomorrow ... i can see some sky

[ellocolindo]

my brother in law is in jamaica right now. maybe he can bng it for me? how much?

[justvwpower]

it wud cost bout $JA 4000......my biggest dilemma is to scour the junk yard to find the right pulley ihave looked in between the rain fall but to no avail....the P/s pulley specs are .....I.D = 100mm...depth or offset =29mm ..... if you are not clear feel free to query.....thw W/P pulley specs (with inspiration from the A/C delete pulley by BAHNBRENNER)..... the O.D =the same O.D as the original pulley... i just lathed off the rear portion of the V groove and flattened the outer lip.... then i got the fan pulley from the audi i.8t A4 ,lathe out the center and pressed it over the other pulley and tacked welded it ,then lathed down the weld bumps

the audi 1.8t A4 fan assy'
the pulley is behind the fan clutch shown
ellocolindo PM me for a link up w/ your bro inlaw (if its not 2 larte) and lets see wht i can do

[justvwpower]

I thought the rains wudn't stop .... the weatherman says more to come but at least for now i'm enjoying the sun ..... now i know how Noah felt in the ark .... 1 month of rain !!!!!!!DAMN!!!!! let's do that again !!!!NOT!!!! here is a idea of what i went thru





this is a typical sunny day



in between the down pour i have been busy looking for a place to stick my megasquirt and in looking i wound up pulling down the whole car !!!!!whew!!!! i what i have noticed is that almost evrybody who has documented their install don't say where they have put their "box" and i need my glove box

[justvwpower]

searching 4 a place to put MS "box"



1 thing with mega squirt i makes u wanna get rid of unecessary wiring
i finally decided to mount it on the side of the console not happy with that choice but .....
decided to do it so i went about making mounting brackets





my bracket kit

measuring up to do the unbelievable



the final blow in vandalism


not happy with this at all boring up mi car

[justvwpower]

while the rain was falling i recieved a item that i longed for ..........thanx SII2L16V for making this possible



this is really hard to find ...and i got it at a gud price thnax again i'm so happy

[justvwpower]

after i finished my MS "box" install i found this


the cruise control module .....hmmm i dont need this .....
out it goes .... i took out the wires actuators pump evrything ....now i found the ideal spot for my MS box !! damn!!!! relocation time


installing it on cruise control bracket

making the bracket stronger


sorry i nevr thought of this sooner

[ellocolindo]

nice spot for it.
but i want to keep my cruise control

[justvwpower]

in the whole JMA all our straightroads put together average 150 miles ... but they are in different part of the country ...... dubbers motto here is.....
Happiness is not around the corner ....happiness IS the corner

[justvwpower]

belt finally arrives from kingston after a long period of searching ...its a 5pk-1575 and it fits beautifully i use 5 instead of 6 as in the VW width because the P/S pully is 1 groove narrower i cud lathe it in but the 5 can do