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

**justvwpower** · 02-04-2011 10:37 AM

i have finished grinding down the throttle shaft to fit the TPS flush to the mount

& made the adapter to fit the TPS on2 the throttle body

now to test the whole setup

next stop installing the IAT

**justvwpower** · 02-09-2011 07:19 PM

the work is picking up in my garage ...barely have time to work on my "project" ...but i did manage to install the IAT

nextime i get a chance i'm gonna wire the connector .....

**WOB16V** · 02-13-2011 10:12 AM

Nice project.I plane to do the same set up for my passat...what pulleys did you used for cranck and water pump?

Originally Posted by 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

**WOB16V** · 02-13-2011 09:38 PM

the way you route the belt isn't the water pump turn backwords?

Originally Posted by WOB16V

Nice project.I plane to do the same set up for my passat...what pulleys did you used for cranck and water pump?

**justvwpower** · 02-13-2011 10:32 PM

Originally Posted by WOB16V

the way you route the belt isn't the water pump turn backwords?

nope....the water pump is ok .... the crank pulley is mk3 ABA no mods .... the w/p pulley is fabbed ... plz see the thread ....

**justvwpower** · 02-14-2011 08:19 PM

Originally Posted by justvwpower

nope....the water pump is ok .... the crank pulley is mk3 ABA no mods .... the w/p pulley is fabbed ... plz see the thread ....

to make my self clear .... YESS the water pump turns backwards ... but it does no harm ..... the european 1.6 8v has an all in 1 serpentine system & the belt is routed the same way

**WOB16V** · 02-15-2011 12:17 PM

maybe that european setup has the pallet on the pump diffrent....I don't know....just curios

Originally Posted by justvwpower

to make my self clear .... YESS the water pump turns backwards ... but it does no harm ..... the european 1.6 8v has an all in 1 serpentine system & the belt is routed the same way

**justvwpower** · 02-16-2011 11:12 AM

Originally Posted by WOB16V

maybe that european setup has the pallet on the pump diffrent....I don't know....just curios

nope its the same water pump .... same repalcement pump as the "regular pump" ...NO DIFFERENCE IN THE DESIGN WHAT SO EVER ......

**justvwpower** · 02-17-2011 09:03 PM

!!!!to hell wid FORD edis .... GOT MY 4G63 CAM ANGLE SENSOR 2 DAY .... gonna be fitting it into the 16v distributor hole soon ...

no crank wheel to weld & sensor to position .....its compact & reliable .....btw i realize that the Mitsubishi.... Mazda... Nissan... cas are all the same ..... jus how they m8 to the cams is the difference ... but the insides are very much identical so much so u can swap them around ....

**MOTA BOY** · 02-19-2011 01:40 PM

Damn nice!

Keep on going!

**justvwpower** · 02-23-2011 10:11 PM

2day i found out i have the 1g cas actually ... the differenve ... the base that goes in2 the cylinder head is smaller ....but i'm not phased .... wud like to machine the 16v distributor housing & put the mitsu cas housing on the 16v waist & weld ....

**justvwpower** · 03-05-2011 10:45 PM

sorry bout takin long to post stuff ...but i have been working ...so i'll be starting again soon ....

**justvwpower** · 03-15-2011 12:20 AM

2DAY I FABBED UP A HEAT SHIELD .4 MY 16V ENGINE ...BECAUSE WITH THE NEW tps ON THE THROTTLE BODY I CANNOT USE Back THE ORIGINAL TPS HEAT SHIELD ..PLUS I INSTALLED THE iat IN2 THE BACK OF THE INTAKE MANIFOLD ....so fearing that the exhaust manifold might damage them i did the precautionary measures ....build a heat shield....

using asbestos as insulation ....

all put together ....

**justvwpower** · 03-21-2011 09:51 AM

putting it all back together yesterday ...i realize that the nipples on the brake master check valve dryrot & broke off ...now while it wud be nice to get a vaccuum manifold (love the 1 4m 42 DRAFT DESIGNS) this is JAMAICA so we do most things on a budget ....so i'm gonna try & repair it ...... worse i dont c it on the net 4 sale .....

**justvwpower** · 03-22-2011 11:45 PM

vw check valve repaired ....

i just used some epoxy around the gaps just to make sure it wont leak ...

next stop fitting up the rest of my fuel rail ....

**16v_HOR** · 03-23-2011 12:04 AM

I haven't been in this thread in a bit, glad to see you still plugging away at it. Good idea ditching the edis, those things suck

**justvwpower** · 03-24-2011 12:08 AM

my fuel rail is finished & installed ...still need a 02a starter ....these things hard to get here ....
pix to follow tomorow ....
also made a battery charger out of an old transformer i found ...not working ...after all that effort ...

not giving up ...sort it 2 morrow ...

**justvwpower** · 03-24-2011 11:22 PM

By darks_aint at 2011-03-24

By darks_aint at 2011-03-24

wish if i cud start driving ...

**justvwpower** · 03-31-2011 01:28 AM

shud be getting a starter 2morrow trading a new 4 wire oxygen sensor for it .... i hope ....

**justvwpower** · 04-01-2011 09:57 AM

nobody never told me that a vr6 starter was different to a passat starter in the manual transmission
so its back to the drawing board .....

gonna start working on the shifter .....(i actually 4got about it )

A/T out ......

**justvwpower** · 04-11-2011 10:27 AM

i finished rebuilding the manual gearbox & am about to put it in ......but i have to rebuild the throw out bearing 1st as i cannot get any to purchase in JA ...so pix are to follow

**justvwpower** · 04-14-2011 12:37 AM

used this tool to help pull it up

i then degreased it & fit it back again

**justvwpower** · 04-14-2011 01:10 AM

i'm not going to use the front coolant pipe on the 16v head ...as i think its a nuisance & the x-flow & the 20v dont use one .....so i decide to put my CTS there so the side of the head can look clean ....

.....so after cutting out a chunk of aluminum & boring the 3 holes its time to shape it .....

boring the 1st hole ....

boring the 2nd & bigger hole to house the body of the CTS w/ the O- ring ..

finished ..... nice whn ur work place has its own machine shop

getting ready to fit it .....

need to do some porting here ...realize the the shape otf the pipe doesn't correspond with the shape on the head ....

my weapon of choice

finished

making the bracket to hold down the CTS ..... sorry for the blur ...had the wrong zoom selected on the camera ..it was farsighted ....

completed ...

this is how it shud look ...

with the bracket on ....

trial fit ...

installed....

**justvwpower** · 04-14-2011 09:35 PM

i cant seem to find a pedal box either ...for the passat ..so i've decided to make 1 by m8ing a pass auto pedal box with a mk3 golf manual pedal box .....

this was decided after i found that the mk3 pedal box doesnt fit so well w/o mods ///better to mod the box ....

**justvwpower** · 04-19-2011 10:02 PM

i got a polo starter housing 2day ....so idecided to change it over ...on pulling off the motor housing i decided to overall it ....

looks cruddy

after further pulling ...i put the parts in the parts washer 2 soak overnite ...

**justvwpower** · 04-22-2011 03:53 PM

got the parts cleaned in a mild caustic solution ...... now in assembly i realized that the bushings need changing in the back of the starter ...... i decided to check the 1 in the bellhousing also ...yep its worn also ...so now i have to go get 2 ..... i h8 holidays ...
!!!!!!!!!HAPPY EASTER!!!!!!!

**justvwpower** · 04-22-2011 08:52 PM

remember the Mitsubishi C am A ngle S ensor..... i have begun to TRY & m8 it to the 16v distributor housing

By darks_aint at 2011-04-22

yanking the bearing & seal out of the Mitsubishi CAS

By darks_aint at 2011-04-22

shown is the seal still in the housing & the bearing

By darks_aint at 2011-04-22

**Bozwell** · 04-26-2011 11:11 PM

lookin good!

**justvwpower** · 05-03-2011 09:50 PM

been away from the project for a while ....been doing O.P.P. (other ppl's projects ) ...right now i'm converting a mk2 golf 4m the dreaded CIS-E to Digifant 2 ..... soon be back here

**justvwpower** · 05-30-2011 07:50 AM

not abandoning the project @2 all ...circumstances came up i had to relocate ma garage b4 time .....wish i had finished it b4 ...but hey its a pioneering adventure

By darks_aint at 2011-05-30

**MOTA BOY** · 05-30-2011 01:30 PM

Love your work!

**justvwpower** · 06-06-2011 11:37 AM

from last week i want to resume ma project...but evryday its raining

......i hope it soon stop ...anyway its life in the tropics....

i'll gonna start on the Cam Angle Sensor next ....wud start sooner but cannot get any help ...looks like its a 1st ....evrybody telling me bout ford's EDIS.....nope caan be bothered ...wanna do supm new ..so as soon as i can find a way to index the 2 housings ...i'll be posting ....in the meantime ...any input will be greatly appreciated.....

my aim here is to put the mitsu CAS on2 the base of the vw 16v distributor housing ......

**justvwpower** · 07-02-2011 04:45 PM

still here ...have not 4 gotten this thread .....just been busy trying to make the money ......& still trying to figure out how to mate the mitsy CAS & the 16v distributor to gether .....

in the mean time i have been looking @ some old fotos of vw being worked on in the late '70's & early eighties (MK 1's) & i found a way to keep my carbon canister active ( evaporative emissions)...rather than leave the hose hanging there polluting the atmosphere....in the '70's vw routed the feeder hose as close to the air filter element as possible ( between the filter & the throttle body....) no purge valve of any sort was used .....
so i got to thinking .....since my MS2 cannot control a purge valve i got a vacuum operated one from an old mk2 & hooked it up

and then i routed it to the original feed on the throttle body

i have used the vaccuum fromthe intake plenum....where i should have used it from the butterfly plate...dont think its any trouble .....
BUT U CAN ROUTE THEE HOSE TO YOUR ENGINE WITHOUT THE PURGE VALVE .....just put the hose as close to the "clean side " of your air filter ... the closer u go to the TB the stronger the vacuum force which u don't want ....
ask if u need more info .....BUT U DON'T HAVE TO LEAVE THE EVAP CANISTER HOSE UNCONNECTED....

**justvwpower** · 08-10-2011 11:14 PM

sorry to have been a way so long ...between family & work, heart attack ....im just busy ...but dont give up hope ...i'll be back ...with pix also ....

!!!!!STAY TUNED

!!!!

**diagramOSC** · 08-11-2011 01:34 AM

I so love this thread.

VWVortex

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

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adapting new tps

installing the IAT ...

hi

distributorless on my mind .....

re 4g63 cas ....

pause for a cause

Time to move on .....

!!!!!darn!!!!!!

my fuel rail all dun ...

plx !!!!

!!!!!!!!! Starter @ last ?????

!!!!oh man !!!!!!

putting in the gearbox

dismantling 02a throw out bearing ....

fabbing a coolant temperature housing ....

now back to the gearbox ....

ok then ... back to the starter ....

Elsewhere in the lab .......

pause

relocating the garage

!!!!darn rain .....

!!!still here!!!!!

!!!im back!!!!!

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