Turtledub's Armageddon Build

[2OVT]

The plugs are left over. I am not sure what I will do with them. What other pictures do you want? I am not familiar with t10 plugs.



So I do not need the evap plug. I am doing the plug upgrade. I got a new harness from ECS and a set of 2.0t red coils. I also opted for the IE spacers for the AEB valve cover.

t10 plugs are the colored plugs. i.e. AWP's are brown, black, white, orange, and grey.

[turtledub]

t10 plugs are the colored plugs. i.e. AWP's are brown, black, white, orange, and grey.

Ah, gotcha. I cannot get female plugs for them so I will probably cut the plugs off and get some other plugs to make a harness to connect the harness to the fuse block end of things.

[turtledub]

This is how I was going to run the coolant lines. I would have had to get a tee made. The local radiator shop wanted $30 to do it. I thought about it and I decided I did not like how the upper radiator hose was sitting close to the intake manifold. It probably would have rubbed.


So I bought one of these insead.



This will be able to tee off to the coolant bottle and then I will run a line down to the oil cooler. Then the other line coming out from the oil cooler will go into the water pump. Of course this means I had to change out the water pump for the AEB 2 outlet pump.



I did change the t-stat housing to the G60 one so the bottom line fits. Also money shot of my ABF alternator set up. U-jelly? Here is a shot from the front.



I also did not like the way I had run the harness the first time so I decided to move it. The ECU will now be located close to the fuse box. Moving it was rather time consuming. We had to dremel out an unsued hole locaed right behind the driver's side strut tower. Well in order to get to the hole to run the wires I removed the dash.
Dash in.



Dash out.


I pulled the dash myself. I would recommend suckering a friend in to help if you decide to do it yourself. I broke the clamshell and my hazard light button.
On a good note I found out why my steering wheel was loose. The Momo hub was not tightened. That will be nice to fix.
I found this while taking the dash off. What is it?


I managed to get the fuse block down. It does not give me much room to work. It would be great if it came out another few inches.


After all the dremeling we got the harness plugs through the hole.



This is how the harness now goes.


I will need to extend the a few connectors but I like this placement better.

Do I need this? I think it is the cruise controll. It was getting in the way the whole night when we were trying to fit the harness.


Now comes the time to start cutting wires and soldering. I also need to make a stop at the parts store and get some radiator hose. I hope my throttle cable comes today. It would be nice if the OBD port would show up. While I have the solder gun I will also wire in the new coil harness.

[2OVT]

I found this while taking the dash off. What is it?

i believe that is the wing control module.

[2OVT]

Do I need this? I think it is the cruise controll. It was getting in the way the whole night when we were trying to fit the harness.


Now comes the time to start cutting wires and soldering. I also need to make a stop at the parts store and get some radiator hose. I hope my throttle cable comes today. It would be nice if the OBD port would show up. While I have the solder gun I will also wire in the new coil harness.

yup, took mine out yesterday. easy. have to find plugs to plug the previous wire/vacuum holes in the firewall for it.

[turtledub]

Today was a slow day. I spent the afternoon at the York Fair eating all maner of fantastic foods. Nothing like deep fried Oreos and smoked turkey legs to make you want to just sleep and get diabeetus.
Ah, the smell of burnt wires. Started to solder the AEB harness into the fuse block. I followed the set up from here:
http://myweb.whitman.syr.edu/srotblat/swap/
So far, so good. I only have 2 more on the fuse block end. One is the EC Upower and some other wire. I am waiting for my OBD port to show up so I can get that wired in. I am also still waiting for my throttle cable.
Next up will be the coil conversion and on Monday I will stop by and get some heater hose. I am also going to buy an AEB front o2 sensor.

[2OVT]

gah, I haven't even started wiring yet. I'm being lazy.

can't you just use a VR throttle cable?

[turtledub]

gah, I haven't even started wiring yet. I'm being lazy.

can't you just use a VR throttle cable?

That is the plan. I bought one from another member here but I have not recieved it in the mail yet. I hope is shows up soon. I realy hope to have this running and drivable by h2o. I also need to get a better soldering iron. It took forever to do the bigger wires. I also need to get a better heat gun. My wife's hair dryer takes forever. All the wires from the fuse box were cut at the firewall. i will remove the other half of the wires from the firewall forward at a later time.

[dri0514]

That is the plan. I bought one from another member here but I have not recieved it in the mail yet. I hope is shows up soon. I realy hope to have this running and drivable by h2o. I also need to get a better soldering iron. It took forever to do the bigger wires. I also need to get a better heat gun. My wife's hair dryer takes forever. All the wires from the fuse box were cut at the firewall. i will remove the other half of the wires from the firewall forward at a later time.

I don't know if you have bought it already but replace the AEB 4 point blue plug with the 97 ABA 4 point black plug with yellow stripe. You will have the correct temperature reading on the gauge.

[turtledub]

I will have to keep the plug thing in mind. I have not picked one up yet.

[turtledub]

Not sure how much I will get done tonight. I will be spending the evening otherwise engaged. Tomorrow should be a productive day. I am hoping to get the wires squared away. Tomorrow I should be picking up a new set of wheels as well.

More good news. I picked up a welding cylinder from a friend. I will get it filled and then maybe this weekend I will get the car started and then begin on the rocker. I just might make it to h2o!

[dri0514]

Not sure how much I will get done tonight. I will be spending the evening otherwise engaged. Tomorrow should be a productive day. I am hoping to get the wires squared away. Tomorrow I should be picking up a new set of wheels as well.

More good news. I picked up a welding cylinder from a friend. I will get it filled and then maybe this weekend I will get the car started and then begin on the rocker. I just might make it to h2o!

I hope you can make it!!!

[turtledub]

Yesterday was bitter sweet. We had to say goodbye to my wife's Cabriolet. It served us well and is going to someone who will be able to spend the time on it. It was sad to see it go but it will be nice to not have a dead spot in the yard.

[turtledub]

Well my three day-get-it-all-done-just-in-time weeked just got blown to crap. Work called.

Sorry guys, I do not think this car will make it this year.

[turtledub]

Wiring to the fuse block is almost complete. I just have to ground the OBD port. I might be able to get some more done tonight. Maybe if I am lucky I can get all the soldering done. I should only have the coil harness to wire in and the ICM delete.

[dri0514]

Well my three day-get-it-all-done-just-in-time weeked just got blown to crap. Work called.

Sorry guys, I do not think this car will make it this year.

AWWW that sucks!! By next year it will be a beast.

[turtledub]

AWWW that sucks!! By next year it will be a beast.

Tell me about it. I am still going to try to make it though. I have the welder ready to go for the rocker panel. I am ordering more silicone tubing for the diverter valve and coolant lines. I will order them Saturday.

[dri0514]

Tell me about it. I am still going to try to make it though. I have the welder ready to go for the rocker panel. I am ordering more silicone tubing for the diverter valve and coolant lines. I will order them Saturday.

Oh OK. The car is back to being my daily driver and its awesome!

[turtledub]

More soldering today. I got the fuse block back into place. I then started work on the coil upgrade and ICM delete. I have all the wires sorted out but I am not quite sure what to do with some of the old ICM wires. I have 4 leftovers. I am following this thread for the coil upgrade.
http://www.audizine.com/forum/showth...GTI-ULEV-Coils

This one has nice pictures.
http://www.passatworld.com/forums/61...elete-diy.html

I am going to try to finish up the soldering tomorrow. Monday I plan to tackle the rocker panel and set up a time to get the windshield swapped out.

[dri0514]

Those are the ones I used to do my conversion too.

[turtledub]

Those are the ones I used to do my conversion too.

What did you do with the old ICM wires? I have the 4 that I cut off of the plug. They are grey and brown.

[turtledub]

To do list before H2O
1. Rocker - Tuesday
2. Put driver's door back on - Tuesday
3. Finish engine bay wiring - Monday
4. Put dash/interior back in - Wednesday
5. Exhaust - Thursday
6. Coolant plumbing - Wednesday
7. Intercooler plumbing - Wednesday
8. Windshield - Friday
9. Start car - Wednesday

I am sure there is something I forgot. I think I might make it. The car will not be pretty if I make it.

[turtledub]

http://forums.vwvortex.com/showthrea...ght=icm+delete

In this write up the grey and white wires are not used.

I also began welding last night. I found out that my grinder is going to get a work out. I think I need a smaller wire. I keep burning through the sheet metal. It is at least tacked in place now.

[turtledub]

All the wiring in the fuse block is done. I soldered and heat shrinked the connections.


Fuse block is back in place.


More spaghetti.

This was the harness after it was split for the ICM delete and new coil harness.

Everything was traced back to where the harness split.

Here are the wires I used after the ICM delete. The write ups for the 2.0t coil upgrade do not use the other grey and brown wires that go to the ICM.
Write up again:
http://forums.vwvortex.com/showthrea...ght=icm+delete




Here are the coils test fitted.



Here is everything installed.

Artsy shot.


The spacers are from Integrated Engineering. I remembered that I waited for the red ones to be back in stock. Looking back I think I should have gone with the black ones. Oh well...

Next on the list is the rocker panel. The previous owner managed to mangle the rocker panel with a jack. This was covered up with a ton of bondo. So the old panel was removed. Last night I managed to get the new panel ready. I found a weld through primer.
This junk is made out of pennies.




I did not get any pictures of the rocker tacked in. Quite frankly I am embarrased about the welds. My grinder will be getting a work out later. Tonight I will continue on the rocker unless my coolant stuff shows up. I want to try and start the engine before I kill myself on the body work.

[turtledub]

It is looking like it will not make it. I was unable to get anything done Tuesday. Kind of bummed about that.

[turtledub]

Back from H2O. Had a good time Corradoless. I picked up an 034 coil cover.

[dri0514]

Back from H2O. Had a good time Corradoless. I picked up an 034 coil cover.

I just picked one up too. I have to trim the stock cover bolt mount in the back side near the belt so it can fit.

[turtledub]

I just picked one up too. I have to trim the stock cover bolt mount in the back side near the belt so it can fit.

I got the raw steel cover. I am going to paint it with that black wrinkle coat paint.

[dri0514]

I got the raw steel cover. I am going to paint it with that black wrinkle coat paint.

Same here. I might powder coated since its free. Did you pick up the 97 ABA black with yellow line 4 pin coolant temperature sensor?

[turtledub]

Same here. I might powder coated since its free. Did you pick up the 97 ABA black with yellow line 4 pin coolant temperature sensor?

Not yet. My Subaru Outback has started making a chattering/scraping noise from the gear shift area. It sounds like something is scraping against the drive shaft. I looked under it yesterday and I did not see any evidence of anything contacting the drive shaft. It doesn't matter if I have the clutch engaged or disengaged. It doesn't matter if I am accelerating or slowing down. It kind of has me worried so I have decided to hold my Corrado spending until I figure out what is wrong with my Scoobie.
This doesn't mean that I will stop working on it though. It just means I will not be buying it any goodies.

[dri0514]

Not yet. My Subaru Outback has started making a chattering/scraping noise from the gear shift area. It sounds like something is scraping against the drive shaft. I looked under it yesterday and I did not see any evidence of anything contacting the drive shaft. It doesn't matter if I have the clutch engaged or disengaged. It doesn't matter if I am accelerating or slowing down. It kind of has me worried so I have decided to hold my Corrado spending until I figure out what is wrong with my Scoobie.
This doesn't mean that I will stop working on it though. It just means I will not be buying it any goodies.

I can definitely relate to that. The clutch and flywheel just became my stopping point on my parts spending.

[turtledub]

More welding and grinding tonight. My grinder is getting a work out. I guess I am better at grinding than welding.

[2OVT]

keep up the good work bro.

[dri0514]

How's the car coming along?

[turtledub]

My Subaru needed some work on it. It has 255k on the clock and I am trying to scrape funds together for a TDI. My commute is 46 miles one way. I have been a tad busy and it is getting colder outside. The garage is not heated. I guess I am getting old. Then the holidays are coming up. I have not given up. I hope to pick things back up soon.
It just needs:
Oil
Coolant
Battery(or a jump)
Body work
Paint
Turbo oil return line
Thats the major stuff. We will see if anything car related winds up under the tree this year. That will get me jump started again.