My second T4, operation de-chav

[regcheeseman]

Cambelt on

Old injectors out - one tap with the slide hammer, makes it so easy.

Activ - how did you pipe up the air filter kit, I've not really looked at it, be interested to see how it was mounted up and how the MAF was plumbed in. Would all VW from similar era use the same signal levels for the MAF? Not sure if I should fit a new genuine genuine MAF, it has a 'genuine' ebay one at the moment that was labelled as Bosch but it was cheap and there are counterfeit ones out there, so I have my doubts regarding it's provenance.

[Activ8]

IIRC I had a pal print me off a mount to take the ID of the CIS intake pipe. Fitted beneath the offside headlight. I bought and replaced the oem screen tank/pump. The MAF intake was a matching diameter to the MAF. I then used a RamAir flexi intake hose to the tapered 90mm turbo intake hose.

I think fitting a new genuine Bosch MAF would be sensible. The MAF sensors may be similar but the housings can be different, sizes and shaping, air flows are mapped to the vehicle.

[regcheeseman]

Does your water bottle accomodate the original pump (front and rear washers) and if so - link?

[Activ8]

Does your water bottle accomodate the original pump (front and rear washers) and if so - link?

I didn't use the oem pump Reg , I don't recall if it could of been used tbh but I'd previously disconnected the rear wipers to be removed. The supplied pump has worked well.

[Activ8]

This is the part I had printed up to secure the CIS intake pipe to the headlight fixing plate. Got an aluminium one coming to create the external opening through the front trim.

Heres the link for the water bottle kit, others look similar. Size is good albeit smaller than the oem and the pump works very well. I paid £10. I mounted it on stainless plate using the airbox locating lug holes. Existing electrics and water pipes were all used. Think I found a VAG 2pin plug at the scrappies to wire the supplied pump in.

https://www.amazon.co.uk/dp/B01GJTGC...ing=UTF8&psc=1

[regcheeseman]

While the bay is stripped I dealt with another job that's been on the to-do list for a while - moving the expansion tank to create more room.

I had the old bracket off the T4 I broke, modified to sit tighter to bulkhead and at a different angle, made a bit of a mess of the plug welds securing the bracket, so they needed a grind back, also had smoke coming up from dash so I had to take the glovebox out and make sure nothing was alight.

A mate totaled his escort, the garage and the house when he was welding outside the car, oblivious to the inferno that was raging inside the car, given the amount of accelerants stored in a garage, it quickly spread....

[regcheeseman]

Did you try the 240mm DMF in the 02B?

Doesn't fit, there's a raised section in the bell housing periphery that reduces its internal diameter just above the starter gear, you could remove a bit of casting but then the ring gear on flywheel would hit the starter pinion - the raised bit of casting is there to stop numpty's fitting a flywheel that is too big for the starter to fit.

[Fife t4]

A mate totaled his escort, the garage and the house when he was welding outside the car, oblivious to the inferno that was raging inside the car, given the amount of accelerants stored in a garage, it quickly spread....

I have this fear. When I welded the sills on the golf I got Michelle to sit inside it on fire watch.

Sent from my SM-G960F using Just T4s

[regcheeseman]

Must have spent a good hour and a half looking for a set of ACV injector pipes, that I bought ages ago and put somewhere safe. Found three sets of AJT ones

Ended up bending one line on the AJT set to fit the longer Bosch needle lift injector, which is position four which may be position three or five depending on your perspective....

Engine is built and attached to gearbox ready to refit. Now to get the engine bay sorted first, got a bit more fabrication before I can re-paint it.

[S49]

Repaint it! You'll loose that white heart.

[S49]

A mate totaled his escort, the garage and the house when he was welding outside the car, oblivious to the inferno that was raging inside the car, given the amount of accelerants stored in a garage, it quickly spread....

I have this fear. When I welded the sills on the golf I got Michelle to sit inside it on fire watch.

Sent from my SM-G960F using Just T4s

The roof burnt off are house in 81, the Volvo garage i worked at burnt down in 97 and 2 years after i left the garage in Lemster burnt down while they had their usual half hour tea break. Started in the metro they were welding and by the time they noticed it was too late, took their landlord next doors shed as well full of vintage tractors. Love Metros me.

[regcheeseman]

so your house burned down, the garage you worked at burnt down and the next garage burnt down due to a fire that occurred at a time you knew they would be all at tea break......hmmmm


(makes mental note to be nice to S49 but never invite him round for tea)


Not a lot of progress today, mostly looking at things, sizing them up, trying stuff and eventually fitted this small bracket



woo!

extended the wire for needle lift sensor and discovered my cam pulley was on backwards.

[regcheeseman]

Started to clean a few of the rusty patches off my coolant pipe and ended up with this,



This wasn't the cause of my coolant loss but it could have been a future breakdown, glad I caught it now. Bit of careful welding around the hole one spot at a time to build a ring of thicker material round the hole and then fill it in and then dress it back.



This morning was clear and dry, not very warm but at least it was dry, I put the site lights under the bonnet to try and get some heat into the metal, warmed up the rattlecans with a hot air gun and then with a rattlecan in one hand and the hot air gun in the other I painted the engine bay, turned out ok given the conditions.



Then I warmed up the dinitrol 4941 and sprayed the underside of the chassis and the wheel arches.

[S49]

Rattle can in one hand heat gun in the other? The sort of short cut are dad you to cuss me for. Love it.

[regcheeseman]

Rattle can in one hand heat gun in the other? The sort of short cut are dad you to cuss me for. Love it.

Works fine, just keep moving and keep heat in the panel