The Pictorial Work Sequence -
Page 2 |
Click on the thumbnails for a bigger image
|
 |
 |
 |
37.
Accurately shaping ignition switch console |
38.
A bit of wiring to do in the front |
39. A rev counter, turbo boost, and oil
temp gauges |
|
|
|
 |
 |
 |
40.
TDI isolator ring and made up key with chip |
41. Nicely finished altered console to take
isolator ring |
42. T3 connector box, cut
holes, protected to stop chaffing |
|
|
|
 |
 |
 |
43. Alloy welding for
adaptor and intercooler fixings |
44. HA-Projekt
intercooler and fittings |
45.
Bending the special intercooler fixing bracket |
|
|
|
 |
 |
 |
46.
Correct shape obtained |
47.
Completed banana bracket |
48.
Intercooler stainless fixing studs |
|
|
|
 |
 |
 |
49. Charged air, angled
pipes, from Passat |
50.
Coolant and charged air pipes |
51.
Position of intercooler |
|
|
|
 |
 |
 |
52. Air vent T piece |
53. Air bleed bottle from Fiat clutch |
54. Position of air bleed
bottle |
|
|
|
 |
 |
 |
55. Air bleed T piece, intercooler rad |
56.
Topping up intercooler bleed bottle |
57.
Example of HA-Projekt positioning of inter, oil cooler rad |
|
|
|
 |
 |
 |
58.
Removing gear box |
59.
HA-Projekt 22mm TDI shaft |
60.
Bell housing off |
|
|
|
 |
 |
 |
61.
Old and new shafts |
62.
Special tool to undo diff bearing adjusters |
63.
Adjuster removed |
|
|
|
 |
 |
 |
64.
Mark position before removal, enables exact replacement |
65.
Loosen off flange before removing circlip |
66.
Easy to remove circlip |
|
|
|
 |
 |
 |
67.
Gearbox ready for fitting with stainless back plate |
68.
Easier to fit engine first then gearbox |
69.
Throttle potentiometer arm mod |
|
|
|
 |
 |
 |
70.
Sizing up potentiometer position using cardboard template |
71. Accurately cutting template |
72.
Further sizing to get it right |