Date: Thu, 2 May 2013 23:12:32 -0400
Reply-To: Steve Cotsford <cotsford@AOL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Steve Cotsford <cotsford@AOL.COM>
Subject: Re: Bluestar project progress-small problems
In-Reply-To: <E00C3579-5A89-41D2-AA10-729DDE9E371F@AOL.COM>
Content-Type: text/plain; charset=us-ascii
OK I think I have solved my mystery connector issue. Dennis put me on the right track.
I have discovered that my engine is from an '86 syncro. As such, it has a METAL thermostat housing and a temp gauge sender that just has one wire (fits like a nail head on the sender instead of a plug. This sender screws into the housing.
The van is an '89 2wd and presumably it had a PLASTIC thermostat housing on the original engine. It seems it had a 2 wire temp gauge sender as the wires in Bentley jive with this (two pin, red/yellow and brown wires). The sender would have been held in place with an o-ring and clip.
What I need to find now is a two wire temp gauge sender that threads into the metal thermostat housing. Alternatively, I need a plastic thermostat housing to take the place of the metal one, so I can install the sender that gets held in place with an o-ring and clip.
Does anyone know if in fact there is screw in two temp gauge sender ? If there is, I believe it would be for a 1987-1991 syncro with metal thermostat housing.
Its confusing that both the temp gauge sender cable and the catalytic converter cable have plugs with same color wires (red/yellow and brown) as well as the same kind of connector. Only the length of the pigtail differentiates them.
Thanks in advance for any help.
Steve
On May 2, 2013, at 10:37 PM, Steve Cotsford wrote:
> Thank you Dennis for your comprehensive reply.
>
> I solved my heat shield problem by drilling additional bolt holes on the engine side of it so the bolts hold the shield 2" lower.
> Both the coolant bottles fit nicely now.
>
> I checked out the list you made:
>
>>
>> The heavy green wire is the coaxial signal wire for the o2 sensor.....................OK I also have a red/yellow and brown plug I suppose for the o2 heating element.
>
>> From the
>> left side there are the two connectors for the injectors...........................................OK
>
>
>> a black connector
>> for the temp gauge..........................I dont seem to have this but there is a second temp sensor on the back side of the thermostat housing for a single wire.
>
>> a green connector for the temp two sensors...........................my temp II sensor has two wires, green/yellow and brown/white but I'm comfortable that it is properly connected.
>
>> the
>> connector for the two oil pressure switches.............................................................OK
>
>> There is also wiring for the AC
>> compressor and AC power going directly to the alternator...................................OK
>
>> You need to locate
>> the idle stabilizer valve,.................................................................................................OK
>
>> crankcase vent heater,...................................................................................................OK though i am presently missing the heater/orifice
>
>> throttle switch,...................................................................................................................OK
>
>> and of
>> course the distributor......................................................................................................OK
>
>> The ground wire in the distributor harness is the
>> very important one. It is the reference for the O2 sensor circuit. ...........................OK, I will ground the eyelet to one of the pressure regulator screws as suggested.
>>
>> 3 I have a single wire with a yellow plastic spade connection. It
>> comes out of the same loom as the cables that go to the box above the
>> ignition coil. It is not the single wire with the yellow connector that
>> connects to the a/c compressor. I have already located that one. Anyone
>> know what its for?
>>
>> I'm having a brain freeze on that one!
>>
>> That spade on the side of the distributor was for the interference shield on
>> the distributor cap. Use the later cap with the plastic looking shield I
>> think 03-214. That rings terminal connection has to go to real good ground
>> point as mentioned above. I use one of the fuel pressure regulator screws.
>
>> I am still puzzled by the extra red/yellow, brown connector. I'm going to have to check out the temp gauge wiring too.
>
>> Hope I helped,
>> Dennis
>
> You helped a great deal ! Thank you again.
>
> Steve
>>
>>
>> On May 1, 2013, at 10:19 PM, Steve Cotsford wrote:
>>
>>> I found the heated barbed fitting on a German site
>> http://syncrowiki.org/wiki/Datei:025_906_391_A-1.jpg
>>>
>>> Steve
>>>
>>> On May 1, 2013, at 8:47 PM, Dennis Haynes wrote:
>>>
>>>> That fitting is both an orifice and heater. It provides a restriction
>>>> to the blow by that can make it into the intake air. Since this blow
>>>> by contains water vapor the heater prevents that vapor from freezing
>>>> and blocking the vent. In the wire box on the left side of the engine
>>>> compartment there is a fuse just for this heater. There is a two wire
>>>> connector in the harness for it.
>>>>
>>>> Dennis
>>>>
>>>>
>>>> -----Original Message-----
>>>> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On
>>>> Behalf Of Steve Cotsford
>>>> Sent: Wednesday, May 1, 2013 8:31 PM
>>>> To: vanagon@GERRY.VANAGON.COM
>>>> Subject: Re: Bluestar project progress
>>>>
>>>> Well it seems that barbed fitting is something more. From what I can
>> see,
>>>> the hose from the breather tower plugs into the fitting and there is
>>>> some kind of electrical switch in the fitting itself. The other side
>>>> of the barbed fitting plugs into the second hole in the air intake
>>>> boot coming from the air cleaner to the throttle body.
>>>> I have an electrical cable with a plug just like the one that goes to
>>>> the coolant level sensor with nowhere to go. Wire colors are black and
>> beige.
>>>> The label says "air intake hose switch".
>>>> It seems I am missing this barbed fitting with a switch in it. At the
>>>> moment, I have no idea of its purpose. In Bentleys diagram 24.47 you
>> can
>>>> see it poking out of the "air intake hose" or boot.
>>>>
>>>> Can anyone cast some light on what this switch is for and what I can
>>>> go shopping for....part no?
>>>>
>>>> Thanks, Steve
>>>>
>>>> On May 1, 2013, at 5:51 AM, Frank Condelli wrote:
>>>>
>>>>> Steve, sounds as if you're making good progress. I couple of
>>>> pointers to help you out. Antifreeze should be Phosphate free. I
>>>> find Prestone LongLife to be the best due to its easy availability
>>>> and cost. The bung for the J-pipe, I have one or two, OEM parts that
>>>> may be available from your dealer, Cap Nut, 4A0 131 737A - M14x1.5,
>>>> you can always just weld it closed also as it serves no useful
>>>> purpose these days. Don't know the part # for that barbed fitting
>>>> and cannot find it in the parts program however, I may have a spare
>>>> lying around. The missing engine splash shields are not that
>>>> important, like you figured they were intended to keep dirt and
>>>> splash out of the engine compartment. You may be able to find good used
>> ones eventually.
>>>>>
>>>>>
>>>>>
>>>>> On 2013-05-01, at 12:00 AM, Automatic digest processor
>>>> <LISTSERV@GERRY.VANAGON.COM> wrote:
>>>>>
>>>>>> I am getting close to where I can install my 2.1 wbx engine. New =
>>>>>> pulley is installed as well as the exhaust system, heat shield etc. =
>>>>>> Still short a couple of small parts.
>>>>>> Its sitting ready to go in but I still have to get the clutch
>>>>>> release = mechanism checked out and the new throwout bearing installed.
>>>>>> The coolant that was still in the engine was dark green in color, a bit
>> =
>>>>>> like British racing green, not a generic antifreeze. Does this sound
>> =
>>>>>> like the right kind of antifreeze? Is the pink VW antifreeze that I
>> =
>>>>>> use on my Tdi ( G12) suitable for use in this engine or should I
>>>>>> look = for something very specific?
>>>>>>
>>>>>> I need help with a couple of parts:
>>>>>>
>>>>>> The exhaust "J" pipe has a port on the underside, near the catalytic =
>>>>>> converter. The cap is missing from this. Does anyone know a part
>> =
>>>>>> number for this cap or what thread it is? I'm thinking I should =
>>>>>> probably just weld it closed or tap it for a close off screw..
>>>>>>
>>>>>> There is a hose that goes from the breather tower over to the intake =
>>>>>> boot. There is a barbed fitting that fits the hose and the boot. I
>> =
>>>>>> am missing this barbed fitting. Does anyone know the part number for
>> =
>>>>>> it? Its a bit bigger in diameter than the 3/4" one I found at Lowes.
>>>>>>
>>>>>> The big heat shield has some holes each end where side plates bolt
>>>>>> on = and fill the the gaps between the fuel injector areas and the
>> inside =
>>>>>> wall of the engine compartment. I am missing these plates. How =
>>>>>> important are they? Do they do more than just stop dust etc from =
>>>>>> blowing up into the compartment?
>>>>>
>>>>>
>>>>>
>>>>> Cheers,
>>>>>
>>>>> Frank Condelli
>>>>> Almonte, Ontario, Canada
>>>>> '87 VW Westy, '00 Kawasaki 250 Sherpa, "98 Ducati 750 Monster &
>>>>> Lionel Trains (Collection for sale) Frank Condelli & Associates -
>>>>> Vanagon/Vanagon Westfalia Service in the Ottawa Valley Vanagon
>>>>> Stainless Steel Exhaust Systems BusFusion a VW Camper camping event,
>>>>> Almonte, ON, June 06 ~ 09, 2013
>>>>
>>
