During my recent Vanagon engine conversion, I was "surprised" at how much corrosion I found in the donor and Vanagon harnesses. I was thankful to have spare Vanagon and Mk3 harnesses lying around. This autosport web page: https://www.rbracing-rsr.com/wiring_ecu.html might have useful and relevant harness construction and repair info. This image re: wicking water up wires from same says a lot to me (you need to zoom in): https://www.rbracing-rsr.com/turbo/wiring_pix/wicking_salt.jpg On Mk3 harnesses I've seen, each engine sensor wire where it enters the connector has a silicone sealing bung. On my first Mk3 ABA conversion van, I replaced all 3 heat damaged (cracked casing) and corroded wires to dizzy hall connector with non "sealed" used VW wires. I then sealed up wire entry points at connector with red RTV *and* applied dielectric grease at exterior of that connector. Ironically, over years, moisture still managed to corrode the hall contacts which eventually caused an intermittent engine cut out at highway speed. I did my best in a campground parking lot to clean them (host was hustling me out) thought I'd addressed the issue but that fault soon caused a nasty stall during a left turn in traffic. I think the connectors need to "breath" or be 100% sealed, if that's even viable. Neil. On 4/7/19, Dennis Haynes <d23haynes57@hotmail.com> wrote: > I have some theories. First the terminal ends for many connections are not > sealed. Water, salt etc. get on the ends and capillary action moves that > into the wire. Next, the insulation itself has some porosity or gets damaged > from heat or abrasion allowing oxygen and whatever else to reach the copper > and corrode it. We tend to take wiring for granted. I have even seen that > trans to boy ground look OK but still not carry current for the starter. Why > we need to learn how to use meters to test voltage, resistance, and > current. > > Dennis > > > From: Dan N <dn92610@gmail.com> > Sent: Sunday, April 7, 2019 1:34 AM > To: Dennis Haynes <d23haynes57@hotmail.com> > Subject: Re: 2000 rpm buzzer of oil pressure > I got no signal from the coolant sensor... I clipped the tip and make a new > connector ... errrr... NOPE... so I clip about 5" more, solder a new wire > and connector and it's working.... -- Neil n VE7TBN 1988 Westy 50º ABA swap: https://tinyurl.com/yap5hpwt 1981 Westy 15º ABA swap: https://tinyurl.com/y9n4xob8 VAG Gas Engine Swap Group <http://tinyurl.com/khalbay> |
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