20thAE Build/Picture Thread

[MNShortBus]

The HVAC box had a heater core in it already. Looked brand new so I used that.

Waiting on the block to get back from the machine shop. but in the meantime ill be drooling over this.

[MNShortBus]

UPDATES! (finally)

Got some goodies from 1stpartsvw. New coilpack harness, the old one was starting to crack so why no replace it now? So sick of wiring though...

New power steering pressure switch
New slave cylinder
New seals for the quick release connectors on the radiator
New hose for the coolant ball
6 clutch bolts, didn't want to reuse the old ones.
New fuel filter



Rubber cup holder inserts because I hate how anything in the cup holder rattles. They are a little too big so they will have to be trimmed down.



Took the shifter bracket out to clean in up a bit and install new bushings. No more rubber in the shifter at all. Can't wait to see what difference these make.


Before:


After:



Cleaned up and slightly polished the trans.





My OBD2 port bracket cracked. Anyone know a part number for this? Cannot find one anywhere stamped on it, or online.

[MNShortBus]

Moar updates.

Finished installing the installing the new coilpack harness(never again, this sucked to do )
Steering wheel and center console are back together
Installed my early Passat mirror switch from Europe
Painted the sub frame because there was visible rust.

Coilpack harness ECU side, suck to work with as there are 3 safety keepers to keep the wires from moving(Purple things on the left)


Just add this into the correct pins. Wires are labeled for the correct pins from the factory.



Sub frame before(MN winters....)


After.


Moved the brushed handle over to the new bezel.


Wiring it up and getting ready for solder.


Pin 2 on the passat switch to Pin 5 on the Mk4 harness(Gray/Blue wire)
Pin4 on the passat switch to Pin 10 on the Mk4 harness(Gray/Yellow wire)
Pin 6 on the passat switch to Pin 6 on the Mk4 harness(Gray/White wire)
Pin 8 on the passat switch to Pin 8 on the Mk4 harness(Brown/Blue wire)

The remaining 2 wires are for defrost. That will be wired up the CCM later and controlled by the rear window defrost switch. This is how it was across the pond, and how it should have been here.





Radio area fully assembled

[Digital K]

all the wiring makes my head twitch. mirror switch is a nice touch!

[isonic]

Rubber cup holder inserts because I hate how anything in the cup holder rattles. They are a little too big so they will have to be trimmed down.



Took the shifter bracket out to clean in up a bit and install new bushings. No more rubber in the shifter at all. Can't wait to see what difference these make.


Before:


After:



Cleaned up and slightly polished the trans.

do you have part numbers for the cup holder cover and shifter bushings? Also, that is one clean transmission. Looks good.

[MNShortBus]

Its actually a rubber insert, not a cover. I just took that picture for size reference.

Part number is 1K0 863 301 A

There is no part number for the shifter bushings, sorry. They were made by a friend and the family business. There may be more but I would have to check.

[JUSTION337]

Iirc 42 Draft Designs makes bronze shifter bushings like that.

[MNShortBus]

I believe 42DD makes them for the shifter endlinks only, not the bracket.

Said bushings:

[tauntedmonster]

My OBD2 port bracket cracked. Anyone know a part number for this? Cannot find one anywhere stamped on it, or online.

6n0 972 559

[MNShortBus]

Sweeeet. Thank you!

Too bad I just put in another order for parts. I'll have to wait until the next one.

[JFettig]

Just hit up Johns Auto and pull the bracket from a vehicle.

[MNShortBus]

Made a lot of progress this weekend despite having to but everything away for next weekends grad party.

Girlfriend got some parts powder coated for me for my birthday.
Polished the valve cover nuts, engine mount bolts, and other random things.
Installed the new coolant ball and hose.
Installed the new heater core hose. The old one was rubbing on the brake booster creating a hole, luckily it never burst open.
Replaced the o-ring seals on the quick connects on the radiator.
Installed the new cabin filter.
Replaced the broken supports for the panel under the drivers side dash. It doesn't sag anymore.
iPod hookup is now back in the car.
Put the door panel back on after installing the mirror switch and rewiring the defrost operation.
Interior is now 100% back together.
Installed the Komfort Blinker retrofit kit (3 blinks with the tap of the turn signal stalk).
Replaced the fuel filter. The previous one had about 40k on it.
Battery holder and wires are now back in place.


Powdercoating!


These are the nuts for the valve cover. Should look great next to the black.


Komfort Blinker from VW. Part number: 000 998 229 A


Installed.


Time for some Comfort Control Module education...

I went the extra mile and decided the change the way the mirror defrosters work. Since the new mirror switch doesn't have the defrost function on it I have to change the way they get the signal to turn on. In Europe the rear defrost switch sends a signal to the Comfort Control Module (CCM) and then that device controls the defrost function.

On the mirror switch Pin 7(voltage supply) and Pin 9(CCM signal) have to be left in the connector, and insulated. Or remove the wires completely.

From the rear window switch run a wire from T7/3(7 pin connector, pin 3) to T23/16(23 pin connector, pin 16) on the CCM. You will need to remove the wire that is in the there currently and insulate the end.

This is for CCMs with part number 1C0 XXX XXX. All 20ths should have this part.

CCMs with part number 1J0 XXX XXX the pin to remove and run a new wire is T23/1.

Pin 16 removed


New pin 16 added. I used a section of wire and the connector from my old coilpack harness. Worked perfectly.



This came out of my fuel filter when I tipped it upside down... ISH.


Picture of the new trans mount with the polished bolts.


New coolant bottle. Walbro pump lurking in the back.


Battery tray back in.

[9jetta6]

dang dude, keep up the work!

[MrScary]

Did you polish the nuts and bolts yourself?

[MNShortBus]

Yeah, I used a dremel and some different sanding disks.

These:


and these: