Alternator installation

The TDI alternator is Bosch 120 A and is way better than the old one. The connectors that exist are B+, D+ and DF. DF is connected to the regulator on old alternators, but on these newer thingys they are a signal for the engine ECU. The only sockets that must be connected are B+ (of course) and D+ (goes to the charge warning light).
But hang on - the tachometer W connector is missing! Yes, because TDI'ed cars gets the tacho signal from a sensor at the third diesel injector.
This is easily solved though. At the back panel of the alternator there are six connections spread around the edge, each connection is a clamp with two copper wires (you can see it through the vent hole on one of the pictures). That is a W tap!
I removed the plastic cover, cleaned one of the points and soldered a cable right on to it. The tachometer is moving as expected again.

A big thanks to Adam at Frej Bildelar who sorted the wiring out for me. He's the king of car electrics!

It's running!

Glow system upgrade

Shorter and thicker cables, the glow relay will only act as a signal to the double relay that feeds the plugs.
All cables soldered
Crimped, soldered and tied togheter

This is the 50 A fuse replacement for the electrical box

Customized intake close up

Here's a closer look at the re-welded plastic intake.

Customized intake and IC placing

I cut off the turbo intake, turned it 120 degrees clockwise, made an angle to better point into the side vent and then welded it back together with a soldering iron. The original pipes to the IC is the same plastic so it can be used as extra soldering material.
I would like to have better filtering, but to get this thing running I mounted an open filter for now. It's soon autumn and then a long winter, no dust anyway and I get plenty of time to make a box.

I moved the electrical box and cut away the panel. The pipes to the IC goes up above the gearbox. I actually used a universal coolant hose for the last part...

Sell and buy-dilemma

Should I swap my long bed Sinka that's in need of quite a lot of rust and chassi repair in favour of a Syncro Doka with a broken engine and gearbox that needs a repair?

IC routing

Moved the electric box and made a cutout for the pipes to the intercooler. I will place it beside the gearbox.

When on vacation thee shall read

Found another website with a lot of nice info and images. Go there and see for yourself!

http://www.karmann-coachbuilts.com/technical/tdi.htm

GGAAAAAAH!

The bloody bleeder vent for the rear brake broke on the right side! Now I can't bleed the brakes, and it will take hours to get it away. I have a solution for that, scrap the old ugly drum breaks and put the discs on!

A few days of vacation and then back to the garage in the end of next week. :)

New clutch pin

The clutch pin was in really bad condition and the gasser version is shorter. I made a new one.