- Hardware (1)
- Body (3)
- Body Electrical (11)
- OXS Light (1)
- Fuse Panel (1)
- Electrical Terminal Part Numbers (1)
- Lighting (5)
- Brakes (3)
- Engine Mechanical (6)
- Audi Engine Codes (1)
- VW Engine Codes (1)
- A1 Engine Mounts (1)
- 2091CC 8V Frankenstein Stroker Motor (1)
- Belts (1)
- Fuel System and Fuel System Electrical (4)
- Ignition System (2)
- Interior (1)
- Megasquirt (14)
- Suspension and Steering (1)
- Terminology (1)
- Transmission, Drivetrain, and Clutch (1)
- Site (1)
- Uncategorized (1)
Technote Index
Megasquirt Settings
I’ve reached the point of a pretty good running car. This configuration is for my car as it is today, December 3rd, 2023. It’s got a 1.8L 8v JH engine, Cabriolet Digifant intake manifold, Corrado G60 injectors, Passat 16v throttle body with TPS, and a knock-sensing ignition system from a 1985 GTI. This is a fuel-only install, and the RPM signal is coming from the knock computer.
MSQ – Tune File:
https://vintagewatercooleds.tech/Link/2023/MegasquirtSettings/2023-12-03_Snapshot_Tune.msq
Dashboards:
https://vintagewatercooleds.tech/Link/2023/MegasquirtSettings/Main%20Dashboard.dash
https://vintagewatercooleds.tech/Link/2023/MegasquirtSettings/Tune%20Analyze%20Live%20Dashboard.dash
Screenshots:
Electrical Terminal Part Numbers
There are two main types of terminals used in early watercooled VWs. The first style is the 1/4″ quick-disconnect terminals – called FASTON. The other type typically goes into multiple contact plastic housings. While it is most commonly know as a fuel injector connector, the correct name is Junior Timer and was made by AMP.
The type of crimp is called an F-crimp. This is sometimes referred to as open barrel and is similar to GM/Delphi Weatherpack/Metripack crimping. This is an open, double barrel crimp. They usually have a section that crimps a wire, and a larger section that makes a mechanical connection with the wire insulation. This crimping method is easily repeatable, reliable and more corrosion resistant than soldered connections.
These part numbers can be found on electronic suppliers such as Mouser or Digi-Key.
Fuel Injector Type Terminals
The 2-pin connectors used everywhere on VWs, Audis and many other brands. These are commonly known as Bosch connectors, AMP connectors, or fuel injector connectors. They are actually called Junior Timer connectors. The company currently making them is TE Connectivity (Formerly known as Tyco Electronics and AMP).
The later series called Junior Power Timer has an extra stainless steel cantilever spring, and an additional locking tab. These are used on Audis, and on later VWs. They are generally compatible with Junior Timer housings.
P/N: 170209-1
Name: Junior Timer 2.7mm receptacle
Wire Size: 14-20 AWG
Max power: 24A
Material: Copper contact with tin plating
Max Temperature: 125°C
Locking Lance: Yes, 1 on back
This is the standard receptacle terminal with one locking lance. The width of the terminal fingers is about 2.7mm. This is used in various places:
- Cold Start Valve
- Aux Air Valve
- Idle Boost Valves (2-pin on/off and 3-pin variable on 16Vs and Digifant)
- Warm-up Regulator
- Frequency Valve on CIS-Lambda
- Differential Pressure Regulator ON CIS-E and CIS-Motronic
- Fuel Injectors on Digifant
- Throttle Position sensor on some Digifant and Motronic systems
- Oxygen Sensor Heater connector on 16V and many later cars
P/N: 927879-2
Name: Junior Timer 4.8mm receptacle
Wire Size: 13-17 AWG
Max power: 40A
Material: Copper contact with tin plating
Max Temperature: 125°C
Locking Lance: Yes, 1 on back
This is a wider contact, only used in a few places:
- Transfer Pump connector inside the fuel tank on 2-pump cars such as 1984.5 – 1992 Sciroccos and later Cabriolets
- Possibly the terminal used in the Mk3 starter solenoid connector
1/4″ Quick-Disconnect Receptacle Terminals
These are known as FASTON receptacle terminals. They are described as .250, 6.3x18mm, or just 1/4″ quick disconnects. Sometimes incorrectly described as spade terminals. The measurement is based on the width of the tab. They have a locking lance on the back for locking into terminal housings. They are very common in many cars, and other applications. Just a few examples of where they are used:
- Ground connections at fuse panel (with no housing)
- Many single connectors on the back of the fuse panel
- Throttle wide-open switch on CIS cars
- Oil Pressure sensors
- Oil and coolant temperature senders
- Radiator fan switch connector
- Various in-harness connectors
P/N: 626094-2
Name: FASTON 250
Wire Size: 17-20 AWG
Max power: 28A
Material: Brass, tin plating
Locking Lance: Yes
P/N: 42238-2
Name: FASTON 250
Wire Size: 14-18 AWG
Max power: 28A
Material: Brass, tin plating
Locking Lance: Yes
P/N: 170054-1
Name: FASTON 250
Wire Size: 16-20 AWG
Max power: 28A
Material: Brass, unplated
Locking Lance: Yes
1/4″ Connector Housings
These are the clear plastic housings that are normally over these connectors. This is a clear/natural plastic, and matches the original types typically in 70s and 80s VWs. The locking lance on the FASTON terminals will lock into this.
P/N: 8-735075-0
Name: Low profile, single contact, FASTON 250 housing
Color: Natural
P/N: 5-154509-4
Name: Single contact, FASTON 250 housing
Color: Black
The black variation of the plastic housing. This is used specifically on the throttle body open-throttle switch connectors on some cars.
Headlight Connectors
The H4/9003 bulb and the sealed beams use a larger size .312 or 8mm/7.92mm connector. The American size of 5/16″ (0.3125″) The flag terminal style is seen often here in aftermarket connectors for a low profile.
P/N: 180422-2
Name: 312 Series FASTON 90 degree flag terminal
Wire Size: 10-18 AWG
Max Power: 28A
Material: Brass with tin plating
Locking Lance: Yes
P/N: 180913
Name: H4/Sealed Beam Connector 3-Pin Housing (Flag Style)
Color: Natural
P/N: 180913-5
Name: H4/Sealed Beam Connector 3-Pin Housing (Flag Style)
Color: Black
VW Sunroof Repair
Leaking slow hard to crank sunroof? This ATS technote will show you how to replace the seal and remove, adjust, and lubricate the sunroof to get it working again.
Continue reading VW Sunroof RepairBolt Measurements
Most of this is applicable to the JH engine (1.8L 8v) but much of it covers more related engines. This is a running list that will be updated often, I’m measuring things as I go.
Water Pump
Pump to block – QTY-2 M8x1.25x30mm, QTY-2 M8x1.25x50mm. all are 13mm hex-head drive.
Water pump housing – QTY-8 M6x1.0x18mm flanged. 10mm hex-head drive.
Pulley bolts – Non-A/C M8x1.25x14mm socket head (Allen) 6mm drive.
Freeze Plugs – 36.5mm diameter. Zerostart 3100034 block heater.
8v Intake Manifold
QTY-3 M8x1.25x50mm, QTY-3 M8x1.25x80mm, socket head (Allen) 6mm drive
Cold Start Valve – M6x1.0 (unknown length, but likely around 15-20mm)
Vacuum lines are 4mm, 3/16 used in the US is a close equivalent.
Valve Cover
For use with ABA rubber valve cover gasket – M6x1.0x32mm, 10mm of thread on each end. No shoulder in the middle.
Transmission
Speedometer cable – M7x1.25x13mm 11mm hex-head drive (This size is very unusual and almost non-existent)
Bumper
US bumpers have M12x1.5x22mm with 19mm hex-head drive.
Euro bumpers have M12x1.75 pitch
Brakes
Bleeder valve M7x1.0x32mm, Speed Bleeder (built-in check valve) is Dorman P/N 12708
Rotor screws are M6x1.0x14mm with a flat head – FH (countersunk), various lengths are available. Drive is P3 Phillips. Do not use a standard P2 Philips on these – the head will strip. Similar screws are also used on Honda/Acura, but they use a JIS spec drive. Use anti-seize when installing, especially on the bottom of the head. Late model VW/Audis use a similar part, 16mm long, with a Torx T30 drive instead of the Phillips head.
Wheels
Ball Seat (Spherical) R12 , 17mm hex-head drive.
Steel Wheels: M12x1.5x19mm
Aluminum Wheels: M12x1.5x23mm
Aftermarket wheels are typically conical seat. If you are running wheel spacers, you will need to get longer lug bolts to suit the extra thickness.
Fonts
This is the Mk2 type font, used in the 80s on the Quantum, Mk2 Scirocco, the Mk2 Golf, the Cabriolet, and the Mk2 Jetta:
https://vintagewatercooleds.tech/Link/Fonts/MARKTWO.zip
I never finished making the Mk1 type font. Here is everything I have – outlines related to that effort: Mark One FONT.zip
https://vintagewatercooleds.tech/Link/Fonts/Mark%20One%20FONT.zip
More Fonts
Here’s a some good Mk1 fonts:
020 Transmission Output Flanges
In mid 84, VW change the 020’s transmission from 90mm output flanges to 100mm output flanges. Mainly writing all of this down with what I found out about my 100mm flanges today. I will expand this as I find more information about the earlier transmissions. There was a weird transition period from 83 to 84 where there were two case styles.
Bolts for axles to flanges: M8x1.25 (48mm long)
Torque Spec: 45 Nm (33 ft. lbs.)
Part Number for 6mm Allen head type: 113 501 229 D
Part Numbers for 8mm XZN Triple Square head type: 893 407 237
N91108201
W01331834815
ATM 893407237
Axle Nut Size: M20x1.5 (30mm socket required)
This is a self-locking nut (lock nut), and should be replaced every time.
Torque Spec: 240 Nm (173 ft. lbs.)
Circlip (Lock Ring) for the differential pinion shaft that goes inside the output flange: VW Part Number 113 311 287
Tool for removing: Lisle 44900 Lock Ring Pliers
Kit for output shaft seal, including circlip, cap, and seal: 020 498 085G or 020 301 189H
Output Shaft Seal for 100mm flanges (around the outside of the flange): 50mm x 65.2mm x 10mm (ID x OD x Thickness)
1.969″ x 2.565″ x 0.394″
Part Numbers:
National / Timken 710651
Febi 01519
Kaco 216415
88996656
020301189E
020301189G
020301189H
020301189M
020301189N
020301189R
020301189S
020301189T
020498189E
020498189G
02M409189
02M409189B
Output Seal for 90mm Flanges (Coming Soon)
Older pre-83 cars used a “Fat” seal 36x58x15
Flange Seal – this is a cap that goes inside the flange to cover the pinion shaft with circlip, it separates the viscous CV joint grease from mixing with the gear oil inside the differential: 020 409 289 B
Tool for pushing in axle flange: VW 201
Basically is a M10x1.5 at least 130mm threaded rod with a bent U shape to push down on flange. You will need enough clearance to get the lock ring pliers in.
Broke VW Reference DIY page:
http://www.brokevw.com/020flange.html
ATS – Mk2 Brake Light Mod
This is an original ATS technote from 9-29-2003
I know, you have seen a dozen web sites with this modification on the web for the MK1 and MK2 well perhaps you want to look closer.
I will admit once again I took a readily available idea on the web, but I changed it around. Every single one I have seen so far (and I have counted over 18 sites with this modification listed), and I noticed ONE common factor, everyone is copying, every one else, and put their brake lights together, some how, like an unspoken standard, became apparent to my eyes…
Though the listed modification helped me a great deal in figuring it all out, I could not bring myself to make the same boring change as everyone else. So? what did I do that is so different?
Continue reading ATS – Mk2 Brake Light ModRound Lights on a Mk2 Scirocco
Round Headlights on a Scirocco, is like returning what was taken away with them 4×6 headlights. Annoyed at the cost of euro lights and its wide distribution, I decided to move back into time and change the missing link on my Scirocco. to give it back its purebred look that VW took away in 82.
Parts needed for this project:
2 complete PAIRS (4 assemblies) of Scirocco Mk1 headlights frames,
1 complete pair (2 Assemblies) of Mk2headlight (USA OEM),
1 GTI or Mk1 Scirocco Grill (or make your own).
Fuse Panel
Here is a color picture of my Fuse panel – In my 1984 Scirocco with A/C and Power windows. List Should be the similar for any German made car after 83 until 93 (CE1 and CE2)
This is from rocco_luvr on vwvortex about a 1978 Scirocco’s Fuses
1) L headlight, low, 8A 2) R headlight, low, 8A 3) L headlight, high/high beam warning light, 8A 4) R headlight, high, 8A 5) rear window, 16A 6) break lights/emergency flasher, 8A 7) interior light/”cigar” lighter/clock, 8A 8) turn signals/turn signal indicator light, 8A 9) back-up lights/horn, 8A 10) heater fan, 16A 11) windshield wiper and washer/rear windshield washer only, 8A 12) license plate lights, 8A 13) R parking lights/R taillight/R side marker, 8A 14) L parking lights/L taillight/L side marker, 8A 15) Radiator fan, 25A 30) inline fuse under dash, rear window wiper, 8A 40) radio, 5A |
Relays From the Bentley manual: (For German-made cars 83-93) Relay panel diagram:
19 | 20 | 21 | 22 | 23 | 24 | Top (Accessories) |
13 | 14 | 15 | 16 | 17 | 18 | |
1 | 2 | 3 | 4 | 5 | 6 | Bottom Section |
7 | 8 | 9 | 10 | 11 | 12 | |
Fuse Panel |
Location | Description |
1 | Digifant control unit 1990-1993 |
2 | Fuel pump relay |
3 | Seat belt Warning Buzzer |
4 | Upshift LED control unit |
5 | Air conditioner (If installed) |
6 | Horn Relay |
7 | – |
8 | Load Reduction (X relay) |
9 | – |
10 | Intermittent wiper relay |
11 | – |
12 | Turn signal flasher, hazard lights |
13 | – |
14 | Hot-start pulse relay (1983-July 1987); Cold-start enrichment (July 1987-1989); Radiator fan after-run control unit (1990-1993) |
15 | CIS Power supply (1983-1989); Starter interlock (1990-1993 automatic) |
16 | Idle speed boost/stabilizer control unit (1983-1989 CIS), Hot-start pulse relay (CIS-E), open (1990-1993) |
17 | Fuses – A/C thermofuse (30A), Power convertible top circuit breaker (20A) – Cabriolet only |
18 | Coolant low-level warning control unit; Idle boost control unit (CIS-E) |
19 | Power window fuse (20A) and Power window Relay |
20 | – |
21 | – |
22 | – |
23 | – |
24 | – |