The Greenland Polo by the brit

11 minute(s) of a 249 minute read

Posting from somewhere in central PA, just left the DMV headquarters in Harrisburg with the (freaking sweet) plate for the car. More updates later, of course!



Arrived home from the early morning roadtrip and found that the main fuel pump had arrived. Thanks BJ (great seller!).

In-tank pump is installed (left it out to let the epoxy vent), and the fuel lines back there are hooked up. I also took another look in the engine bay, and there's plenty of room for the main pump so I'm starting to build a little mounting strip for it. The factory fuel line can be cut and reused for it.

I also just installed the coolant temp sensor and the rest of the hose clamps on the system. It's now ready to be filled so I can try to spot any huge leaks before pressurising it (by hopefully running the engine) later. I'm making a shopping list as I go, so far it has gasoline and distilled water on it..

I need to sort out a fused 20 amp switched power feed for the pump, and another relay for a couple of other things (injectors etc). I was hunting around for a nice bosch relay with holder, but instead found the factory relay with fused strip from the Polo, which was used for the glow plugs and radiator. Its mounting points are right there on the firewall, so i'm going to use this for everything instead. I'll need to wire it in, and make a little match wire to switch it, but otherwise it should be a nice factory solution.

I'm studying the wiring diagram and making some pasta for lunch right now.

I'll post this here in case anyone who is a electrical engineer or who is 12 years old and taking basic science in school is reading it.. I do feel dumberer for not being able to remember how to read the schematic..

Are Pins 1 & 3 the grounds?

Pin 2 is coming from a ignition switched +12v, which I think it allowing the relay to then be activated by the switched grounds that are controlled by the ECU. I think this is what is confusing me, so just want to double check.



In other words, to make it a 'dumb' relay (i.e. no ECU control), I can connect pins 1&3 to permanent ground, pin 2 to ignition switched +12v (low amp), then that will give me outputs marked RV and GK as equally amperaged +12v outlets (high amp). And of course pin 30 gets direct +12v from the battery

edit: Just realised that it looks like:

Pin 3 is the ground that switches RV
Pin 1 is the ground that switches GK
Pin 2 is the +12v that is the master switch for the whole relay.

So, not that it matters for my purpose, but if 2 = 0, then 1&3 cannot control it; but if 2 = +12v, then 1 or 3 can be on/off independently.

I'm going to work for as long as I can. My garage is still full so the Polo's still outside, but I've got lucky with the weather tonight. I'll post updates when I come in to eat / drink / check diagrams / sleep. I figure why wait until the last night to do that all night thing.. might as well move it forwards any either have those final nights in reserve, or get to take it easy then.

The photos are going to be unedited basically, so tough.

Light setup:



1 vacuum leak solved - booster line run, re-bent with a heatgun.



Found the N75 connector (white/yellow wire):



Vacuum line for the fuel pressure regulator; another vacuum leak from the manifold solved.



Went to install the cabin filter so that i could install that side of the raintray cover, and found this little stowaway. He's pure Pennsylvania though, not a Greenland import:



9/22/10

So, back inside for a drink and a update. Maybe this routine will be the key to not falling asleep. I did manage to just forget what a diverter valve was though, which doesn't bode well

The morning TCL crew are going to wake up to a butt load of photos:

Empty hole in the golf/jetta intake boot.. what the hell goes here, and why can't I remember:



Run over to my 2003 GTI and check.. ahh, it's the damn diverter valve. I must be sleepy, or way overloaded on this car..



Found my spare G/J intake boot.. but it's gone already:



Nice! It's still on the Passat intake boot:



Working on the other tubes in that area, the N75 valve line doesn't reach due to extending the upper tube (temporarily with aluminum tube and connector until I can get it tig'd):



Recycled another Passat part, to make it a hard line for most of the length now. My neighbour just came home from working second shift so I was too busy chatting to him to remember a photo of it installed, but it's in and looks decent and takes a lot of pressure off of the intake tube actually.



See you in another hour or so.

I've almost finished running the positive supply wire for the fuel pump. As mentioned in the thread before, the diesel didn't have a in-tank pump so when I installed a gas pump it went from a two prong connector to a three prong. I'm installing the extra wire in the same harness as the rest of the fuel level sender stuff, so it means stripping out the interior plastics, folding back the carpet, feeding it through all the holes etc and then clipping it in, and retaping it all:



The interiors pretty torn up right now..



But the fuel gauge works. Good news on two accounts - 1) the cluster gauge works and 2) the cluster works with the fuel level sender from a mk2 Jetta. It is currently using only the ground from the gauge panel, so i'm going to install a second ground wire for the extra draw that the fuel pump will add.



There are three empty relay spots on the panel. They appear to have all terminals, but I do not know what's going on behind them. Any ideas (I'm looking at you 2526..)?







Testing the old glowplug/radiator fan relay. The small output works, the large is not testing okay, so scratch that idea:



I think my ipod got sleepy. It did this for about 30 seconds, then started playing from the beginning again.



Alright, back at it. I'm getting sleepy but I want to at least get the fuel pump wiring at the pump finished, the interior back together (except seats) and see whatelse I can get done.

I just got a message that I'm allowed to officially announce that the Polo is going to be on display all weekend at the VWVortex booth, right in the center of the show. It will be there on both Saturday and Sunday. It's probably going to be the odd duck with its dents and scratches, parked next to the ususally excellent fare that the VWVortex and VWoA bring .

This is of course assuming that it makes it. With about 48 hours to go, it still has not moved. Here's the to-do list:
Finish engine wiring.
Finish fuel pump wiring.
Finish boost hoses.
Install downpipe and exhaust center section - hope it fits.
Install radiator fan, and wire.
Install seats.
Install rear suspension.
Put wheels on.
Test drive.
wash.

Fuel pump wiring. I finally found a relay holder. It clips on top of the fuse panel, 30 & 85 get switched fused live (going to try and find the output from Fuse 18 (fuel pump/engine heater and use that.. any spot it on the diagrams?), the output goes to the two fuel pumps, and the relay will be tripped by the switched ground from the ECU (so we all don't have to worry about the fuel pumps running on in the event of a accident, hooray).



Removing the old exhaust, the O2 sensors from the 'new' exhaust (thanks Ben) and some tools that everyone must own, no excuses. Even if you don't have a O2 sensor, the socket works on a bunch of other random things, such as being perfect for the strut top bearings on a VW Polo.







Fuel pumps are correctly and fully wired. (not tested, but otherwise done).

Downpipe is bolted on, delivery of washers didn't show up, so I went to Home Depot. The downpipe is a VERY close fit to the firewall, maybe less than 10mm, but it doesn't appear to hit so far, and when the rest of the exhaust (err.. what exhaust?) is fitted, it should pull the flex joint down a little.

There is a massive thunderstorm rolling through, so that's stopped work for now. Hopefully is misses us and doesn't soak everything.

Laura picked up the final intercooler elbow on the way home from work, so I can work on tightening up a few items on that in the basement while the weather hopefully improves. A couple of the temporary aluminum pipes don't have beads on the end (is that the right word? I'm getting tired..), so i'm going to weld up a pair of vice grips and add some myself.