Hinge Covers

Installed Type 3 hinge covers and modified with heat gun. More at vwbughead.com.

Vacuum Hoses

Installed new vacuum hoses all around. See vwbughead.com for layout and parts list.

CHT Ballast

Adjusted warmed up CHT resistance to about 225 ohms by adding 150 ohms jumper between CHT sender and harness lead. 225 ohms is lowest value that the ECU can adjust fuel mixture. My sender was giving readings of 75 ohms without the added ballast resistor when the engine was warmed up resulting in less than optimal temperature responsiveness.

Tests & Valve Adjustment

Tested Manifold Pressure Sensor (MPS) with Actron Vacuum Pump to 26 in Hg for 15 minutes without any leakage. Measured primary coil resistance of MPS (outer two leads) and found 98 ohms (spec 90 ohms). Measured secondary coil resistance of MPS (inner two leads) and found 382 ohms (spec 350 ohms). Thankfully, MPS is in good shape! However, spare from parts car has vacuum leak so I'm on the look out for a good spare.

With AAR fixed, set Idle Speed Limiter gap and tested vacuum side with Actron to 26 in Hg for 10 minutes without leakage.

Cold start valve has been bypassed with fuel by previous owner. Measured cold start valve coil resistance and found 4.8 ohms (spec 4.2 ohms). I will check for leaks when injectors are tested.

Valves adjusted. No "white" spot for #2/4 TDC, so created right angle cardboard template to find it and mark it with white-out. Location verified using spare fan and counting blades. New valve cover gaskets installed after scraping/cleaning old ones glued onto cover:(

Aux. Air Reg. (AAR) Repair

Fast idle fixed by repairing the AAR. Fun project. Details here.

D-Jet Ignition Upgrade

Upgraded ignition system with Pertronixs electronic ignition for the Bosch vacuum advance distributor, Bosch Blue coil, and Bosch W7DTC tri-electrode spark plugs. More info here.

Air Filter Replacement

The car did not come with an air cleaner filter. Efforts at finding a replacement here. SureFit Travis of shoptalkforums.com will send an extra OEM replacement filter from Prince George, BC - much appreciated!