Since last entry, time has been spent thinning the wiring harness. I purchased a copy of "VCDS" and an interface which is used for coding VW modules. With that I was able to tell most of the modules to not worry about the Auto trans, Electric power steering, tire pressure monitoring, Airbags and bunches of other non essential items. Haven't had time to try and recode the ECU, which is a bit trickier, but with the changes so far we are able to still start the motor without the items previously mentioned attached. With that completed we opened up a lot of the wire harness and started removing unneeded wires. I know wiring is not what some people enjoy but for me it feels like a mix between a puzzle and a treasure hunt. Working on the wiring has been a relaxing activity for the both of us on many evenings.
If memory serves, the past 2 Saturdays were spent making test fit alternator brackets to check clearances. Holding the alternator in position to check clearances and make templates was very difficult so went with the plan to just make something quickly out of scraps and then measure how far off it was to make another better one. Was a good strategy as the first one made didn't work out. no surprise. Originally I mounted the alternator as close to the motor as possible. My first thought was to skip using a tensioner but just swing the alternator out to tension the belt. I'll include a picture of that original setup. But to tension the belt I'd have to slide the alternator up more than pivot it. Decided a tensioner or at the very least an idler pulley would be best. There was no space for the original Passat tensioner and the alternator at the same time. Thought of making my own thing but it looked like the tensioner from the 3.2L 24V VR6 would fit my engine and that tensioner has most of it's structure forward and right of the alternator leaving room for the alternator. Alternator bracket was quickly revised to test placement. In the picture of V2 the tensioner is locked in the nearly full loose position. It will swing to the right (left in the picture) to apply tension to the belt.
Now to see if I can get a belt the right size and make a permanent bracket.
