TDI Wonder 4.0

[mr.mindless]

Crap start this morning. Some fuel at the lines on the IP after cleaning all last night to leak check. Hopefully that’s all it is. A few other adjustments to try too before pulling things apart to double check accuracy of timing marks plus accurate setting thereof.

Bah. Glad it’s not salting season quite yet

[mr.mindless]

Adjusted glow time. Started decently.

I think it’s about as ready as it’ll get

[mr.mindless]

This leaked fuel the very first time I filled it, when I vented.

Sarah lost the top 1/8 tank way too fast and it left a puddle last night.

No obvious source. I removed the lines and the fuel sender. Fuel all over the top of the tank there. Gasket in good shape, sender and retaining nut in good shape. All plastic.

Hoping the r&r fixed it. May do a low pressure test once it’s below half a tank. Running great and starting reasonably otherwise.

[mr.mindless]

Door switch fixed. I think this one may get a new latch sometime. Have to put pressure on the plug to make good contact. Complex assembly to look for loose pins inside it. No stock on the shelf at the moment.

Nice to have remote lock work along with cabin lights and the key and light buzzers

[etk300ex]

So you disassembled and fixed the existing switch?

[mr.mindless]

Yup. I have micro switches in stock to replace.

It’s an impressive amount of labor to strip the door and not fuck anything up. I have it down to a science now after doing 3 doors, 5 times. Lol

[mr.mindless]

Fuel leak found and fixed. waiting for RTV to set before I re test and put the tank back up.

mouse nest between the body and the fuel tank, mouse chewed through one of two fuel vent lines that run from the top of the tank to the fuel filler neck. No way to get the tank all the way out without dropping the beam. Just enough clearance to work above the tank with shocks pulled and tire removed and tank tipped towards the rear. Patched the plastic line with 1/4" fuel injection line, brass nipples, and adhesive shrink tube to up-size the 1/4 barbs to the plastic line. coated the outside of the adhesive shrink with black RTV and hose clamps. It's a vent line, so no pressure, but I'll see if it deals OK with intermittent diesel contact every time the tank is filled full 🤞🏻

Otherwise I'll have to get a factory replacement line and cut the stainless steel keepers at the filler neck and at the tank.

[mr.mindless]

Bastard nicked the other line too. Video screenshot. Almost couldn’t see where it was coming from.

[mr.mindless]

Low coolant today. Topped off. No gross leak found. Monitoring… do have a rad in stock, it looks old and is likely going to be the issue.

[mr.mindless]

Hopefully, she makes it back home before the light comes on again

I wouldn’t bet on that

[etk300ex]

coolant?

[mr.mindless]

Yes coolant

It gave a lot light yesterday

[mr.mindless]

Have been adding coolant. Hope to get the rad changed this week. Uugh

Had to swap a battery today. I think that’s the battery it came with. The blem I grabbed for the allroad fit so that’s what it just got.

[mr.mindless]

Confirmed intital glance yesterday: not radiator.

Found bad routing on lower rad hose that had it almost worn through against another clamp, and when I shifted that I got a drip out of the thermostat housing at the block. No new o rings in stock. Ordered a thermostat kit; some extra o rings for stock; and a new lower hose.

[M4wdFab]

that sounds potentially less annoying  than changing a rad