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How to TDI a Karmann Gipsy by Tudor Morgan |
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The Pictorial Work Sequence - Page 2 |
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Click on the thumbnails for a bigger image
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| 37. Accurately shaping ignition switch console | 38. A bit of wiring to do in the front |
39. A rev counter, turbo boost, and oil temp gauges |
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| 40. TDI isolator ring and made up key with chip | 41. Nicely finished altered console to take isolator ring |
42. T3 connector box, cut holes, protected to stop chaffing |
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43. Alloy welding for adaptor and intercooler fixings |
44. HA-Projekt intercooler and fittings |
45. Bending the special intercooler fixing bracket |
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46. Correct shape obtained |
47. Completed banana bracket |
48. Intercooler stainless fixing studs |
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49. Charged air, angled pipes, from Passat |
50. Coolant and charged air pipes |
51. Position of intercooler |
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| 52. Air vent T piece | 53. Air bleed bottle from Fiat clutch |
54. Position of air bleed bottle |
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| 55. Air bleed T piece, intercooler rad | 56. Topping up intercooler bleed bottle |
57. Example of HA-Projekt positioning of inter, oil cooler rad |
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| 58. Removing gear box | 59. HA-Projekt 22mm TDI shaft |
60. Bell housing off |
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| 61. Old and new shafts | 62. Special tool to undo diff bearing adjusters |
63. Adjuster removed |
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| 64. Mark position before removal, enables exact replacement | 65. Loosen off flange before removing circlip |
66. Easy to remove circlip |
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| 67. Gearbox ready for fitting with stainless back plate | 68. Easier to fit engine first then gearbox |
69. Throttle potentiometer arm mod |
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| 70. Sizing up potentiometer position using cardboard template | 71. Accurately cutting template |
72. Further sizing to get it right |
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