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2000 EVW alternator swap and brush change: 150A to 90A
This alternator service/swap 150a to 90a was done as and experiment since I decided I didn¡¯t needed the big bad 150a for my needs and could possibly achieve some very small MPG gains w a 90a. Now 3 years later I can say there¡¯s no noticeable difference... ?  150a alternator on the top, 90a on the bottom?
 Brushes still functional with normal wear but down to the last 25%. Bentley wear limit is 0.10mm iirc so always to go still technically but as they say, ¡°an ounce of prevention is worth a pound of cure¡¡±
 New brush pack on L
 New brushes installed?
  Part number for reference?
?Post is copied from my recent blogpost:? -- Justin 2000 EVW 1.9TDI Syncro 5-spd 501k mi :-) |
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Re: New topic = new thread please
On Mon, Jun 3, 2024 at 01:10 AM, John Kolak wrote:
Where is this forum page? I don't see anything like that at groups.io, and I only have the email list subscription.The group Home page is at /g/eurovanupdate.? If you're signed in, you'll see a menu on the left side of the page that includes New Topic as about the 4th item down.? If you're not seeing that, then you're not logged in.? There's a Members Manual that includes instructions for logging in, even if you've never done so.? Note that if you're using the Groups.io app, things will look different on the small screen, but it's all still there. -- Duane 05HD Rialta 227K Miles |
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New topic = new thread please
Just as a general rule of thumb / good forum etiquette: ?when posting a completely new topic please start your own thread! It¡¯s simple, just click on the ¡°New Topic¡¯ button on the L menu bar (4th one down). Thread hijacking is becoming very common here and it detracts from the functionality of the well-oiled machine / searchable repository of information this forum could be. We will all benefit from this simple action.
-- Justin 2000 EVW 1.9TDI Syncro 5-spd 501k mi :-) |
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Re: can I drive van with door harness removed
The OEM wire bundle is thick and doesn¡¯t flex, so it bends into a Z shape and the wires begin to break at the sharp bends. I only replaced the section removed for repair and did not add any length. You will find that all the wires will not need repair. After repair I wrapped the bundle with the same type OEM tape, sticky fabric black tape. Exercising the door with wires in place before attaching the door panel will show you the movement path, it will be minimal and seems to be acceptable. When splicing in sections try to use like gauge. If you do one at a time you will reduce your chance of a mistake, I used a piece of wood to separate out the wire being worked on from the bundle, made it easier to do soldering, also did not twist wires but just a half inch side by side solder joint making it easy to slide over the shrink wrap. Good luck!
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Re: can I drive van with door harness removed
Thanks for that info Bill. I haven't pulled the panel yet to see where the clamp is and where the wires are broken but plan to add about 6" of wire. Do you think that is too much or too little? If you don't clamp on the door side does the wire just hang or float inside the door? Thanks for the info. Spencer On Thu, May 30, 2024 at 8:40?AM Bill Wiggins via <billwiggins=[email protected]> wrote: I repaired this harness on my 2003, I found a design flaw, the harness has nowhere to move when door is moved, it¡¯s clamped at both ends, inside door and in cabin. Since it needs to be clamped in the cabin, being behind fuse panel, I recommend not clamping it in the door. When you inspect the harness you will see what I found, where all the wires are breaking inside the rubber tube. I repaired by soldering in wire sections using heat shrink over the connection. It¡¯s been holding for a few years now. |
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Re: front door pull handle cover removal 02mv
Thanks all!? I got some from ebay someplace in between those two prices.? It fit *ok* but I'm going to try to adjust this weekend.? The hardest part was pulling the pin from the handle lever to get the new rubber gasket in place, and then doing the angle-tilt dance to actually put the handle back in.? I made the mistake of not paying attention to the angle when I removed it, but youtube had the answer ;)? () Appreciate all the help!? next up is trying to deal with the black vinyl on the B and C pillars that is peeling and cracking.? I bought a kit a year ago with precut pieces, but have been intimidated by the removal and trying to tuck the ends in without removing the windows. MJ On Thu, May 30, 2024 at 6:51?AM Bob H via <bob=[email protected]> wrote: Maybe try Ali Express...? DZ Auto Parts Store.?? |
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Re: can I drive van with door harness removed
I repaired this harness on my 2003, I found a design flaw, the harness has nowhere to move when door is moved, it¡¯s clamped at both ends, inside door and in cabin. Since it needs to be clamped in the cabin, being behind fuse panel, I recommend not clamping it in the door. When you inspect the harness you will see what I found, where all the wires are breaking inside the rubber tube. I repaired by soldering in wire sections using heat shrink over the connection. It¡¯s been holding for a few years now.
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Re: Stereo - how to wire
¿ªÔÆÌåÓýHaving just wired up a new stereo, some of this is fresh in my mind. ?A few points:1. most modern radios have two power inputs (colored Red and Yellow). ?Red is usually supposed to be switched, and Yellow is "always on". ? I assumed that the amperage draw would mostly be on the Red wire, with the Yellow only being used for keeping the memory alive. ?However, with my newest radio install, I noticed the yellow wire is thicker than the red, which could suggest the opposite. ? In my installation, I have wired Yellow to the starting battery and Red to the House battery, but this may not be doing what I assume. 2. As you've discovered, simply having a switch in the circuit doesn't do what you want, as it ends up connecting the two batteries. ? You need a relay. ? /g/eurovanupdate/message/161861?is an old post that shows how, but I'll include it here again. (Note: as Duane points out, not sure if your 93 has this Accessory circuit or not?) Here's how I wired in a custom toggle switch and relay which switches the radio into three states: - Always On (house battery) - On with Accessories (house battery) - Always Off Parts: * A 12V relay? * a 3 position switch (On, Off, On) * a fuse (likely 10A to 30A, depending on your radio) * some wire (the trigger wire can be small, but use 14 gauge or thicker wire for the red lines * wire connectors & heat shrink tubing or electrical tape 1. First, find the nearest source of house battery 12V+. ?If you go up behind the fusebox, it's relatively easy to push a wire through the firewall and connect it to the relay in the engine compartment. 2. Add a fuse 3. Wire it up as shown in this diagram. ?? Note: switches and relays may have different?wiring diagrams, so double check your work.
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Re: Stereo - how to wire
On Tue, May 28, 2024 at 08:01 PM, Droppin bombs wrote:
Prefer the ignition key position to still turn on radioI think you have a 93EV, so that's what I'm basing my response on.? On the later models, and probably yours, turning the key on turns on the radio.? Turning the key back off leaves the radio on until the key is removed from the ignition.? If that's true, then you don't need any other wiring or the rocker switch to isolate as you want to.? Just make sure the amp/sub are powered by the house battery and that the battery cu tout relay under the seat is working. -- Duane 05HD Rialta 227K Miles |
Justin Soares
Duane
Bob H
Bill Wiggins
Spencer Allen