LEAKOIL Forum

Nice job - look at all those clean wires and shiny connectors!

Had the truck on the farm last week for Third Thursday. Some minor things need to be addressed, but all saftey lights, flashers seem to be in order.

I'm pretty impressed Marla was able to complete this by herself, very few owners would be able to install a harness and make things work correctly.

Great job!

Thanks Bruce! Now I’m considering doing Gunther. That will be a project for next spring though.

Looks great Marla! Did the Wolfsburg West harness come with all the connectors?

I did some detail work on Marla's single cab I'll document here:

1. Install battery, redrill holddown clamp to accommodate wider battery. Remove and clean ground strap at connection to body. Remove clamp bolt- ends of clamp are touching, use cutoff wheel to remove material to make clamp function correctly. Clean bolt and redrill bolt hole in clamp. Chase threads in body with tap, install new bolt and flat washer. Check ground strap at trans, appears clean and tight. Check voltage drop while cranking between battery negative and engine case, within spec at .25v.
2. Indicator Light Issues- both oil light and generator light inop. Test circuits to find them complete. Remove light bulbs to find them LED normal polarity, circuit is reverse polarity and a single polarity LED bulb will not function. (VW wires this circuit reverse- bulb base is positive, bulb tip is negative) Install new regular bulbs and warning lights work correctly. Check charging voltage, 14.5vdc/2000rpm is normal.
3. Turn signal indicator works with key off, but not with key on. Load test power and ground circuits in dash to 9 amps-OK. Check 4way relay to find it marked as 6V, install standard 12v Bosch 5 pin relay in its place. Test flasher unit to find it intermittent, replace with ’68-70 Beetle flasher relay and install ground wire on flasher. Indicator light on dash needs ground input rather than power input to work correctly, remove black power wire at top center of speedo and tape off. Install ground wire at this terminal to complete circuit, indicator now works correctly with both turn signals and 4ways. Install Phillips head screws on speedo head and most dash switches as they are much easier to remove and install. Mount both relays to dash. Correct power feed causing slow drain to battery.
4. Test wiring to wiper motor- good. Wiper motor is faulty.
5. Test fuel gauge circuit- good. Fuel sender resistance reading is infinity meaning sender is faulty. Fuel gauge sweeps full range when wire is grounded, meaning gauge circuit is good. Fuel gauge is marked 6v, meaning a 162 ohm resistor on the power input will be needed to make the gauge work accurately (as accurately as they can be). Correct gauge ground problem by grinding the rear of dash where the gauge mounts.
6. Dome light inop- remove dome light and bead blast housing to clean terminals, lube switch and install with new screws and LED bulbs. (bulbs are polarity sensitive and won’t work if installed backwards). Test dome light draw to be .17ADC.
7. Install power port under dash for powering accessories powered from fuse 2.
8. Install red fuses at location 1 and 2 in fuse block. Remove tiewraps securing fuseblack and use modified fender washer to secure fuseblock to dash.
9. Road test-OK. Turn signal lever does not cancel correctly. Brake pedal feels soft like adjustment is needed. Lube driver’s door gaskets with silicone to make door operate easier- needs hinges adjusted and weatherstrip installed.

I don't know why some of the pics are posting inverted, so live with it.

Awesome! Cant wait to see it!