it wasnt as bad as I thought it would be.. your directions were perfect-
from now on, this will be known as the "paul method":
take a 19mm socket, or anything bigger than the lower bushing, a long bolt that is smaller than the shaft of the alternator bolt, a washer or something bigger than the bushing so it presses against it, and a smaller nut that threads onto the small bolt.
hold the end of the bolt and turn the nut in, and it presses that lower bushing back into the mounting ear of the alternator:
one that one was flush with the ear, I ran the top one in slightly to make it easier to line up the alternator on the bracket, then the lower bolt of the alternator snuck right in without hitting the frame rail, making installing the alternator as easy as it could be.. removal is not exactly the reverse of installation, as you'll have to press that bushing back in to get the alternator back out again, so make damn sure you have everything else ready to go before you install it.
alternator installed:
new wiring, since the old exciter wire was an eye terminal instead of a plug (I just took a wire from the old '97 GTI wiring harness and pressed it out of its existing plug, then put it into the lower of the two terminals on the back of the alternator plug, the top remains unused):
hammer tuned frame rail to accommodate serp belt tensioner pulley, probably only necessary on an A1 install:
only hardware other than the stuff already on the 16v is a double sided stud with a 17mm head that goes in the top left mounting position for the water pump, and the crank pulley bolts from an ABA- the water pump pulley is the VR6 one, and when installing it, you have to put it on backwards from the way you think it should be- its pretty obvious that it will only line up one way.
everything installed, now I need to figure out what size belt to get:
remember when I said I wished I'd purchased a 90 degree npt to -10 fitting? now I really wish I had:
rough installed repainted valve cover and new intake to check clearances:
dug this old thing out of storage and cleaned it up, going to try and figure out what I need to do to un-looptune my power steering system... it did still have fluid in it, so that's a good sign... I need a new cap for it.
you'd think with all the fucking fittings I bought that I'd be able to put the new FPR adapter on, the fittings that come with the new one do not work with the original BBM one piece rail. I need to buy more shit to get that to work..
I removed the blue fuel lines, and I did cut the factory double flare end off the fuel line to check the compression fittings paul gave me, and they're going to work just fine. The adapters that summit sent me to convert from 1/4" NPT to -6an are wrong, they're somewhere between -6 and -8. The replacements are apparently in the mail right now.
still on the shopping list:
90 degree -10 fitting for the breather
whatever pipe thread the fuel rail is to -6 o-ring seal fitting
o-ring plug for the passenger side of the rail (the -6 plug I bought is totally the wrong thing)
1.5" or so flat stock to make the bracket for the catch can
oh well, made some progress tonight.. I've been awake about 21 hours now, so I'm going to go die.
anyone have a power steering pressure line for a scirocco, or know if an A2 one will work?
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