So after years of operation, it comes as no surprise that several of the wires have deteriorated. In many of the extreme areas in the engine bay, the wires have baked and the insulation has crumbled off exposing vulnerable copper. This leads to oxidation of the copper, higher resistance, and possible shorting of the electrical circuits. All of these lead to malfunction and potential damage.
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| The pin extractor tool allows safe and easy removal of most pins from their connectors |
I found wires to sensors, switches, and fuel injectors frayed and exposed. These were going to need to be rectified if all sources of the intermittent idle are to be eliminated. Even the wires to the Idle Stabilizer valve was cracked and broken.
To remedy this, I cut out any damaged or compromised wires. Then carefully replaced the cut out sections with fresh copper wire. In some cases this required the removal of the connector and soldering fresh wire directly to the connector pins. To extract the pins requires a special tool. What I use is the Lisle 56500 Pin Extractor tool. It's available from several places but I purchased this one from Amazon. It is under $10. I have other optional tools but the Lisle is the most important. Once extracted, I can replace with fresh wire, then solder the new wire to the pin, then reinsert the pins back into their proper position in the connector. Pay special attention to where you pulled the wire from as its very easy to disorient the configuration which may cause you more problems than when you started.
I also used heat shrink wrap tubing to add an extra layer of protection to exposed wires. this is especially true for those wires in extreme heat zones in the engine bay.
Lastly, I treat each of the contact with an enhancement solution known as Stabilant 22. This stuff is interesting in that it is used in numerous industries. Some measurements have found a 90% increase in contact electrical efficiency after application of this solution. Although it enhances the electrical conductivity of the contacts, it does NOT cross connect adjacent connectors. I don't know how it does it but it works.
This will prevent any further corrosion of existing connector surfaces, enhance those connections which are marginal, and further ensure I 've eliminated any wiring issues. Stabilant 22 is expensive. It costs roughly $45 for the small bottle. The bottle is mixed with 90% Isopropyl Alcohol and is applied with a brush or with a syringe. This is used in electronics, audio, electrical and numerous other industries.
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| Contact enhancer fluid applied to all electrical connectors |
With the wiring refreshed, I've increased my confidence that I'm eliminating many potential problems in the future. Old VWs are notorious for electrical issues and I aim to minimize any such complications in the Endless Corrado Project.
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| Finished wiring to the Idle Stabilizer valve |
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