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Wiring Harness Questions and Mailing Instructions

 

 

Planning on sending us your harness or ECU? Take a quick glance over this page, making sure that you have everything sent to us at the same time, to help expedite your order.

Please fill out our Mail In Request Form.   Mail the package with the form inside, to the address listed on the form..

What type of harness do I have?

Most pre 1999.5 engines

  • Engine Control Unit (ECU). (Most mk3)
  • mk3ecu
  • Harness from Engine to ECU.
  • mk3harness
  • Accelerator Pedal connector with at least 10 cm of wire. (TDI ONLY)
  • mk3mk4 pedal (Left: Mk3; Right Mk4)
  • If you want to convert to a mk4 style pedal for your mk3 TDI just let us know, its easier to get replacement pedals, and we have a bolt in bracket from your MK4 to MK1 accelerator pedal.
  • mk1DBW1

 

Engine Control Unit Engine harness Accelerator pedal plug (MK3 style)

mk3tdiplug

 

If you are missing some of these items, no problem! We usually can supply them to you at a reasonable cost.

 

Most post 1999.5 engines

  • Engine Control Unit (ECU)
  • mk4 ecu
  • Large connector ECU Harness, has 4 or 5 colored plugs to rain tray plenum, (or under the beetle dash cap)
  • mk4body harness mk4bodyharness2
  • Small connector ECU Harness has the majority of the connections to the engine.
  • mk4engineharness
  • Glow Plug Relay (TDI Swaps only) with it’s base and at least 6″ of wire. (pictured is an 02-up, pre-02 is under the dash)
  • 02up glow plug relay
  • Accelerator Pedal connector with at least 6″ of wire. (pictured on the left is the mk3 connector, Right is the mk4 connector)
  • mk3 mk4 pedal harness

If you are missing some of these items, no problem! We usually can supply them to you at a reasonable cost.

Other parts you will need You will need these parts to complete your installation. However, we don’t need them to work on your wire harness, so please don’t send these parts to us, unless you just enjoy paying for shipping costs..

  • Accelerator pedal (mk4 on the right, mk3 on the left)
  • mk3mk4 pedal
  • Turbo control valve (N75) (gas 1.8t on left, TDI on right)
  • gasn75 tdin75
  • EGR control valve (N18) *
  • tdi egr tdi egr asv
  • Intake Manifold Flap Valve  *
  • tdi asv
  • Manifold Absolute Pressure (MAP) sensor
  • tdimap
  • Intercooler
  • tdiintercooler
  • Mass Air Flow (MAF) sensor *
  • tdimaf

 

 

* To make your installation process simpler for you, we can delete these items from your harness. However check local laws before doing so as you may not be able to pass certain emission tests.

 

How to remove your harness – 

 

 

How to correctly send us your wire harness

 

The fastest and cheapest way to send a wire harness is with the Post Office. If you live outside of the USA, you will more than likely have to fill out a customs declaration form, this process is quite simple! An important note: you are not selling us these parts, rather you are sending them for repair and to be returned! So when filling out the form simply write: Automotive wire harness sent for repair, no commercial value. In the value field, put one dollar. In the insurance field, insure it for whatever amount you feel comfortable with.

To help us plan our time around the arrival of your harness please forward the tracking information to our email.

If you insist on sending with a courier such as UPS / Fed­Ex you will be 100% responsible for all fees incurred.

What happens when the harness gets here?

Before starting the harness we will email you to ensure both parties are on the same page. If there are any missing parts or concerns that we may have with the harness, this will be discussed before any work commences. The harness will be sent back and labeled as a “repaired automotive wire harness.” Again, if you have any questions or concerns, please let us know!

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Grumman

 

 

It is for no better explanation, a sales pitch.  Grumman Olsen was trying to get the USPS bid for manufacturing the postal carrier vehicle..   between 1983-1985 they produced 500 kubvans in 2 different models (70 and 100) with a couple different options.  High or low Floor (cargo area) dual or single rear doors, automatic or manual shift and right or left drive.

Most were automatics, almost all were diesel, I have heard that a few may have been ordered with the CIS gas engine.

Mine is a 100, with a manual trans (1/23 supposedly) single rear door, high floor.  I looked for almost 4 years for one, and in January of 14 I found one in Ohio.  After alittle time talking with the owner we struck a deal and it was on its way to me.

kubvan 002kubvan 001

I drove it around the neighborhood for a while trying to find out what worked and what didnt .. all the while thinking of paint schemes and engine options.

With a local show coming up in April I wanted to have it there and the simplest way with our work load and project list piling up was to work on the exterior first and then pull the original drive train out after the local show.

kubvan 003 A little bit of OD Green and Raptor tintable bedliner produced the finish I was looking for, and I can scrub it with a brush if it gets dirty and not worry about scratching the paint.

 

kubvan 004

 

 

 

We added a bullbar for safety… you know how rough the city streets of Chattanooga can be..

 

 

Final touches were a set of wheels that I use on every car, but never sell with a car. My Ronal Turbos. They were not what I had in mind but with the fenders and the offsets I was going to have to work with, these fit the bill.  We also added a roof rack and a functioning ladder to access the rack.

kubvan 011

It made it to the local show and we had a great time.

 

 

 

kubvan 012

 

 

From the local show to SOWO14 was only 30 days, so we were still under a bit of a time crunch to get the new driveline inplace to make it to Helen GA.

kubvan 008

The rebuilt ALH motor from an 03 Beetle TDI was painted CAT yellow before installing the accessories or transmission parts.

 

kubvan 009

 

 

 

With all the accessories on we were ready to try out the new MK1 02A mounts and mk1 02J shift linkages we had made.  Of course they fit like a glove and work even better.  The Eurovan Cable Clutch conversion kit was also used on this chassis to simplify the mk1 02a/j conversion.  Scirocco 16v axles were used with the standard mk1 hubs.

 

IMG_4328

IMG_4327

 

 

 

 

 

 

 

With those installed we were onto wiring, inter-cooler plumbing,and maintenance parts on the spindles and hubs.

kubvan 020After a snafu with the VNT 17 turbo we put on it having locked up vanes, we got a new one in a hurry and installed it, made about 20 miles of test drives and set off for SOWO14.  We received our new decals as we were pulling out of the shop

kubvan 015

 

We made the trip with out any issues,  had a great time cruising around town seeing old friends.  They had a mobile dyno setup so we crawled on top of it to see how we did. kubvan 017kubvan 016kubvan 023 The video is not that great as we were having issues finding a tach signal to work off of.  After that was sorted we got 3 good pulls and managed 325ft/lbs of torque and 146hp.

 

Overall I am very happy with the performance and drive-ability of this vehicle,  I have put a total of 1000 miles on the swap as of 6/4/14 and will continue to update as we add new parts.

kubvan 022kubvan 014