Completed mechanical and electric work.
The list below covers the Mechanical and electrical items we have fitted or modified on the van.
For the list of all the mechanical and electrical work planned, in progress, or completed, see Permanently fitted or available complete list, 1.
The headings in “Blue” below provide a link to related items from all categories & include the items we intend to make, modify or buy.
The items in “black” are completed, (some with links to more information).
Any items in “mauve” need to be replaced, or upgraded or we need more ASAP.
The items in “Green” are almost completed.
The items in “italics (any colour)” are also listed in another category, (see links).
I will add links to reviews and more information ASAP.
Engine.
EE20 Subaru engine, (removed, see follies).
1900 TDI AHU engine, (replacement for the Subaru).
Replace the accelerator cable with an electronic accelerator pedal, (see ECU ).
High torque, gear reduction starter motor.
Engine control.
ECU, for EE20 Subaru engine, (now removed, see follies).
ECU, for 1900 TDI AHU engine.
New ECU junction box.
Electronic accelerator pedal.
Fuel system.
Stainless steel straps fitted on the original fuel tank.
Oil system.
Items to come.
Charge cooler system.
Charge cooler.
Integrated main, charge cooler & air-con rad, (see engine cooling).
Lower or move the charge cooler, (may not be required now).
Reroute charge cooler pipework, (to allow for storage/battery compartments).
Engine air supply.
Items to come
Engine cooling.
Lower water expansion tank, (may not be required now).
Reroute radiator pipework, (to allow for storage/battery compartments).
Integrated main, charge cooler & air-con rad.
Engine bay cooling
Items to come
Exhaust system.
Stainless steel exhaust system for Subaru, (removed).
Subaru turbo, (removed).
Stainless steel exhaust system for 1900 TDI AHU engine.~
Turbo for 1900 TDI AHU engine.
Drive train.
Subaru dual-mass clutch & thrust bearing, ( now removed, see follies).
1900 TDI, dual-mass clutch.
Non-return valves on clutch servo bleed point.
Upgrade gear selector lever, (temporary until cable gear linkage is installed).
Upgraded gearbox.
Cable gear linkage, (should also allow for a second full-size underslung box).
Decoupler.
Viscous coupling serviced.
Front & rear ATB (Automatic Torque Biasing) differentials.
CV boot protector.
Suspension & Wheels.
Bushes replaced with poly bushes where possible.
Go-westy progressive springs, (front fitted).
Adjustable front ride height.
Adjustable shocks front & back.
16″ trailing arms.
Wheel spacers, (front & back).
16″ rims with A/T 235-70-R16 tyres.
All-terrain tyres.
Braking system.
Up-rated brake servo.
Uprated front disk brakes.
Uprated back brakes, (disks fitted).
Non-return valves on brake bleed points.
Rerouted back brake pipes, (over trailing arms).
Reroute hand brake cable, (to allow for a second underslung storage box).
Steering.
Factory-fitted hydraulic power stirring.
Engine-driven power steering pump, (on 1900 TDI AHU engine),
Electric power steering pump, (removed with Subaru engine).
Electrics.
Batteries moved to the underslung box under the floor.
The new dashboard, (overview, see Dashboard).
Fusses replaced with circuit breakers, (some left to change).
Upgrade wiring harness.
Larger starter battery.
Twin leisure batteries, (fitted not wired in yet).
Lighting.
LED indicator lights.
LED approach lights in front indicator housings.
LED DRLs in front fog light housings, (under consideration, if legal).
LED light bar on the front of the roof rack.
LED high-level hazard lights at the front.
LED twin front fog lights.
LED side lights
Fully LED rear light clusters.
LED side lights / DRLs, (linked with the front DRLs).
LED indicator lights.
LED twin rear fog lights.
LED brake lights.
LED reversing lights.
LED high-level hazard lights at the back.
LED floodlights on each side at the rear, (possibly linked with reversing lights).
LED internal van lighting.
Front overhead courtesy lights.
Map light.
Dashboard.
The old dashboard, (and the planned upgrades).
The new dashboard, (current progress).
Fabricating the new dashboard.
Switch layout.
Power outlets.
Communication & Navigation Systems, (CB, Wi-Fi, phone, & radio).
Heater & ventilation control system.
Vacuum switch system, (diflock controls).
Air-con and Arial connection panel.
Upgraded dash clocks, (calibration and wiring to complete).
Stirring column cowl.
Overhead switch panel, (see switch connections for more info).
Heating, Cooling & Ventilation.
Remove the old air con unit.
Reposition ventilation & heating controls, (see dashboard modifications).
PWM fan control, (see dashboard modifications).
Move air-con controls to the dashboard, (see dashboard modifications).
Driving aids.
Reversing camera for the dashboard head unit, (needs wiring fixed).
LCD display driving mirror and rear camera, (fitted at a high level).
Electric heated rear window.
Fix electric window winders, (intermittent problem needs investigation).
Safety equipment.
Fire extinguisher, (old, needs replacing, must be available quickly).
CO2 smoke detectors, (need replacing).
Automatic fire suppressant system in the engine bay, (needs installing, ASAP).
High-level rear brake lights, (see lighting).
Communication & Navigation systems.
Sat-Nav head unit, (see dashboard).
Compass and clino, (see dashboard).
CB aerial connection, (see dashboard).
Traveling comforts.
3000W/ 6000W Pure Sine Wave Power Inverter, (see wild camping).
Of road additions.
All-terrain tyres, (see suspension & wheels).
Reinforce engine cradle.
Modified front bash plate, (with storage facility).
Modified sump guard.
Uprated front winching attachment points.
Under-slung sand ladder racks on the roof rack, (see recovery kit for sand ladders).
LED light bar on the front of the roof rack, (see lighting).
LED floodlights on each side at the rear, (see lighting).
Wild camping.
Twin leisure batteries, (fitted not wired in yet, see electrics).
3000W/ 6000W Pure Sine Wave Power Inverter.
Twin 60W solar panels on the front of the rack, (see wild camping).
Long-term protection.
Automatic fire suppressant system in the engine bay, (needs installing, ASAP).