I’m confident in my ability to do a relatively decent job cleaning up the aluminum on the engine, as well as aspects of the 2020 AJ engine rebuild, but there was some more generalized items I was hesitant to start given the fact the wiring harness is 41 years old, and the contacts have had all that time to get oxidation on them, not to mention other things.
I posed some questions at The Samba forums and of course, others have done what I’m now attempting to do.
Other members have directed me to some threads that should be useful.
Now I generally know how to approach this, but my real concern is that whatever I do, I cannot risk negatively impacting the original harness, connections, sensor electronics, etc.
Some products to consider:
- 10% acetic acid solution
Some other info…
Soak a cloth in vinegar, then wipe it across the oxidation. Scrub with a soft-bristled brush, then wipe away the vinegar and lifted oxidation with a damp cloth. Don’t use abrasive materials like steel wool or sandpaper to scrub the surface of the aluminum.
This video shows a more “destructive” method. Not sure if I want to risk this level of abrasiveness.
This one uses a toothpaste of all things. But the result is nice.
Throttle Body Bushings/Seals
A very old thread (from 2009), but it indicates that it is identical to clutch pushrod seals on early Golfs.
Someone even mentions using a leather washer of all things.
An update 5 years ago indicated a company named Harwal has made something that can be used as an equivalent. It looks liked product 071505A is it. At least I think this is referring to the Beetle throttle body and not the But equivalent.
Note: O.D. of throttle valve shaft seat is 15.15mm. Shaft diameter is 7.93mm.
Now I have an extra throttle body coming from Bug City so it’ll be interested to see if there are solid seals still in that one. I could move those to the AJ engine, and then keep searching for new ones.