Overdue update...newfound urgency to get the car road-tested before salt. Putting the electric pump aside for now. There's probably 5 months of garage confinement during the winter where I can pick that back up. I focused on reassembling the front end with plans to drive the car daily for a few weeks.
Spent a lot of time on the climate control. Box disassembled, cleaned, reassembled with new foam and core. A little bit of Simple Green thrown in the high-temp dishwasher cycle cleaned the plastic nicely. Exact-replacement heater core was Nissens 73940.
Turbo plumbing isn't solved yet, and the intercooler setup is a mystery, but for road testing this simple setup works.
MAF/breather/bypass plumbing is also not solved. The OEM 3B hose is too large, as the 20v turbo sits so far forward. Running without bypass for now, and the breather is open to atmosphere. Grabbed some random Saab piping from the Pick-n-Pull that's correctly shaped, more or less...
In typical 20v fashion, the once orderly engine bay is again a complete mess. There are a few sections of the 3B harness that need to be lengthened or shortened to fit the 20v. Crimps for now, soldering and clean-up over the winter.
Here's what the engine bay looks like now.
As for driving it, I have put on 20 miles around the neighborhood so far. And, it's really exciting! The 3B Motronic controls the motor well, no codes observed. The wastegate is not connected to the N75 yet, so boost pressure is only spring pressure. Quick car though! It was 80F last week, started right up. 30F last night, also started right up. With no bypass valve the MAF gets confused...nowhere for the air to go, so it blows reverse past the MAF and OUT of the intake if the turbo was spooled. Need to fix this. Nice whooshing turbo sounds though.
Great results at this point. Main thing I've got to work on now is some custom plumbing for the pre-turbo and MAF components.
