TDI engine timing belt replaced

Last night, I had my friend (and TDI-mechanic) Justin over to go over the TDI engine with me. I would have preferred to have done this a year ago when I bought the engine, but time money and smarts were all against me then. It turns out, it didn't much matter. Today's posting will serve partly as a postcard of what was done and partly as a checklist for what remains to be done on the engine itself before its ready to install.

timing belt, inspection
We dug through the engine, looking for signs of trouble - cracks or leaks. We didn't find any. We did find a few rare casting marks, which Justin attributed to this being such an early version of the TDI engine. He was able to determine how the vehicle got hit, based on which brackets were damaged. Having seen the body, I knew he was right - that was just freaky. He determined that the car wasn't going too fast, based on the superficial damage to the engine mount that connects at the timing belt area. The valve train looked very good. He believes the valve cover had never been removed. The inner timing belt cover had been damaged, so we pulled off all the splintered material. He, then did the timing belt replacement pointing out what different things were along the way. Justin, you're a star, man.

Vacuum pump trouble
One of the parts that needs to be removed to perform the timing belt replacement is the vacuum pump. The one that was on the engine had the valve broken off. this could have happened during shipping, or it could have happened in the accident. regardless, I knew it ahead of time, and bought another one from an on-line vendor of used parts. Unfortunately, the part I was sent was full of sandy grit and needed to be dismantled and cleaned before we could use it. The one-way valve was completely gummed up. Considering the part was sold as a direct-replacement not as salvage, I was pretty disappointed with the vendor. He chose to not stand behind his part, and will not see any more of my business unless he is willing to do make up for this in some way.
Fortunately, we were able to get the pump clean with elbow grease and detergents. The timing belt replacement is practically complete. Once the engine is in the bus and start-able, the injection pump timing can be prefected, and it will be 100% done. Justin will be doing that part too.

what's left, engine-wise
So, what's left? I need to pull the intake manifold and clean the soot/gunk out. this is more muscle than brains, so I can handle it. Once removed, the EGR stuff will remain off, so I'll have to fabricate a couple of block-off plates. Why is the EGR staying off? It is a source of intake problems, my emissions aren't tested (1972 bus) and I'll be running BioDiesel anyway, so my emmissions will be significantly better than they were with the old gas-burner. I need to replace all of the vacuum lines (only a couple are bad, but why go piece-meal). I have a new glow-plug harness and glowplugs. I need an accessory belt, but a special size (no A/C, no power steering). Then, the engine should be ready to install.

Gotta go. I'll post more progress when there is some. I'll be building a shed during my limited "free" time, so this project will sit idle for a few weeks.