Building AAZ motor; meet Harley - page 19 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• #270 by Gizmoman on 14 Oct, 2013 05:51
• Nice work - very clean.
  Your bedroom is going to get big again but now you have to sleep alone
• #271 by CrazyAndy on 20 Oct, 2013 17:09
• Quote from: Gizmoman on 14 Oct, 2013 05:51

  Nice work - very clean.
  Your bedroom is going to get big again but now you have to sleep alone
  

  
  Speaking of which, the bedroom is quite roomy now . . .
  
  Got the engine out to the barn where I've been keeping the Rabbit.  I got the car prepared for the engine by draining the tank and cutting off the old exhaust.  I pulled the 2-ish gallons of old diesel out of the tank and it wasn't bad, but I'll still start with some new fuel for posterity.  The exhaust was easy and only took 12 minutes and an angle grinder.  Then I loosely installed the valve cover and tested the oil system without the cooler take-off installed.  Se makes oil pressure easily and without a single leak; the 18V drill wore out it's two batteries pumping the oil!  Before all this, back home, I had installed the oil dipstick tube.  Kinda neanderthal'd the end by hitting it in with a 3/3+ extension, knocking it square, but the plastic tube covers it snugly so I'm not worried.
  I really wish I could have timed the engine, but no local parts shop had an old style timing belt tensioner, so that will have to wait until next weekend to go on.  After that, it's installation time.  Still need to buy electronic control components for the new stuff in the bay, as well as planning how to get it all to fit around the radiator and still have fans on the coolers.  It's getting so close to install day, but that doesn't mean the work is over.
  
  
  
  
  
  
  
  
• #272 by Gizmoman on 20 Oct, 2013 18:22
• You look very proud in that photo - you should be.
• #273 by CRSMP5 on 21 Oct, 2013 10:52
• bob's luck.... rain storm and buildings lightning strike... or some theif watching this thread... get it in the car...
• #274 by vanbcguy on 21 Oct, 2013 11:20
• I love this picture:
  
  

  Quote

  

  
  That thing just needs a propeller on the front and it'll take off by itself!!
• #275 by CrazyAndy on 24 Oct, 2013 17:18
• Going through parts list on what to buy still, and kind of ran into a snag.  i already asked something like this on Lucas' thread, but I'll ask here for posterity:
  
  I was originally thinking of running a Carter P60430 fuel pump like I do in my Bus (http://www.summitracing.com/parts/crt-p60430/overview/) since I have had good experience with that pump.  Also since it's a scroll type it will still pull if it fails.  It wouldn't be hard to mount under the floor near the tank (better pusher than a puller).  Has low amp draw, too.  Only downside is that it's kinda loud; I can hear it under the Bus at KOEO, 7 feet away under the floorboard.  Thoughts?  Think it will be adequate for my setup?
  
  As for auxiliary electrics I think I  have settled on my relay/fuse setup:
  Hella interlocking fuse and relay blocks (http://hellahd.com/index.php/default/electrics/accessories/electrics-product-13/, http://hellahd.com/index.php/default/electrics/accessories/electrics-category-1/electrics-product-13/)
  Bud Industries weather proof box mounted in rain tray (http://www.mouser.com/ProductDetail/Bud-Industries/NBB-15240/?qs=sGAEpiMZZMsrGrAVj6eTvdqSgsXeLH19lHTJT81EOYk%3d)
  Last part, little iffy (radial plug pin numbering and arrangement confuses me), but box-out connector will be screw-in mil-e-qual radial plug (http://www.nxtbook.com/nxtbooks/waytek/catalog226/#/41/OnePage, second from top on catalog page, the 14 pin)
  Sheath it all up in some heat shrink rubber tubing and branch it all off to input/output/signal wires accordingly.
  Doesn't sound too bad of a setup, and should be safe from the elements.  Only thing now electrical to plan is to find out how to get the tough EGT cables into the cabin.  Any recommendations?
• #276 by theman53 on 24 Oct, 2013 17:47
• Sounds good on your setup. No real recommendations on the pump. BUT for the EGT line, I got this stuff from Gee Bee on the board. I think he called it fire shield? It can withstand over 2200f and is very abrasion and cut resistant. Maybe try contacting him and see if he has it. It was pretty cheap IIRC but this was 4 years ago or so. I don't know if you could tell in the pics I have but if you can see it in my pics in my thread it also houses my boost tubing for the gauge. It is black and textured, not like the black silicone hose. It is probably 5/8" OD. Worth a shot.
• #277 by Gizmoman on 25 Oct, 2013 05:41
• Not sure what your mount set-up is, but if it's hard mounted using a steel strap/clamp to the frame or body, the whole car is a speaker.
  Mount it using some rubber mounts from McMaster Carr and I'll bet it's much quieter. They are about 2 bucks each and you'll have them in a day.
• #278 by CrazyAndy on 09 Feb, 2014 18:57
• AND THIS THREAD LIVES AGAIN!!
  
  Finally got the bolts for the transmission housing from Lucas, so it's time to install the engine.  Luckily everything else was up where the car was stored, transmission and all, so I went there and got to work.  With the new bolts and washers installed, it was time to raise the hoist up and drop the engine in.  The positioning of the engine was easy enough; it was the alignment of the two side motor mounts that was the hardest part.  The installation position of the crane canted the engine forward just enough that the mounts' center holes for the bolts were not aligned with the mount points on the body, necessitating the raising and lowering of the engine multiple times with the bolts half-in their holes so that the engine weight would torque the mount center sections enough so that the bolts lined up.  But after raising, lowering, prying, holding, and cursing for over 2 hours, the engine is finally in the car where it should be; granted it sits a little torqued since the front mount has yet to be installed, but it is in at long last.  There is still much to install, clearance, test fit, fasten, route, wire, and break in, but this wayward puzzle has found it's biggest missing piece.
  
  
  
  
  
  
  
  
  
  
  
• #279 by 745 turbogreasel on 09 Feb, 2014 19:08
• 
  BAM! Loving the sock filter too:D
  
  

  Quote from: Gizmoman on 25 Oct, 2013 05:41

  Not sure what your mount set-up is, but if it's hard mounted using a steel strap/clamp to the frame or body, the whole car is a speaker.
  Mount it using some rubber mounts from McMaster Carr and I'll bet it's much quieter. They are about 2 bucks each and you'll have them in a day.
  

  Those are free of the air cleaner of Mercedes diesels too.
• #280 by theman53 on 10 Feb, 2014 05:32
• Good job, crazy andy,mike,spongebob. Soon it will roar to life. Take it easy on that turbo
  
  also, with your luck, I would cover the fuel inlet on that pump. Don't want junk dust or whatever getting in there.
• #281 by bbob203 on 10 Feb, 2014 07:45
• no oil cooler?
• #282 by CrazyAndy on 10 Feb, 2014 15:42
• The cooler boss was left off for initial oil priming to leak check; it will be installed and the oil primed again before initial start up.   I'll also get back up there and tape off the fuel inlet.  Hopefully the pump doesn't have anything else in it from sitting all this time empty.
• #283 by Rising on 15 Feb, 2014 10:23
• Beautiful! Psyched to see the rabbit coming to life finally!
  
  Sent from my Nexus 5 using Tapatalk
• #284 by deepgrooves74 on 18 Mar, 2014 01:29
• Please video her first startup!! Congrats!