Author Topic: AAZ project update  (Read 19773 times)

Reply #30July 04, 2013, 04:02:49 pm

Gizmoman

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Re: AAZ project update
« Reply #30 on: July 04, 2013, 04:02:49 pm »
Your trans was already set up for the AAZ engine so you shouldn't have to mess with the input shaft.  The gasser transaxles have an input shaft that is approx 11mm longer and so if fitting a diesel bell housing to gasser trans you need to call a rabbi.   
Hahahah
Thanks for the clarity - I think I'll be ok if I can get the motor in - man it's way too hot for this type of work. I have so much sweat on my glasses, I can't see
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #31July 05, 2013, 06:14:49 pm

Gizmoman

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Re: AAZ project update
« Reply #31 on: July 05, 2013, 06:14:49 pm »
Just thought I'd let everyone know the reason the engine wouldn't spin using the starter - both batteries were shot.
It seems odd as I disconnected them during the rebuild and it started fine when it went down.

I did some clearancing of the bell housing and starter nose as it was touching a very tiny amount. Even after that - the starter just wouldn't turn it more than one rev.

I now have two new dry cell batteries with a three year unlimited warranty - man it cranks now!

Next issue will be figuring out the wiring. I know it should be very simple but the PO had a WVO system in the van which I have since removed. He hacked up the wiring quite a bit adding solenoid valves, relays, an additional pump and fuel heaters.

There is a pump mounted to the frame which I'm sure is used to get the diesel to the IP. My first step is figuring out how to get power to that.
« Last Edit: July 05, 2013, 07:23:15 pm by Gizmoman »
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #32July 05, 2013, 10:50:51 pm

CRSMP5

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Re: AAZ project update
« Reply #32 on: July 05, 2013, 10:50:51 pm »
 ;D  big alagator clip to batt..  8)

Reply #33July 05, 2013, 10:59:55 pm

libbydiesel

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Re: AAZ project update
« Reply #33 on: July 05, 2013, 10:59:55 pm »
Pull out the bentley.  There really is nothing to it. 

Reply #34July 06, 2013, 12:48:51 am

Gizmoman

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Re: AAZ project update
« Reply #34 on: July 06, 2013, 12:48:51 am »
Pull out the bentley.  There really is nothing to it.
I'll figure it out (with help from the Bentley). I think I'll cut out all the crap and start fresh - it really is quite a mess.
I am adding a bit to the system what with the water pump for the WAIC, the fan for the oil cooler, EGT, oil temp, air temp (post WAIC), and water temp as well. I also need to finish the glow plug pimping ;D


;D  big alagator clip to batt..  8)
Yeah, I basically did that just to check it - it runs fine. I'll re-do the relay tomorrow - he had it wired wrong.

BTW, I picked up a licence plate overflow tank locally for 20 bucks - good ol craigslist. My van never had one mounted (no holes for it) so I guess the diesels didn't need one - but I like having it and it will be much easier to check.
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #35July 06, 2013, 07:13:41 am

CrazyAndy

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Re: AAZ project update
« Reply #35 on: July 06, 2013, 07:13:41 am »
Pull out the bentley.  There really is nothing to it.
I'll figure it out (with help from the Bentley). I think I'll cut out all the crap and start fresh - it really is quite a mess.
I am adding a bit to the system what with the water pump for the WAIC, the fan for the oil cooler, EGT, oil temp, air temp (post WAIC), and water temp as well. I also need to finish the glow plug pimping ;D
Sound like you are where I am in therms of figuring out wiring for new accessories.  I do have some wiring ideas and sketches I could MS paint-ify and throw up here if you want.  You'll need an aftermarket fuse/relay box to hold the added fuses and relays, but I can provide links for that stuff.


Reply #36July 06, 2013, 08:15:09 am

Gizmoman

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Re: AAZ project update
« Reply #36 on: July 06, 2013, 08:15:09 am »
Pull out the bentley.  There really is nothing to it.
I'll figure it out (with help from the Bentley). I think I'll cut out all the crap and start fresh - it really is quite a mess.
I am adding a bit to the system what with the water pump for the WAIC, the fan for the oil cooler, EGT, oil temp, air temp (post WAIC), and water temp as well. I also need to finish the glow plug pimping ;D
Sound like you are where I am in therms of figuring out wiring for new accessories.  I do have some wiring ideas and sketches I could MS paint-ify and throw up here if you want.  You'll need an aftermarket fuse/relay box to hold the added fuses and relays, but I can provide links for that stuff.

Thanks a lot Andy - I may need it before I'm done but there's no issues as yet. I already have a 6 fuse block four for the GP's and the rest for the rest.
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #37July 06, 2013, 09:27:20 pm

CrazyAndy

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Re: AAZ project update
« Reply #37 on: July 06, 2013, 09:27:20 pm »
Here you go!



Please be aware this assumes the installation of the above components.  No recommendation where to splice in 15 power on a vanagon; on a rabbit the best suggestion is either the ignition switch or the fuel shutoff solenoid wire.  X power would be best taken off either the ignition switch or power feed to the light switch.  30 power is obvious, just pull off the battery.  Use your manufacturer recommended fuses for the consumer side of the relay circuits; control circuits should use no more than a 5 amp fuse.  This diagram assumes a common fuse mounting location.  Do not taunt Happy Fun Wiring Diagram. 

Have fun!  :)


Reply #38July 06, 2013, 09:32:00 pm

Gizmoman

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Re: AAZ project update
« Reply #38 on: July 06, 2013, 09:32:00 pm »
Thanks Andy - prety slick
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #39July 14, 2013, 10:04:31 am

Gizmoman

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Re: AAZ project update
« Reply #39 on: July 14, 2013, 10:04:31 am »
Here you go!



Please be aware this assumes the installation of the above components.  No recommendation where to splice in 15 power on a vanagon; on a rabbit the best suggestion is either the ignition switch or the fuel shutoff solenoid wire.  X power would be best taken off either the ignition switch or power feed to the light switch.  30 power is obvious, just pull off the battery.  Use your manufacturer recommended fuses for the consumer side of the relay circuits; control circuits should use no more than a 5 amp fuse.  This diagram assumes a common fuse mounting location.  Do not taunt Happy Fun Wiring Diagram. 

Have fun!  :)

I am (still) working out the details of my 82 vanagon wiring and have a few questions based on the great diagram from Crazy Andy.

1. Is "15" the circuit that goes off during the momentary on as the starter is engaged?

2. The diagram shows "X" driving the intercooler fan and pump. Wouldn't they need to be also off during the start? This assumes X is on as soon as the key is turned.

I am no automotive electrician
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #40July 14, 2013, 12:09:35 pm

libbydiesel

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Re: AAZ project update
« Reply #40 on: July 14, 2013, 12:09:35 pm »
30 is always live.  15 is live with ignition On or Start.  X is live with ignition On and off during start.

The diagram is fine.  I would probably just run one relay for the oil cooler fan, intercooler fan and pump.  I'd also move all the accessories except the lift pump to X but it will work as is.  None of that helps decipher the stock '82 wiring, tho.   

Reply #41July 14, 2013, 01:14:29 pm

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Re: AAZ project update
« Reply #41 on: July 14, 2013, 01:14:29 pm »
30 is always live.  15 is live with ignition On or Start.  X is live with ignition On and off during start.

The diagram is fine.  I would probably just run one relay for the oil cooler fan, intercooler fan and pump.  I'd also move all the accessories except the lift pump to X but it will work as is.  None of that helps decipher the stock '82 wiring, tho.   
Thanks libby,
I guess I had it backwards. Also nice to know I can run one relay for all three. That simplifies things quite a bit.
I have  both Bentleys - Jetta/Golf and Vanagon - I'll figure out what's what from those.

Here's some shots of why I'm not done yet.
WAIC exchanger fan shroud/mount


WAIC exchanger ready to mount


WAIC pump with aluminum bracket - rubber mounted - the shoulder bolts are from a previous suby swap.


Aluminum WAIC water tank bracket(mounts under the back seat in the van). BTW, I removed the cheezy sticker from the cap ;D


The start of the gauge housing for the EGT, Water temp, Air temp and oil temp (all four combined).


Tappin the housing for the gauge


The gauge mounted in the housing


The housing is hanging after paint. I'll post a pic when it's mounted on the dash.

Thanks for all the help!
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #42July 16, 2013, 09:19:27 am

Gizmoman

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Re: AAZ project update
« Reply #42 on: July 16, 2013, 09:19:27 am »
I figured out where to tap in the oil temp probe - the banjo bolt on the turbo feed line off the filter mount.

Hopefully the 1/8" probe doesn't affect the flow :-\
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #43July 16, 2013, 11:12:04 pm

CrazyAndy

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Re: AAZ project update
« Reply #43 on: July 16, 2013, 11:12:04 pm »
It looks far out enough so as to not cause undue strain; you have a good idea there.  Is it a pyrometer?  It looks like one.

You did a good job fabbin all that recent stuff up.  I like the gauge pod, but It looks kinda big, and for the life of me I can't tell where it'll go by looking at it.  But you have more tools than me, so you know what you're doing. :)


Reply #44July 18, 2013, 08:09:10 pm

Gizmoman

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Re: AAZ project update
« Reply #44 on: July 18, 2013, 08:09:10 pm »
It is a pyrometer - one of four.
Thanks, yeah the gauge pod is big - has to be - and its going to mount on the dash to the right of the instrument cluster. I may change my mind - well see.
The tools are the result of a steady goal and time - lots of time. ;D
« Last Edit: July 18, 2013, 08:22:16 pm by Gizmoman »
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost