#101
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Throttle spools
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I haven't been getting notices on thread replies so am a little tardy in replying. I found a LONG throttle cable from an early 1990's Datsun or Nissan which worked after hours of fitting, modifying and making brackets. It loops almost to the grille then back to the IP. I'll get a photo this weekend.
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
#102
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
#103
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
#104
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You're also right in the time needed to finish the project, I felt 90% done three weeks ago!! The custom brackets, hose and wire routing and extra pieces and parts are extremely time consuming and, like you've observed, I don't want to skip the details towards the end of this project. It's not very often when we, as long term users with mechanical experience, can factually improve upon the original engineering but it does occur.
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
#105
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Does your engine have the mounting location for the plunger style pump as well? I wonder why they used this different setup here. Maybe something about the vacuum demands on the original car the engine was in being greater than the other type pump could supply, and this pump has higher capacity to compensate? Like if the former automatic trans had a vacuum based control system, or vacuum hvac or door locks like some cars from the '80s did? Maybe we will never know for sure. Quote:
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86 745 D24T/ZF 345k lifted 2.5" 83 764 D24T/M46 155k |
#106
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The center and rear differential lock use vacuum to hold the lockers in place so maybe that's why, there's also not much room for the side mounted pump with all the hoses there. I think I'll be working on some of the electrical stuff for some time, the tach, oil pressure warning light which I think has some connection to the tach, re-plumbing the cooling for the waxstat, etc., etc. I'll post more photos today with a few more questions. This is the first time I've done more than just a rebuild or engine swap and it's definitely time consuming. It's so nice to have access to that big shop even though it's 100 miles away, it has actually save me a lot of time; not having to wriggle around in my small garage.
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
#107
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Alternator
Here's some alternator photos, this first one showing a possible W terminal that's currently connected to a suppressor. Is this an actual W terminal? It's the one in the 6 o'clock position; the one in the 3 o'clock position is empty. There's no winding ends on this alternator so the possible W terminal is my only option with this alternator.
Suppressor part number 0 290 800 036. Alternator part number 034 903 016 and from a parts catalog 034 903 017 BX
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
#108
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Oil cooler from Mercedes 300TD
Oil cooler bracket
Bracket with spring keeper. View from the front Tubing and hoses from the oil diverter valve. I'm not sure if my thermostat is working correctly and won't know until I get the engine under a load and hot enough to activate the "waxstat". If it doesn't work I'll just modify it so it's always in the open position as v8volvo suggested. I can just physically cover the cooler when it's real cold.
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
#109
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Throttle cable
Cable routing of a cable off a 1990's Datsun or Nissan.
Custom brackets, circled in red. I sandwiched a piece of a Volvo cable spool to the IP bracket. Sandwich from the side
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
#110
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Airbox from Canadian Audi 5000
I got this with the engine, had to chop it down quite a bit to get it to fit in there. I still not to make some deflectors to prevent rainwater from getting in.
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J.D. in Reno 1958 Mercedes 180D (rebuilding now) 1985 VW Jetta 1.6TD 1985 Volvo 745 Wagon 2.4TD (sold but still maintain it) 1987 VW Quantum Syncro 2.2 (converting to 2.0TD) 1996 TDI Passat 1997 Chevy 3/4 ton 6.5TD 2006 V10 TDI Touareg |
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