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  #141  
Old January 13th, 2019, 01:36 AM
Mr.BlueSky
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Here is the el-cheapo fuel pump I picked up from Autozone. It doesn't push very hard but it was enough to get things rolling.

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I simply split the feed line from the diesel tank and slipped the tubing over the fittings I picked up from NAPA. I also made a simple circuit with a switch so I could move about the room and not leave the pump running while I made adjustments to the injection pump.

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Finally, here is a shot of the whole fueling setup.

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In regards to battery, I ended up running a positive cable to the starter as well as 00 (massively thick jumper cable) from the positive terminal on the Benz battery to starter post and the negative hooked up to a block stud and the negative terminal.

An optima redtop on the right side of the block ran the glow plugs and fuel pump.

A video of the engine running is currently buffering...
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  #142  
Old January 13th, 2019, 01:45 AM
Mr.BlueSky
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  #143  
Old January 13th, 2019, 07:06 AM
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Nice.

With the original fuel routing, it's almost impossible to get all the air out of the OM617 and the 10J, 12J, and 19J.
The 12V pump does the job.

With a proper exhaust, it'll sound even quieter.
The OM617 is very smooth and even smoother off idle.

Once its installed, you can adjust the ALDA and boost to get the "off the line" right where you want it.
Start saving veg oil, hydraulic oil, used ATF or just use diesel.
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  #144  
Old January 13th, 2019, 10:45 AM
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Congrats on the start. So it was just the fuel not the timing?

I may route fuel differently when I put the OM617 into the 90. I was very impressed by the Standyne fuel filter setup I recently did for the 110 200tdi and hoping I can install one to work with the OM617 nicely.


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  #145  
Old January 13th, 2019, 02:37 PM
Mr.BlueSky
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Quote:
Originally Posted by rdavisinva View Post
Nice.
With a proper exhaust, it'll sound even quieter.
The OM617 is very smooth and even smoother off idle.

Once its installed, you can adjust the ALDA and boost to get the "off the line" right where you want it.
Start saving veg oil, hydraulic oil, used ATF or just use diesel.
Actually I was pretty surprised how quiet it was in the enclosed carport with the dryer hose exhaust... If my memory is serving me correctly, it was running at about the same level as the 2.5na installed.

I will have to snag some rough sound measurements next time I start the OM617.

As of now, the ALDA has been removed, I may reinstall it. But shall see. The Benz folk have two camps, those that remove it and those that don't and it is quite the controversial topic!
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  #146  
Old January 13th, 2019, 02:52 PM
Mr.BlueSky
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Quote:
Originally Posted by don View Post
Congrats on the start. So it was just the fuel not the timing?

I may route fuel differently when I put the OM617 into the 90. I was very impressed by the Standyne fuel filter setup I recently did for the 110 200tdi and hoping I can install one to work with the OM617 nicely.
I think it was mostly fueling, I did end up adjusting the pump some, but barely, not enough that I think it would have prevented startup. I will confirm later when I check the timing on the IP again for finer tuning.

Standyne sounds interesting. I popped over to their website, being unfamiliar with them (and not spending a whole lot of time on it), not 100% how it all works. It almost looks like a replacement for the injection pump? Or is it a mechanical replacement for the lift pump?
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  #147  
Old January 13th, 2019, 04:32 PM
Naplm00
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It's just a replacement fuel filter head. It's in my truck
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I've been rear ended by an fj40 running 50+ as a passenger in a Cherokee, the tool box was in front of the truck. I've been there bruh. Yeah.
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  #148  
Old January 13th, 2019, 09:25 PM
Mr.BlueSky
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Quote:
Originally Posted by Naplm00 View Post
It's just a replacement fuel filter head. It's in my truck
Oh got it, whatever I was looking at was not that....

I'll take a look at it tomorrow when I am over there
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  #149  
Old January 14th, 2019, 07:38 PM
Mr.BlueSky
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Well, I did absolutely nothing on the 110 on Sunday.

Mainly because I:
A) am glutton for punishment
B) need more distractions from all this great progress
C) need to take a crash course in electronic wizardry
D) sm married to a great lady that said I could swap a perfectly reliable Ford Sport Trac econo-truck out of the fleet for this beasty when I cracked a joke about buying it....

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Guess I'll be driving the motorcycle all summer to save on gas!
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  #150  
Old February 2nd, 2019, 10:15 PM
Mr.BlueSky
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Well definitely have not gotten a lot done lately. Combination of no time, working too late, and way to many weekend plans.

While no significant progress has been made yet, I decided to try and accomplish the following on Friday to gather data for comparisons of 2.5na v. OM617 performance.
  • Audio Trace (during morning commute)
  • Weight (just tossed it on the scales at work)
  • 0-60 Time

I was partially successful.

Audio Trace

In the morning I setup a tripod in the cab, fastened to the floor with clamps on rubber bumpers and set the phone at ear height in the center of the cab.

Ideally, I would have done this with an iPhone as studies by NIOSH and OSHA show that the iphone is a bit more accurate, but the Pixel 2 with the "Decibel X" app will have to do.

For those that are interested: https://blogs.cdc.gov/niosh-science-...09/sound-apps/

Unfortunately without the paid version you only get the first 3 minutes of data downloaded. This data represents around a minute of city street and the rest on the freeway.

Results:
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Max: 93.0 dBZ
Average: 83.1 dBZ

For the difference on dBA, dBC, and dBZ there is good brief here: https://www.noisemeters.com/help/faq...-weighting.asp

I will be taking a trace on the same drive after the swap.

Weight

On Wednesday Theresa beat me home and started dissembling and removing the makeshift sleeping platform we had installed in the back and I unloaded all the unnecessary gear that was left in it from the last snow run trip we did. We emptied it completely down to the bare truck.

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On my lunch break Friday I drove it over to our weigh scale and it came in at 2077.45kg (4580 lb). There almost a full tank of diesel.

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0-60

Original I had tried to find a V-box to borrow but I couldn't manage to round one up. Though it wouldn't have mattered anyway.

I had been driving the truck infrequently since the last snow trip as what I suspected was the release bearing started squealing and I figured it would go soon..

As I pulled back into the employee lot, swung in to back into a parking spot, thump went the clutch and I could no longer even budge the pedal...

I grabbed someone and we pushed it into the spot and I went back to work

I am just happy it didn't happen on the scales!!

Luckily, a good friend works nearby and we flat towed it the 20 miles home on the surface streets.

Now I have no excuse keeping me from pulling the drive-line!

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  #151  
Old February 2nd, 2019, 10:57 PM
Mr.BlueSky
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Miles W
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Today spent some more time gathering parts. Finally, the 1.4 transfer case has been acquired.

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Well... at least I think there is a transfer case under that mess...

And here are a few photos of the December snow run.

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  #152  
Old February 14th, 2019, 05:11 PM
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Did you use the stumpy release bearing or a new one that came with a TDI clutch kit?
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  #153  
Old March 25th, 2019, 10:17 PM
Mr.BlueSky
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Hey Robert!

The release bearing (see post #116) is a billet bearing that was machined to the stumpy spec. I believe I listed the correct part number in that post.

Actually haven't gotten any work done since February apparently until this weekend...

It seems work and play have gotten in the way...
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  #154  
Old March 25th, 2019, 10:38 PM
Mr.BlueSky
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Finally got around to doing work again...

This weekend pulled the 110 back in under the carport and started digging out the 2.5na

- Exhaust removed
- Electrical harness removed and untangled
- All fluids drained and hoses removed (except diesel and fuel lines)
- Radiator and front supports removed
- Throttle linkages removed

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With any luck I'll have it pulled by Sunday afternoon. Goes pretty quick with an impact and a set of spanners!
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  #155  
Old March 27th, 2019, 10:32 PM
Mr.BlueSky
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Had about an hour after work today to make some pre-weekend progress.

Sprayed down every mounting bolt on the underside along with the engine-tran-tcase bolts with penetrating oil in preparation for the weekend. They can sit in peace and soak!

Also got a good start on cleaning out the interior to gain better access for the swap.

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  #156  
Old April 2nd, 2019, 11:39 PM
Mr.BlueSky
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Talking The 2.5na tastes freedom at last

Saturday was the day!

We had a small gathering of people that subscribe to the land rover disease over so I had a bit of help. A Discovery, LR3, and a Allisport radiator came over to be played with as well.

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Overall it was a pretty easy job.

The rear of the truck served as storage for all the removed components so far.

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We dropped the cross member with a bottle jack and section of 2x4. For some reason we were laughing the entire time... Can't remember why.

The transfer case dropped easily enough as well with the floor panels taken up. A strap around a 2x4, some prying with the prybar and one forgotten linkage to disconnect later and it was hanging in free space. We then guided it to the floor with the jack and said strap.

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Then with a bit of pull and tug, and maneuvering with the hoist and floor jack the engine and transmission were pulled.

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Unfortunately the bell-housing pinched the front left brake line. So that will need to be replaced.

Overall, not a bad way to spend the afternoon.
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  #157  
Old April 2nd, 2019, 11:54 PM
Mr.BlueSky
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Sunday Cleanup...

Sunday was spent cleaning up the rover paddock.

First Theresa helped by splitting apart the engine and transmission while I opened Robert's crate back up.

Robert's crate may be one the best and most underated parts of the swap kit! It is one helluva black hole storage box!

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After digging out the new trans and other components needed for the next steps I took a look at the split engine/tran combo.

Sure enough, the throw-out bearing had died.

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The rest of the day was spent rearranging things on the shelves and getting carts built for the 2.5na and a transmission cart to roll the new R380 and LT77 around on and out of the way.

Change of plans

Originally I had planned to rebuild a 1.4 transfercase before completing the swap. At this point, I think I will stuff the 1.6 back in to save on time and get the 110 back on the road.

There are too many exciting trips being planned for the summer I hope to make!

Then I can rebuild the 1.4 at my leisure.

Next steps
  1. Order a bunch of odds and ends parts. Mostly trans shift boots and insulation
  2. Install the new uprated clutch kit
  3. Mate the OM617 to the R380
  4. Powerwash out the engine bay
  5. Strip out unneccesary 24V wiring and any wiring not needed after the swap
  6. Recoat engine bay
  7. Repair that brake line!
  8. Look into power steering conversion
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  #158  
Old April 3rd, 2019, 06:31 AM
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Looks like the release bearing became hot and melted into the plastic due to bearing failure or under adjustment.
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  #159  
Old April 9th, 2019, 10:35 PM
Mr.BlueSky
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Quote:
Originally Posted by rdavisinva View Post
Looks like the release bearing became hot and melted into the plastic due to bearing failure or under adjustment.
Agreed. It is cooked.
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  #160  
Old April 10th, 2019, 12:17 AM
Mr.BlueSky
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Going off the deep end...

Welp, I did some cleaning of the engine bay over the weekend and came to the conclusion I should just dive into the bottom of this thing.

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I was happily surprised to find the wheel well liners are galvanized. Apparently they all were up to 1991?

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I just sprayed oven cleaner in the engine bay, let it set in, scrubbed and hosed with copious amounts of water!

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Then after removing stuff off the wings, decided that I am going to fully remove the wings and spray the accessible bits of frame, bulkhead, as well as respray the hood and fenders.

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I've got a gallon of paint so I may as well do it now.... I mean there is what, 30 bolts??
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