Got another one! Project: PolarXJ

[xj_man_646]

Awesome progress!

[6DoF]

forgot to post the vid!

https://i.imgur.com/IKHkg2t.mp4

[6DoF]

COMPLETELY forgot to install the CPS before swinging the engine/trans in ... that was more of a b!tch than the stock XJ cuz the bell housing is higher now.

-one heater hose is on
-entire power steering is plumbed with the remote res mounted

i think i have the new acc belt routing and custom tensioner figured. going to take a little fab and ordering a hopefully correctly measured belt, so we'll see. also think the VW alternator has the same B+ and 2-wire hook up as the XJ. it's a different connector, but i'm hoping the XJ computer will control the field wires for me. cross your fingers.

i'm dreading doing the exhaust ... it's suuuupper tight in there ...

[xj_man_646]

just run a hood stack

[6DoF]

wasted friday and saturday dealing with Hank and trying to get a new transmission, but did get some good work earlier in the week and on Sunday.

fuel PSI was a pain, i don't get why EFI pumps have to be SO extra that it takes 2 regulators to get to a "carb" psi n flow. first is a dead headed to make the stock system return some on it's own, then the second is a return bypass reg to really set a good psi n flow to the pump. i tried both individually and they weren't even close, but together are great.

got the whole interior back together including the B&M short throw shifter. they don't actually sell one for the XJ, but the TJ one seams to be fine. i guess it's a little closer to the dash, but with my arms it seams fine. worst case i can cut n weld it later.

started getting the wiring all figured out for gauges and such. ripped the old wiring off the AW4 in the scrap pile and started using it. NSS is bypassed, the key'd ignition source is the pump fuel solenoid on/off, and found the wire i need to give 12v for rev lights. also got the main 4.0 engine harness all figured out and labeled. orange is worthless, blue is labeled with what it's for. once i confirm everything works i'll strip out the unused, but for now it's a rat's nest on the motor

i was able to confirm the tach started working with a quick jump across the cam sensor wires thought! huge win!

finally i got the belt tensioner designed. 3D printed some parts to trial fit and measure for the belt, then sent everything to SendCutSend to get some laser cut parts. with that designed, i can get the whole front clip back together and plumb the radiator/intercooler.

[6DoF]

turbo piping is all fit ... just need to bead roll the ends i cut.
radiator piping is fit ... just need hose clamps.

also got the vac system sealed up and connected. a little manifold where the 4.0 intake used to be and the turbo VNT actuator direct hosed in. i'll mess with a boost controller eventually.

[Cobound]

Just in time for $7/gal diesel...or non existent fuel, which will be first

[6DoF]

Originally Posted by Cobound

Just in time for $7/gal diesel...or non existent fuel, which will be first

it's imaginary and will re-set yet again soon enough.

better tell all those ppl heating with oil, and the entire goods transportation network, or maybe all international shipping. plus biodiesel is easier, more cost effective, and has higher yields than ethanol. and i can run on straight waste motor oil, or straight peanut juice.

[MBood82]

That engine is so tiny! Went in very quickly though, looks promising to be a very clean installation when finished.

Also, I think you are missing a shock nut on your drivers side upper shock mount. :-D

[6DoF]

Originally Posted by MBood82

That engine is so tiny! Went in very quickly though, looks promising to be a very clean installation when finished.

Also, I think you are missing a shock nut on your drivers side upper shock mount. :-D

i feel like i need to do something with that space! maybe a raw vegie oil tank so it can stay warm under there?

that's a stud for the airbox, the shock is significantly more of a pain to get to under the brake master :facepalm:

[Cobound]

Just ribbin

[6DoF]

hotwired the cam sensor to a relay and sure as ****, the tach works on start-up! just need to rip down the old engine harness to clean that up a ton, and wire this relay for real.

- tubing bead roller should show up today to finish the intake tube fab
- hose clamps to finish the cooling system should also be here today.
- acc belt tensioner parts won't be here til next week. has to be on before i can fiddle with getting the alternator charging
- can start front suspension tear down and get the new bushings/arms swapped in
- can build the bump stop extensions to keep the axle from eating the oil pan
- need to build out the exhaust

last night i got the vacuum system all sealed up, including plumbing the turbo directly in with no controller. now when i start the engine it begins to whistle

[xj_man_646]

Its possible I missed it, what is the vacuum line on the turbo for? VGT?

[6DoF]

Originally Posted by xj_man_646

Its possible I missed it, what is the vacuum line on the turbo for? VGT?

yup, the factory turbo is variable geometry. VW calls it VNT, this is a VNT-15, just a little tiny thing.

full vacuum is full boost, fastest spool-up ... but not as efficient at low throttle cruise. i have a pair of boost control valves to set one for max boost, and one for max boost low throttle. the low throttle switch is just a pneumatic limit switch on the throttle linkage that bypasses that control valve. see post #62

[xj_man_646]

Got it. Very cool!

[6DoF]

head pipe all figured! after final welding and clean-up, it's getting TI wrap as well, hopefully help the starter live longer. the piping is factory 2.25" WK2 exhaust that i took off when the StainlessWorks pipes went in, i love free bits! turned out to be a pretty satisfying routing i think, and kept it high clearance for rocks. speaking of clearance, i had to beat in a little wrench clearance for one bolt, this pipe is bigger than factory VW.

the AL pipe is my sample trial with a new pipe bead roller. china left, me right. i did the rest just a little less pronounced, but that thing worked out awesome everywhere i cut the universal "kit"

[6DoF]

huge win this weekend on the XJ! got my SendCutSend parts in and the new belt routing / tensioner is working! longer alternator bolts, some spacers, and a plate to bolt an old stock TDI belt pully to.

didn't actaully get that much time in the shop this weekend, but did also get the 4.0 engine harness cut down quite a bit to only what i need. it's all routed and plugged in, just need the tach-trip relay to short the cam sensor. messed with injection timing a bit and realized i had other issues for the rough idle. research suggests bad injectors, so i tried to swapped in the new ones i already had. too bad they didn't come with the crush seal, and i'm now stuck waiting til next week.

[xj_man_646]

A friend of mine was going through some rough running issues on his TDI awhile back. Ended up being injection timing.

I recall it because he said the VW tool tells you how far you are from ideal injection timing, but it doesn't tell you if its advanced or retarded, so you have to guess which way to adjust it first

[6DoF]

Originally Posted by xj_man_646

A friend of mine was going through some rough running issues on his TDI awhile back. Ended up being injection timing.

I recall it because he said the VW tool tells you how far you are from ideal injection timing, but it doesn't tell you if its advanced or retarded, so you have to guess which way to adjust it first

yeah, the VAG-COM tool. i used the VAG-com one time it was funny cuz you loosen the top of the pump, but not enough that diesel sprays out, and you smack it with a hammer til that number goes in range

the injection timing is SUPER easy to adjust on this engine, so i have run it thru a whole range. i apparently did a decent job on the TDC set-up, cuz i can go both too advanced and too restarted in the current set up. it's a 2 piece pump pully with slotted bolt holes. pop off little plastic cover, loosen, turn, tighten. i don't know exactly where i'm at, but i know i'm in the middle of the good range, and no where in the range would it idle without earthquake mode.

[xj_man_646]

Earthquake mode