1991 200TDI to R2.8--couple remaining questions

abraded

Active member
Maybe components are changing since the engine was first released. This looks different.
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MountainD

Technical Excellence Contributor
Yeah. That’s actually a marketing photo from a couple/ few years ago. Don’t think they ever actually came painted.
 

MountainD

Technical Excellence Contributor
For the temp sender, again just reusing some VDO Vision gauges I have-- I am using temp sender VDO# 323-092 which is an M12x1.5 thread sender corresponding to the port in the front cover (waiting to arrive and then I will verify it fits correctly). This is a single wire sender (I couldn't find one with integral ground) so you will need to ground the front cover (FYI).
PSA: The sender, M12-1.5 is not the right thread. I pulled the plug and checked the pitch and the correct thread is M12-1.25 for the sender. I will need to use an adapter as I can't find this thread in a sender...
 

MountainD

Technical Excellence Contributor
HOLIDAYS! Ton's of stuff as we prep for X-mas, so not a load of car stuff, just a load of friends celebrations (and loss). LIfe. As for the truck, I ripped off the fenders to get more room (highly recommended) and have been mounting the full Engine/Tranny lump together to prep for mock ups:
Assembled lump.JPEG

It was great to put it together. Then I fit it into the engine bay and the next step was getting the tranny mounted to the chassis--this would position the forward position of the motor and the location of the shifters using the Stumpy/R380 combo. Why the stumpy? Someone got a R380 HD from Ashcroft but it came stumpy and he needed NAS, so I got a decent enough deal plus bird in hand and hence Stumpy. It definitely has it's pro's and con's position wise but I will give impressions once it is driving. Engine is in to see how it will lie:
Engine Mockup.JPEG

Well, it fits. It is wide. The bell housing/flywheel are quite large. Starter is right there too. With the LT230 mounted, the starter is right near the inside of the footwell, the DOC is at the passenger footwell (LHD). If you were going to use the DOC in stock position, it won't fit with the stumpy
 

MountainD

Technical Excellence Contributor
Made some cardboard mount mock ups. Getting the engine situated and depending on how I feel about the position, I will be ready to tack, remove everything and burn in the mounts. Still more tests and trimming of the mounts in the morning.
Carboard2.jpeg
Cardboard1.jpeg

Used those for basic templates to slice up some steel. Loads of testing, trimming and fitting. Still need to final cut.
Engine Mount P side.JPEG
Engine Mount D.jpeg

Got them trimmed and fitting enough to consider tacking them in the morning. Want to look at a few things first on the positioning but pretty good. and once tacked I'll toss on the fenders and make sure height works. For the night, the engine is sitting on its mounts...
Engine on mounts.JPEG

I think I will clock the power steering pump inlet---it looks like a press fit, and bet I can put a rod in the hole and give it a twist... or it will break, lol... We will see. More soon enough!
 

MountainD

Technical Excellence Contributor
Won’t seem to exciting for some, but mounts burnt in and painted— the engine has its final resting home/position.
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bext is to prep/clean the bulkhead, relocate rear main harness, remove old fuel lines and tank.
 

jymmiejamz

Founding Member
Callsign: KN4JHI
Made some cardboard mount mock ups. Getting the engine situated and depending on how I feel about the position, I will be ready to tack, remove everything and burn in the mounts. Still more tests and trimming of the mounts in the morning.
View attachment 21860View attachment 21859
Used those for basic templates to slice up some steel. Loads of testing, trimming and fitting. Still need to final cut.
View attachment 21862View attachment 21861
Got them trimmed and fitting enough to consider tacking them in the morning. Want to look at a few things first on the positioning but pretty good. and once tacked I'll toss on the fenders and make sure height works. For the night, the engine is sitting on its mounts...
View attachment 21863
I think I will clock the power steering pump inlet---it looks like a press fit, and bet I can put a rod in the hole and give it a twist... or it will break, lol... We will see. More soon enough!
Did you make your own motor mounts?
 

MountainD

Technical Excellence Contributor
I got the generic mounts from Quickdraw and cut them for my use. You could easily make them but I don’t think I’d save much by $/time to put them all together myself. Either way, not hard. Positioning is tricky due to interference with bulkhead. This engine has very wide hips. Wider with DOC in stock place, to point sides touch and you can’t move stubby forward to clear or shifters get buried. Long bell housing is about 3” further forward and clears better but right at power steering (if I went that route I’d do RRC steering box outside frame rail).
 

jymmiejamz

Founding Member
Callsign: KN4JHI
Ah okay, I thought they looked like something laser cut, so I was curious how you did that.
 

MountainD

Technical Excellence Contributor
Slow progress as the holiday season and spending time with friends and family is just taking precedence, but I do try and get to the garage for a couple/few hours on the weekend. I got the engine bay cleaned up, sound deadened (engine side) and the engine in! Set up the LT230 linkage while it was still out and started the reassembly of it but I have to wait for some bolts from Belmetric. What I didn't know is that Ashcroft doesn't send the speedometer gearing/housing/seal with the transfer case, so be prepared for that. When I sold my LT230, I didn't remove mine (just the sensor). So I have that on order too. Had to clock the Power Steering Input as it was pointed at the chassis--I tried but it wouldn't budget--but then I tried again with more force after confirming it was a press fit...and got it to spin. Next up is sorting the electrical, reinstalling the clutch/brake and heater, then getting the plumbing sorted. Figured out where/how to put the fuel filter too... AND got up our 17' x-mas tree...
engine.jpg
engine 1.jpg

engine 2.jpg
Trans.jpg

clocked.jpg
harness.jpg

tree.jpg
 

MountainD

Technical Excellence Contributor
Work has been kicking my ass so only a few little things done. Important to keep moving forward.
I installed the Speedo gear, housing and seals in the LT230 and then finished setting up the shifters along with new gators.
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The LT230 shifter needs an adapter. PO used electrical tape. I noticed shifter is 10mmx1.5 thread, so a found a short section of brass, drilled it out, tapped for 10mmx1.5 and cut to length.
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I was gonna turn it down to fit shifter but easier to real home to 1/2. Then pressed it all home. Worked perfectly.
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I also set up my oil cooler to feed remote Derale trans cooler with fan. Should do. Gonna mount it up in seat box vicinity yet to choose.
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dkemm

Well-known member
Work has been kicking my ass so only a few little things done. Important to keep moving forward.
I installed the Speedo gear, housing and seals in the LT230 and then finished setting up the shifters along with new gators.
View attachment 22072
The LT230 shifter needs an adapter. PO used electrical tape. I noticed shifter is 10mmx1.5 thread, so a found a short section of brass, drilled it out, tapped for 10mmx1.5 and cut to length.
View attachment 22073
I was gonna turn it down to fit shifter but easier to real home to 1/2. Then pressed it all home. Worked perfectly.
View attachment 22074
I also set up my oil cooler to feed remote Derale trans cooler with fan. Should do. Gonna mount it up in seat box vicinity yet to choose.
View attachment 22075
Funny, mine had electrical tape too.
I ended up casting my own knobs
 

Napalm00

Technical Excellence Contributor
checkout epco . they have the LT230 pattern on hand as i have made a few with them and can make you a knob in anysize or color. my current lt230 is black with red inlay knob 1 1/8 diameter i think and the r380 is translucent glitter cue ball size with red inlay. cheap and oldschool.




 

MountainD

Technical Excellence Contributor
checkout epco . they have the LT230 pattern on hand as i have made a few with them and can make you a knob in anysize or color. my current lt230 is black with red inlay knob 1 1/8 diameter i think and the r380 is translucent glitter cue ball size with red inlay. cheap and oldschool.




I had something like that in my '68 firebird, but doesn't suit my needs in this truck. More of a wood/leather sort of guy. I have a cool R380 knob from a Banksia seed pod that was lathed. I'll do something unique and similar to the LT230 some day.
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MountainD

Technical Excellence Contributor
Baby steps. I would love to just work on the truck for a couple days but that isn't in the cards at the time with all the "voluntold" things on my list that I have to do. So another small day of work. Really just a few things completed.

I mocked up my new gas tank and figured out where I was going to put in my bungs. I installed a 6AN stainless bung to the side of the main tank that feeds over to the extended wheel wheel gas tank feed. It used to feed from the drain port on the main tank on the bottom of the tank. Frankly, I think it is a stupid place for an extended tank port---if you rip that off, you would lose the diesel in both tanks and, although I am sure there are folks that say they have one and have never done that, I also know that in CO and Utah, my wheeling sees me scrape the back of the truck particularly negotiating big steps. So that had to go. I also did another smaller one for the Webasto diesel coolant heater feed on the other side. They are not at the bottom of the tank, but not that high either. This will prevent the Webasto from ever draining the full tank and I will only miss a little diesel in the aux tank which I can live with. Better than potentially snagging a hose...
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I then plugged off everything and added air to check for leaks on the welds which seem good. Although I weld, I don't have a TIG torch and I didn't want to deal with a leak so I did take it over to my local, Pat at Longmont Welding, and he did it up. Pleased.

I then turned my attention to the Power Steering cooler. I opted for the 13" Delrale unit as it is simple, I trust Derale, and the single pass is a feed through which for my routing works great as I have the reservoir on the opposite side compared to the box. That would provide a perfect place on the back of the front cross member to mount it. There are a lot of ways to mount this sort of thing, but I am a fan of using Rivnuts--I just find them cleaner and appropriate than most other methods.

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Then I moved on to the fender. I want to clean up as many components and get them out of the way as possible and one of those is the big windshield fluid reservoir so I opted to go with the later TD5 style and mount that on my fender on the wheel wheel liner. In order to mount it there, I really need to take off the liner, which I needed to do in order to weld a patch on it from a PO's clearance of a shock tower. I still need to weld it...maybe today... but I did pull back out the riv nut tool and add a few more mounting places to mount the reservoir...

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Everything needs to get done eventually, so I am finding it much easier to bite off these micro projects. Before you know it, things get done, little by little. I plan to have it in the garage all winter, so I am not too worried about it but I do want to have it completed for spring. Worse case scenario is I take some time off work to crank on it as I have so many more things to get done to get it even close to where I want it to be! And I am still waiting on my Intercooler so I haven't even started the cooling stack and it's mounting let alone it's plumbing... But overall, nothing intimidating.
 
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jymmiejamz

Founding Member
Callsign: KN4JHI
Damn you both! (Did you get the Astro version?)
That’s the one I have. It get used almost daily. It comes with a little valve to regulate the pressure which I don’t use. Not using it caused me to bend the 4mm piece. Other than that, no issues. If it broke today, I would buy the same one. I’ve installed hundreds of nutserts with it.
 
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