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635 Rebuild cont.

Hey if I take that job over at Morton, can I stay in your garage for a few days? LOL When you get that airdog in, I'll take that walbro off your hands.

I thought you were closer to getting your motor back that this. I'll have to get that t-valve in the mail to Mr O Thade. Sounds like parts are coming together.
 
jhornsby3 said:
Hey if I take that job over at Morton, can I stay in your garage for a few days? LOL When you get that airdog in, I'll take that walbro off your hands.
Click to expand...
No Problem, I'll even throw in a couple of rubber mats and a blanket if it gets cool. Besides, that's where I keep the sandpaper and polishing wheels. The good parts are locked away though...no touchy.

jhornsby3 said:
I thought you were closer to getting your motor back that this.
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You hold on to that thought, I'm tired of the heavy lifting.

What "T-Valve" for Orionthade; fuel as in fuel t-valve for water drain off FFM?
 
Yeah I told him he could have it since I put larger fuel lines in with the Racor filter. Found it in the tool box when we got here to Boise.

If I take a job there I'll be pulling the trailer over. Most likely in feb or march. Then you can abuse me working on your pick up too.
 
Paveltolz said:
Been working things out in my head while patiently waiting for motor updates
UPDATE: A batch of new cams are in...don't know if one goes in my motor or not...update over.:cheers2:

Ted included a few items in the purchase::nanawrench::present:

1. Two FS-2500 bypass filters. New in box!:thumbsup:
View attachment 35495
One ea. for engine and transmission. I have two methods worked out for mounting. Horizontally underneath between cross frame rails on the passenger side or in the bed, driver's side. The wife suggested I get a tool box that fits in the space that is no wider than the fender well to keep it out of sight. Gotta love it when the Frau suggests truck toys! Will have to check on hose lengths though. Ted's kits have the stainless braided hoses and I'm not certain they are long enough to make it from the Bed to the transmission with the extended cab. Guess I could use couplers to extend them. Talked to Greg at LS and will pick up an Amsoil "Sandwich" adapter fitting for the OEM filter. I guess a full flow set up is needed and one can't simply run things through the bypass only. Not certain as to why. I welcome input without reference to duct tape.:agreed:

2. AirDogII DF-165.
View attachment 35496
Not so new but freshly cut out from his truck. It needs a few parts like the return line adaptor for the filler kneck and such but it will mount up nicely where the Walbro and Wix pre-filter's are currently sitting on the inside frame rail. Ted had it on a vertical mounting bracket inside a toolbox in the truck bed so there is PLENTY of hose. He had to cut the wiring harness at the pump to remove everything but there’s plenty of room to splice the connector back in place.
This leads to my second question: Is the AirDogII harness even necessary? The OEM LP and Walbro worked fine with the 12v they get through the OPS as needed, so why would the AirDog? I sent a query to the AirDog techs but it’s a weekend. Can’t hurt to get some opinions.
Third Question: If I do need the AirDog harness, that leaves the OPS to LP circuit open without a load so will that be an issue? No electrical tape answers either please.

I did get some more polishing work done on the Peninsular Upper Intake Adapter
View attachment 35497

Oh, and I made some improvements to the Aluminum Billeted Bow Tie pictured earlier.
View attachment 35498

Amazing what patience, and 100grit, 180gr, 220gr, 320gr, 600gr, Steel Wool, 1000gr, 2000gr sandpapers plus mag wheel polish, elbow grease and 6" denim, cotton buffing wheels and microfiber towels will do. Oh yeah, and some spare time.
:bling:
Now that I have the technique down, I can start on the T-Stat manifolds and finish up the other pieces. They won't shine like the Bow Tie as they are still textured, but they'll look good enough.:coolgleamA:
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the bypass filter won't flow enough oil for proper engine lubrication hence the need for the oem full flow. I would think you'd need the ops circut for a signal for the airdog to retain the factory safety system
 
ak diesel driver said:
the bypass filter won't flow enough oil for proper engine lubrication hence the need for the oem full flow. I would think you'd need the ops circut for a signal for the airdog to retain the factory safety system
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Thanks for both pieces of info Les. The FS2500 video shows a very high flow rate but that's marketing...Amsoil may just be in the future as an OEM replacement. Best of both worlds. Greg at LS has a sandwich adaptor from Amsoil that will allow for an easier install and I can use the WIX filters at the OEM location. Saves $$ but still have to deal with filter changes under the motor with the 4x4 joy in the way....
The power to the AirDog and completing of ECM signal paths has me concerned which is why I asked. 12v is 12v to run the thing and if it comes from the OPS, it is at the right time and shut down when needed. If it comes from the Key On and bypasses the OPS safety, then that's un-good to my way of thinking.
 
Spoke with Kyle at AirDog and "The harness is simply to have the pump run on keyed power and also keep it fused separately from the rest of the truck." So I take that to mean I can use the OPS powered circuit to run it with. I ordered some necessary parts to allow the installation to proceed without using coathangers and such. Called Greg at Lubrication Specialists to order the Amsoil adapter and a few other parts to make the FS2500 go in that much smoother.
Upgraded 4x4 actuator and harness should be here later this week so I'm looking forward to a few packages over the next few days.

Now to sort out the oil in coolant issue the Passat presented today...no coolant in the oil though so that's good...right?
 
Paveltolz said:
Spoke with Kyle at AirDog and "The harness is simply to have the pump run on keyed power and also keep it fused separately from the rest of the truck." So I take that to mean I can use the OPS powered circuit to run it with. I ordered some necessary parts to allow the installation to proceed without using coathangers and such. Called Greg at Lubrication Specialists to order the Amsoil adapter and a few other parts to make the FS2500 go in that much smoother.
Upgraded 4x4 actuator and harness should be here later this week so I'm looking forward to a few packages over the next few days.

Now to sort out the oil in coolant issue the Passat presented today...no coolant in the oil though so that's good...right?
Click to expand...

No coat hangers or duct tape???:rolleyes5: That's what kept the Army rolling!!:hihi: Isn't that the "It'll get it running until the parts on order come in" method???:skep:

Check to see what kind of amperage the AirDog pump draws compared to the OEM lift pump. If it is close to 1.5 times or more greater, seriously consider using the OPS to energize a fused relay to power the AirDog so you don't run the risk of contact failure in the OPS at a very inopportune time (like pulling that 5% grade with the camper at 10pm on vacation) due to the increased current draw, since we all know that the OPS is prone to failure electrically. That way if the OPS does happen to fail, all you have to do is pull the switched lead of the relay off the OPS and run it to a 12V keyed source like one of the fuses in the underhood fuse box a foot away.

What year Passat? There were some years with the newer 2.0 TDI with OHC bearing failure problems. Have you pressure tested the cooling system to see if you get coolant into the oil yet?
 
Passat issue is a common one as it turns out. Limited to the oil cooler injesting oil and mixing with the coolant. Oil pressure is higher than coolant system so it's one way. New unit installed, will flush out the system tomorrow. Trying to snow on me and the sun went down. Screw that!

Parts started arriving today, more over the next couple of days. No matter, I'll be driving the Jetta to Las Vegas to link up with 635 at the NHRA "Big-O" event this weekend.

Ordered two "Pork Chop Wheel Well Storage Units," passendger and driver's side. Driver's side will hold the by-pass filters and the small stuff I always access like 2-stroke oil and such. Passenger side will hold the jack, extra oil, jumper cables etc. Big box behind the driver will now be used for secure 'trunk' storage on an as needed basis.
Wheel well storage.jpg
I wasn't going to go for them both tonight but the wife said, "They look good, go for it." Sure do love that gal.

635 is in Seligman AZ tonight. He had a great meet with TurbineDoc and Pepperidge in LA before heading west. Drove US-191 with the trailer from Morenci AZ to Egar AZ. That's one twisty road but I know he had fun.
 
Hey Pav, all you have to do with the air-dog harness is run your constant hot and grounds to the battery, then where you would tie the other hot into a key on source, just use the factory lp hot lead. That way it is still controlled by the ops/ecm but powered up directly from the battery. i have the ddrp from fass on my truck and it was a really simple install. Granted i stuck with the key on power on mine but it can easily be wired how i just said.
 
1995yukon65 said:
Hey Pav, all you have to do with the air-dog harness is run your constant hot and grounds to the battery, then where you would tie the other hot into a key on source, just use the factory lp hot lead. That way it is still controlled by the ops/ecm but powered up directly from the battery. i have the ddrp from fass on my truck and it was a really simple install. Granted i stuck with the key on power on mine but it can easily be wired how i just said.
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Very much appreciated. Its kinda scary...I can actually see in my mind's eye how that will run. Normally I need pictures or schematics...thank you.
 
Paveltolz said:
Very much appreciated. Its kinda scary...I can actually see in my mind's eye how that will run. Normally I need pictures or schematics...thank you.
Click to expand...

Remember the old adage about the updates in the Army"? Pictures were only for Warrant Officers to use, because invariably the example form was filled out wrong compared to the Regulation covering it. Always follow the instructions, not the picture!
 
Husker6.5 said:
Remember the old adage about the updates in the Army"? Pictures were only for Warrant Officers to use, because invariably the example form was filled out wrong compared to the Regulation covering it. Always follow the instructions, not the picture!
Click to expand...

Nope.
 
Tins are done
IMG_0861.jpg
Yes Orionthade, that's your old oil pan and valve covers. The worked them over pretty good at SLC Chrome before dipping them.

:bling:

Guess I need to knock out the final work on the aluminum stuff.
Detailing...it is never ever 'finished':agreed:
 
OrionThade said:
Wow. Those look good!
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You should see them in person...seriously. Drop by any time. Did the T-Valve work and any progress on the DVD player? You're probably like me these days, slammed with work and prioritizing the time off.:hello:

Yeah, rust is a concern but I figure if I don't scratch them up on install, they should last longer....if only.:nonod:

New glowpulgs and injectors ordered for the build. I should hear something with regard to the cam in the not to far and distant future as a little bird, ok, a big bird told me some units had come in.:thumbsup:

Time to do the brakes on the Passat and then figure out just where that @#$%^ brown wire from C100 to C120 (transmission) can be best accessed to complete the upgraded transaxle actuator install.:skep:

Then there's still the other stuff. I think I'll stop here and take a nap.:rof:
 
Chrome looks Great! You're probably a pioneer with that detail job but it'll look good at the cruise night. :D :thumbsup:
 
btfarm said:
Chrome looks Great! You're probably a pioneer with that detail job but it'll look good at the cruise night. :D :thumbsup:
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Not sure about Pioneer, but definately going over the top a bit. Boredome I guess.

4x4 actuator upgrade from the old Thermal unit completed. There's something else wrong though because 4x4 still isn't engaging. Time to dig out the multi-meter and the test listings and start checking voltages etc. Something else to do in the meantime.
Two week road trip coming up though so I'm not in a big hurry. Wouldn't matter if I was I guess.
 
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