[joeblack5]

Some more machining of the extension of the transmission shaft. It fits perfect. . More bolts in my adapter contraption.
Hung the tdi motor.. smooth ..
Mounted the cab without raising it. Just to confirm clearances. Fits nice. The tires are 40" ..if I do not need to raise the cab for tire clearance then I will leave it like this.
Need to cutout the aluminum adapter plate a little more to easily mount the starter motor with the cab on.
Now more time can be spend on the clutch... cable or hydraulic. At the clutch pedal the attachment moves 27.5 MM... The first lever is 155 MM the one inside the bellhousing 85 MM.
So at the clutch plate the movement is about 15MM. sounds reasonable, will see what the TDT clutch requires
Also now more in the picture are the remote oil filter....front engine mount/ alternator mount.
Johan

 

[joeblack5]

Since we were so happy with it all fitting we decided to press on.
The water pump inlet is pointing the wrong direction.. our oldest daughter is wrenching on it. Seems it can be modified .

We made some oak " motor mounts"
Then Tanya crafted the cardboard pieces that tie it all together.

With the original M180 the engine hangs in swing arm. I do not see it critical where the swingarm is located along the cross member.

With the tdi a little under and angle and the moor mounting options favouring the passenger side we decided that the pivot pendulum has to move direction passenger side as well. A similar horse shoe brace that is used in front of the M180 is made no under the oil pan and the pendulum is behind the crossmember. All will be bolted so that the oil pan can be dropped easily. Also to benefit the removal of the thermostat housing / water inlet that now is hidden behind the driver side motor mount.
If anyone see a problem please comment.

The original tdi motor mounts and some additional will be used. The alternator will be integrated on the passenger side.

 

[joeblack5]

So please comment on my proposed action above. The motor mount pendulum/ swing arm has moved 4" down and 4" to the passenger side. The pendulum itself has changed from about 2" ctc to about 4"ctc. Original it was on top of the crossmember now it will be 2" to the rear. So it will allow some torque on the crossmember as well. I do not see a problem with this being a lighter engine but of course others have a better perspective.

Thank you,
Johan

 

[MicMoor77]

It seems like you would want to keep the pivot point at the front of the engine along the centerline of the vehicle. Or, I inline with the transmission if it is not in the center of the vehicle.

 

[joeblack5]

I agree. Although first I thought that because of the construction of this TDI engine that I would have to move it over . Here some pics of the first attempt..
Unfortunately I do not have the original M180 front motor. Wonder if I can jam that in there.

 

[MicMoor77]

I agree. Although first I thought that because of the construction of this TDI engine that I would have to move it over . Here some pics of the first attempt..
Unfortunately I do not have the original M180 front motor. Wonder if I can jam that in there.

It your motor is not centered, you can create your mount to be cantilevered. If you need dimensions or pictures of the original, I can help.

 

[joeblack5]

Thank you MicM,
Today I spend some time to liberate a motor mount out of my other 404... . Will see if it can fit tomorrow with the TDI motor mount.

 

[joeblack5]

The m180 motor mount does fit. I do not like the weight distribution to the attachment on this TDI AHU motor. In this picture the center of the crankshaft is about 4-1/2" above the crossmber tube.

Johan

 

[joeblack5]

More work on the front motor and alternator mount. The water pump pulley is a separate v belt that would require an additional tensioner. To keep the design clean and save space we decided to replace it and incorporate it in the serpentine belt loop.
To get more friction with the crankshaft pulley an idler was added. The alternator is pivoting around the top bolt.

 

[joeblack5]

It goes slooooowwww. To many other things that time can be spent on to.

The passenger side motor mount in all it's glory. The driver's side fits as well.

The serpentine is 41" 6 rib... Looks a 40" would be a better fit.

Next stop will be the remote oil filter.

 

[TRUKTOR]

Here are some photos of a clean installation of a VW engine into a 411. Unfortunately, the photos do not clearly show the front mount. I might have better shots somewhere. Note the strut from the front of the engine to the radiator. Also, some shots of the remote oil filter mount.

 

[joeblack5]

Interesting images.

I have to look up if that is the original radiator of that unimog. First I thought that it had an intercooler on the side but after looking at the turbo setup that appears to be the air filter.

It is nice that they were able to maintain the steering pump. In my setup I position as much to front as I could ,like with the m180 but as a result the crossmember is in the way of belts going downwards.

That is an intriguing front motor mount. Looks like they used a threaded rod along the crossmember, but not sure why.

One day I hope that mine will be that finished looking.

 

[joeblack5]

A little bit of work.. the original m180 has extra braces to the bell housing.. I would think in pull arrangement.. they are strips, so push would buckle. Mercedes must have a reason so I will follow.
I will pull all the way from the bell housing to the front motor mount. This just to show the principle.. actual rods will be M12 thread. I will reinforce the front motor mount so it will able to handle the additional forces.

 

[joeblack5]

Oh no, I forgot to make pics.

Front motor cradle reinforced and tested.
Shorter serpentine Installed. Looks much better.
Took motor out to measure the transmission input shaft one more time..made drawing of shaft coupler.

Started looking at exhaust routing but figured it would be better with the cab on.

Looked at location of throttle pedal ...this is drive by wire.

Some fine tuning of starter motor mounting.

Sorry about the pics.

Johan

 

[joeblack5]

Second try,
Time goes fast and other projects needed attention as well.. here is our 1820 log house.. the path to it is not so wet right now so the gd240 was perfect.

On the 404....the material for the transmission shaft extension / coupling is in the lathe and also the remote oil filter is making progress.

Johan

 

[joeblack5]

Another small issue resolved.. the original coolant intake pointed backward... Besides being in the wrong direction it also interfered with the new motor mount. Originally I tried to remake the original one and rotate it 90 degree but this one from a VW gasser 1.8T does exactly what I want. This one is plastic but an aftermarket aluminum one is available.

 

[joeblack5]

One month idle time...filled with higher priority projects..but now back on the ball.

Today finished the extension shaft..The VW shaft has a bore that fits over the clutch pilot stub of the 404 shaft.. then a sleeve that is gones to fit precise around the splines of the 404 keeps the two pieces in one line.

The spline from the old clutch disk is bolted to the sleeve.

Next step is make an adapter for the end bearing on the VW shaft.

 

[joeblack5]

Some more parts..the VW tranny tdi combo does not use a pilot bearing.. the original bearing in the tranny was a tapered one with an od of 45 mm and ID of 22 mm.. the closest deep groove I was able to by was a 44*22*12.
So I had to machine a spacer with a wall thickness of 0.5 mm.. our oldest did the rough in work at the lathe.. this being an 50 yr old 3/4HP south bend ....not much roughing in...but it worked.
Getting closer to final assembly I decided to do some paint work..

All tolerances worked out well.. the tranny shaft can slide 1/16" axially..

 

[joeblack5]

The last two pics from this boring transmission stuff .
To prevent the pilot bearing spacer disk from backing out I drilled the m7*1 and tapped them to thru holes.. nice enough my HB cheap tapset had a M7x1 tap...amazing..
Three screws with washers keep it where it belongs.

The next picture is taken thru the inspection hole in top of the 404 belhousing..
Another thanks to Choprboy for the clutch spline he shipped to me.

In the mean time I cleaned the tdi's manifold and intake from carbon/ oil crap. Took a peak at the cam shaft ..looked ok..and made a plate to block the exhaust EGR.

 

[joeblack5]

Installed engine and motor mounts. Next step is testing the wiring harness..