TDI Ranger Build - Page 4

greengeeker · 08-06-2012, 10:13 AM

Quote:

Originally Posted by shane96ranger

Cool project. I don't know how far I'd trust that radiator support though.

You are correct sir. I'm going to box in my brackets as they were flexing almost as much as the rubber mounts.

**shane96ranger** · 08-06-2012, 10:17 AM

I can't believe how many of these things have rotted radiator supports. Seems like the first thing to rot out anymore.

My F150 is pretty bad, I'm gearing up to replace it soon (before winter).

**snoranger** · 08-06-2012, 10:18 AM

Quote:

Originally Posted by greengeeker

You are correct sir. I'm going to box in my brackets as they were flexing almost as much as the rubber mounts.

I think he was referring to the rust. The rad support rusts from the inside out and once they start, they go fast. I've seen a lot of them that the entire bottom section is just gone.

**shane96ranger** · 08-06-2012, 10:23 AM

Quote:

Originally Posted by snoranger

I think he was referring to the rust. The rad support rusts from the inside out and once they start, they go fast. I've seen a lot of them that the entire bottom section is just gone.

You are indeed correct. I'd replace that thing now while it's torn down that far.

greengeeker · 08-06-2012, 10:24 AM

And here I thought this was just a MN thing...

**snoranger** · 08-06-2012, 10:29 AM

Quote:

Originally Posted by greengeeker

And here I thought this was just a MN thing...

It just a "anywhere they use salt on the roads" thing.

IAmTodd · 08-06-2012, 10:48 AM

I'm looking forward to the outcome. I think a diesel is in my Explorer's future.

Rose2300 · 08-06-2012, 01:51 PM

sub'd. my parents just bought an 02 jetta tdi w/70k on it and it has a suprising amount of pickup for how low the power rating is. i love the acceleration on the freeway with out having to downshift!

b411sac · 08-12-2012, 07:29 PM

Any updates?

Sent from my ADR6425LVW using Tapatalk 2

greengeeker · 08-19-2012, 10:30 AM

Quote:

Originally Posted by b411sac

Any updates?

Yup. Been working hard on the truck and other peoples' TDI's.

greengeeker · 08-19-2012, 10:39 AM

The Ranger of course was fuel injected which meant it's in-tank fuel pump was putting out around ~60psi of fuel pressure which is way more than the 4-7 psi I need for the tdi. So I need to drop the tank to get at the fuel pressure regulator which is also mounted to the sending unit which is convenient since I also need to drain 1/2 of tank of 6 yo gasoline.

Out comes the tank, my fuel pump used to de-fuel mis-fueled tdi's and my spare battery:

Out comes the sending unit so I can get every last bit of gas out:

And here's the sending unit:

In the above pictures you can see the fuel pump, fuel pressure regulator and some sort of EVAP check valve. I'm going to remove the last two and reuse the connectors on the sending unit for return lines (more on that in Part 2).

Here are the connectors as they are installed on the Ford lines. I simply cut a slit to remove them from the lines.

And here they are on the sending unit:

I wasn't too crazy about the return lines the way they were on the top of the sending unit - I figured they would aerate the fuel when the fuel level was below 3/4 tank. To remedy this I went to the bone yard and picked up a sending unit from a diesel superduty for the stainless lines. Don't laugh, this was my first attempt at TIG welding stainless.

greengeeker · 08-19-2012, 10:50 AM

Diesel Vw's are left with the fuel tank portion of the EVAP system from the gas cars. A common mod is to eliminate this system to gain more fuel capacity and therefore longer range...for my Jetta this increased my capacity from 14.5 to 16.5 and my range to around 850 miles.

I of course no longer have a need for the EVAP system and will be deleting every part and using the EVAP line as a fuel return line.

Here is the tank with the hump to the left of the fuel sending unit hole:

I took some measurements and calculated this volume to be worth 1.7 gallons. That plus the volume in the lines should make it at least 2 additional gallons.

In this picture I posted earlier you can see another EVAP check valve on the top of the hump that relieves any built up vapor in the tank to the EVAP charcoal canister located above the spare tire:

I'm going to use this fitting and tee into the main vent line that goes up to the fuel fill neck with some hardware store bling.

Here it is all ready to go back in the truck:

08-06-2012, 10:24 AM	#41
greengeeker Member Join Date: Jul 2012 Location: Cambridge, MN Engine: 1.9L Class: 2WD street Posts: 117 Rep Power: 2 iTrader: (0)	And here I thought this was just a MN thing...
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08-06-2012, 10:48 AM	#43
IAmTodd Junior Member Join Date: Jun 2009 Location: Johnstown, PA Year: 1994 Make: Ford Model: Explorer Engine: 4.0 Class: 4x4 Posts: 45 Rep Power: 8 iTrader: (0)	I'm looking forward to the outcome. I think a diesel is in my Explorer's future. __________________ 2006 Saab 9-3 Aero \| 2.8 turbo \| 6MT \| 280whp/325wtq 1994 Explorer XLT \| 4.0 V6 \| 5MT \| A whole lot of problems!
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08-06-2012, 01:51 PM	#44
Rose2300 Member Join Date: Apr 2011 Location: ID Year: 1996 Make: Toyota Model: 4Runner Engine: 3.4 Class: 4x4 Used For: off road beast Posts: 1,068 Rep Power: 8 iTrader: (0)	sub'd. my parents just bought an 02 jetta tdi w/70k on it and it has a suprising amount of pickup for how low the power rating is. i love the acceleration on the freeway with out having to downshift!
	Tweet

08-12-2012, 07:29 PM	#45
b411sac Junior Member Join Date: Oct 2010 Location: Ft. Drum, NY Year: 2005 Make: ford Model: ranger Engine: 4.0 Class: 4X4 Used For: EVERYTHING Posts: 51 Rep Power: 6 iTrader: (0)	Any updates? Sent from my ADR6425LVW using Tapatalk 2 __________________ I can't win for losing.
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08-19-2012, 10:39 AM	#47
greengeeker Member Join Date: Jul 2012 Location: Cambridge, MN Engine: 1.9L Class: 2WD street Posts: 117 Rep Power: 2 iTrader: (0)	Fuel System, Part 1 The Ranger of course was fuel injected which meant it's in-tank fuel pump was putting out around ~60psi of fuel pressure which is way more than the 4-7 psi I need for the tdi. So I need to drop the tank to get at the fuel pressure regulator which is also mounted to the sending unit which is convenient since I also need to drain 1/2 of tank of 6 yo gasoline. Out comes the tank, my fuel pump used to de-fuel mis-fueled tdi's and my spare battery: Out comes the sending unit so I can get every last bit of gas out: And here's the sending unit: In the above pictures you can see the fuel pump, fuel pressure regulator and some sort of EVAP check valve. I'm going to remove the last two and reuse the connectors on the sending unit for return lines (more on that in Part 2). Here are the connectors as they are installed on the Ford lines. I simply cut a slit to remove them from the lines. And here they are on the sending unit: I wasn't too crazy about the return lines the way they were on the top of the sending unit - I figured they would aerate the fuel when the fuel level was below 3/4 tank. To remedy this I went to the bone yard and picked up a sending unit from a diesel superduty for the stainless lines. Don't laugh, this was my first attempt at TIG welding stainless.
	Tweet

08-19-2012, 10:50 AM	#48
greengeeker Member Join Date: Jul 2012 Location: Cambridge, MN Engine: 1.9L Class: 2WD street Posts: 117 Rep Power: 2 iTrader: (0)	Fuel Tank Mod Diesel Vw's are left with the fuel tank portion of the EVAP system from the gas cars. A common mod is to eliminate this system to gain more fuel capacity and therefore longer range...for my Jetta this increased my capacity from 14.5 to 16.5 and my range to around 850 miles. I of course no longer have a need for the EVAP system and will be deleting every part and using the EVAP line as a fuel return line. Here is the tank with the hump to the left of the fuel sending unit hole: I took some measurements and calculated this volume to be worth 1.7 gallons. That plus the volume in the lines should make it at least 2 additional gallons. In this picture I posted earlier you can see another EVAP check valve on the top of the hump that relieves any built up vapor in the tank to the EVAP charcoal canister located above the spare tire: I'm going to use this fitting and tee into the main vent line that goes up to the fuel fill neck with some hardware store bling. Here it is all ready to go back in the truck:
	Tweet

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