starting my diesel swap, 4cyl MB diesel engine into 89 Astro

[tinworm]

Can the pedal be removed, from your intallation?
I thought I should be able to get a short drill in to drill the holes in mine, because there was room enough to remove the pedal.
Also, have you checked that the steering column still fits in?

I tested the removal of the pedal when I had it clamped in, but that was without the spring. I still need to test it now that its welded and make sure it could still be removed.

Steering column needs to be tested as well, though it should still fit based on measurements. (famous last words )

ok, pedal can be removed well enough with the steering column out, and disconnecting the spring is a lot easier than I thought it might be. Secondly, the steering column fits in well without impacting the pedal pivot area fortunately. I had measured to try and get it mounted behind the plugs, but definitely lucked out, as that measurement moved some when it was finally positioned

[tinworm]

so a few developments, finally got the clutch pedal worked out and fitting with the steering column.
The consistent issue was that the clutch pedal stop was too weak, and also in the way of some electrical connections that occupy the same space with the column up.

column installed with arrow pointing to the stop, that plug fits right into the stop area and cannot be moved, controls brights/turn signals, ect, lever activated from up the column-



Clutch pedal had to be removed and this hole filled in a redrilled. both these holes should be about the same size as a comparison-



Also my steering shaft extension all installed and lined up. Fortunately, it can only be installed one way, they make it pretty easy to avoid getting the wheel mis-aligned with the direction of the tires-

old and new-


new shaft installed-

[doyoulikeithere]

Looking Great !!
Cant wait to see and hear it rolling !

[Smiliesafari]

I believe that switch is headlights only. It's a push on/push off switch. You can move it wherever you want. Just fab a linkage to activate it. The turn signal wiring is in the connector on the opposite side of the column.

[tinworm]

ok cool, it fits right now, but I may move it if I need to. I was thinking it only controlled brights?

couple other little updates-

installed this nice set of drop spindles from meetthespeakers earlier suggested by you guys, worth every penny-



comparison-




very pleased with the new ride height-



the van is now actually within 1/4 of an inch level between front and rear amazingly-

[tinworm]

ive been working on the throttle linkage issue, adapting it to the chevy cable throttle. The MB throttle is done entirely by a bunch of small ball and socket spring loaded levers.

The biggest thing to work out is the return to idle, which is controlled by three springs in the MB application to move the fuel rack back to its stop when the foot is removed. There are two springs (inside eachother) off the back of the injection pump-



separated-



and theres a third big one on the firewall connected to the pedal from the inside-



The big one is the only one that has to be custom modified into a new throttle connection, it will end up on top of the diesel valve cover. Im glad that the astro has a really long cable that circles the entire compartment, gives a lot of options of direction. Im trying to rig something up that leaves the cable in approximately the same orientation as stock, to prevent kinks

[tinworm]

oiling almost resolved, i went through a few different remote plates.

This was the first one where I welded some 10-AN fittings to a 1/4 inch steel plate. It was pretty, but it leaked-



Went back in and welded around and around and around, 4 beads. It was ugly and didn't leak, and of course had I stopped to consider what I was doing, I probably wouldnt have warped the plate as bad and made it unusable except for a machinist to cut down. Sent it off to a guy on the mercedes forums to play with.

version 2-



Then I wised up and went with 1/2 inch steel plate, and drilled and tapped the 10-AN fittings instead, which was a lot cleaner-




fits nicely with the transmission plate, im going to be using pushlok hose and fittings for my connections. I was looking for a basic oil cooler I can adapt to the 10-AN, but after reading a thread over on a mercedes forum written by user mach4 where he diesel converts a Mercedes SL using the same motor series with a similar oil filter issue, ill be following what he did and tapping the holes in the stock MB oil cooler I have since that is possible and looks very clean.



The major hurdle im waiting on still is the power steering line bump fitting ends so I can make custom ones. I do not recommend ordering from "parts dave" for your domestic vehicle, its been 8 days and hasn't shipped yet.

[tinworm]

couple updates-

MB vac pump hooked up to stock GM line, still need to add a port for vac shut off when I get to that, but for now I should have power brakes when I test fire this sucker



New fuel filter installed, made a bracket to hold a 500FG racor fuel filter, huge leap over the stock filter that was for the diesel. Combined water separator as well, nice piece of hardware




also have the oil filter location mounted. Just waiting on a new oil cooler from summit right now, then I can get the three lines made up that I need. I probably already mentioned in this thread, but this moroso head has a provision for a pressure gauge outlet, and a small secondary output I can use for turbo oiling. With the exception of not having an oil thermostat, I should be able to do everything else that the stock oil filter did.
Was looking to adapt the MB oil cooler, but the one I have is so beat up it seems a waste of time making custom line ends to fit on it, so I went with a new one that already has NPT ports on it I can easily adapt to -10 AN

easy access-



one short line might be a bit cramped between the plate and filter head, but worst case scenario, I make a longer one and loop around-



glow plug relay mounted to GM airbox, this way the wiring harness for it is close to the wiring harness I will be creating for the engine. Fits nicely here though

[mdmead]

Really enjoying this build!

[doyoulikeithere]

Really enjoying this build!

Mee Too !
Nice work TinWorm!

[tinworm]

Really enjoying this build!

Mee Too !
Nice work TinWorm!

thanks guys!
Im hoping my new strategy of working on it will pay off in getting it done. Ive come to an agreement with the fiance that I work 1.5 to 2 hours every day after work on this project, in the hopes that it be yard drivable by the end of this month. fingers crossed. Need to consolidate some property, and the van needs to come off the lift for a different project car Im losing parking for this month.

Today made some progress on hydraulics-

brakes hooked up as it was. Im not sure if this was the original design with the splitter, but it was what was on the van when I started, so I just recreated it with mostly new hardware and following the same areas that the stock lines used to



brake side-



junction area-



also hooked up the clutch line. Im not totally happy with the number of connections I made in this line, a total of 5 pieces, but I adapted the fittings on both the slave and master to regular brake line, then used a generic flex line from some unknown application to compensate for vibration. Im considering building a solid bracket for the body side of this flex line to limit broken line issues over time



also decided to pull the fuel tank, here it looks pretty good under its protective plastic shielding-



but its pretty badly surface rusted, it was empty and easy to handle, so ive pulled it to refinish it with rust converter




also this allowed me to get rid of all this rusted fuel and brake line above. Im going full rubber for the fuel lines instead. And I have the obligatory rusted out rear brake line above the fuel tank id really just felt like removing. Ive never owned a single astro where this line was still intact. Everyone runs the line through the tank straps



notice this vice grip! ive owned this van for years and never noticed it



all the parking brakes have been ripped out up to the pedal for the eventual installation of a handbrake

[LiftedAWDAstro]

Getting closer! Can't wait.

[doyoulikeithere]

Its looking great and coming along nicely !!

Actually working on your project for a couple of hours every day ?
#-o Why didnt I think of that ?!?! #-o
Lol.

[tinworm]

lol ^^^

so cleaned up and refinished the top of the fuel tank with rust converter. Fortunately, though it was pretty rusted, it was not through anywhere, should last a good long time with this treatment. Once it dries Ill pull the bottom shield and do that side and reinstall




also my oil cooler arrived! plenty of space for it where the A/C was on this van-



Made a path through the radiator side shielding for the cooler lines, and mounted it in front. This cooler is approximately 2/3rds the size of the MB cooler, but the lines are travelling another foot and a half to get to it so Im hoping for about the same effect in cooling, plus this is way more advanced in design. If I find it inadequate, the way ive set it up means I can go with a larger unit from the same manufacturer and use the same basic brackets, only adding one piece. As it stands its very strong, doesn't need any further bracing



With the oil cooler what stands to be completed next is oil lines, and turbo final installation with all the bits, including feed line and drain lines. Once thats done and fuel is hooked up (pics to come of that), im wiring, throttle, and power steering away from ready to test drive. Power steering im going to do after the test, ill cut the belt for now until I have lines worked out

[tinworm]

todays update-

The underside of the fuel tank was crispy, but not terrible, with the exception of one area where it was pretty rusty, but not through fortunately




refinished ready for installation. Glad I went through with this, I doubt this tank had another winter before it rusted through, especially on the top-

bottom-


top with plastic shield installed-


oil system all hooked up with the exception of the turbo feed line, though I did have the opportunity today to get that made, so I should hopefully get things put together this weekend for the turbo side.
cooler-



lines run by the fuel filter, and you can see here my shut off valve for fuel on the inlet side of the filter-



moroso head. I can't say enough about how nice this oil filter head is, you can see here the small port on the top ill be using for turbo feed, and the port in the middle front will eventually be for my oil pressure gauge.

The way I have this plumbed flow wise is engine, cooler, filter, back to engine. The reason is just in case any crap in the cooler gets dumped downstream, the filter will pick it up before it gets to the motor