BMW Sienna 2.5i build

[jc43089]

I dropped the fuel tank last night, what a nightmare when it is half full.  I didn't figure out until i had it on the ground how to drain it.  The fill tube enters the tank down low, it comes off but there is a check valve inside so no fuel comes out.  I couldn't see the check valve until I got the tank down.  Then I stuck a screwdriver in to hold the check valve open and tipped the whole thing to pour fuel into a drain pan a couple gallons at a time and dump it into my car.  Now I need to clean it off and figure out where to add my fuel return fitting.  I got 1/4" line for the return, I would think that is plenty?  While I have access I am going to test the pump output pressure and flow to make sure I don't need to swap in something different.

[B C]

1/4" sounds fine to me, 

I would expect the pump to be just right as it was fueling 230hp before.

When are you going to splice the driveshafts together? I will be interested to see that

[jc43089]

snap said:

1/4" sounds fine to me, 

I would expect the pump to be just right as it was fueling 230hp before.

When are you going to splice the driveshafts together? I will be interested to see that

With the pump I just mean will it work ok because it was a non return system that will now be a return style.  If it has a pressure regulator integrated to the pump and the pressure is higher than the 3.5 bar regulator on my fuel rail then it should just never open and all will be well.  But if the pump is PWM controlled like my Volvo and other newer cars then I might have to do something different, or just see what it does with straight 12V.  Some part listings show "W/O pressure sensor"  so I'm not sure.

[jc43089]

Great news!  The fuel pump is just a regular motor/pump with a fuel pressure regulator right in the pump bucket.  However the regulator discharge shoots through a venturi which draws fuel from outside the pump bucket in to keep the bucket full at all times until the tank is completely empty.  And the FPR is too low of pressure.  So I will machine a plug to cap the hole where the FPR is supposed to go and fabricate a connection so my returning fuel goes through the venturi and it should work great.  I fail at pictures, I switched back to a flip phone and it takes pictures that aren't worth looking at.  I will have to bust out the old Canon powershot.

Also I was missing the bolt that holds the vanos spline piece to the end of the M54 cam, it is not listed separately as a part so you can't buy one.  A socket head cap screw would work but I would have to machine some of the head off to make it short enough though and then engagement of the allen wrench isn't good.  I found that an ARP bolt will work perfect though, so I ordered a pack of M10x1.5mm x 60mm long, I have 4 spares if anyone else is dumb enough to lose one of those bolts...

[B C]

Nice! Is that vanos screw the one with the left hand threads??

[Earl]

So the tank sorta has a stock surge tank inside? Weird!

[jc43089]

snap said:

Nice! Is that vanos screw the one with the left hand threads??

No it's just a normal bolt, the stock one has a female torx.  If I had an original one I would have had to face the end off anyway so I think the ARP will be a better solution.

Earl said:

So the tank sorta has a stock surge tank inside? Weird!

Yea pretty much.  Also it keeps the pump totally submerged to keep it cool even when the tank is not full.  It is open on the top so I imagine it just overflows when it gets full.  I will take some pictures.  It is a pretty cool design so I am trying to keep it functioning as close to original as possible.

[Jdesign]

jc43089 said:

 I switched back to a flip phone and it takes pictures that aren't worth looking at. 

They still make those?

In all seriousness Im so excited for this you have no idea. So I vote you get a tripod and just set it to take a time lapse. I bet a lot of people would love to see that!

[jc43089]

Jdesign said:

They still make those?

In all seriousness Im so excited for this you have no idea. So I vote you get a tripod and just set it to take a time lapse. I bet a lot of people would love to see that!

Yea, original Samsung Rugby, I used it long ago before I switched to a smartphone and now I am back.  I find it too much of a time waster, there is rarely anything useful on the smartphone but I can't control the urge to just pick it up and waste time so I am done with it.  We also don't have a TV at home so I am pretty much half Amish.  I like the tripod idea, most of the shots would probably be of me drinking beer and scratching my head...

Ok Pictars!

Fuel tank removed.

Pump bucket assembly.

Integrated fuel pressure regulator.

Venturi thing at the FPR discharge.

FPR discharges into the hole with the o-ring.  The flap to the left is where the fuel jets back in.

[Jdesign]

jc43089 said:

 I find it too much of a time waster, there is rarely anything useful on the smartphone but I can't control the urge to just pick it up and waste time so I am done with it. 

We also don't have a TV at home so I am pretty much half Amish. 

ME TOO. I have a love hate relationship with my phone. I find myself on it wayyy too much trying to find deals on things I dont need. I also find my self on it looking up DIYs and part numbers too. So its a total struggle.

I also havent had a TV for years. I have one now, but I use it as a TV monitor more than watching movies or anything. Obviously to look up parts and DIY's LOL

That tank is awesome and should make life easy. Do you have a deadline to when you expect this to be road worthy?

[jc43089]

Jdesign said:

ME TOO. I have a love hate relationship with my phone. I find myself on it wayyy too much trying to find deals on things I dont need. I also find my self on it looking up DIYs and part numbers too. So its a total struggle.

I also havent had a TV for years. I have one now, but I use it as a TV monitor more than watching movies or anything. Obviously to look up parts and DIY's LOL

That tank is awesome and should make life easy. Do you have a deadline to when you expect this to be road worthy?

I'm hoping to have it driving in a couple months.  3 car seats are tight across the back seat of the Volvo. 

I never posted anything but we had a son on the 2/17.  Theodore "Teo"  

[Jdesign]

Congrats man!

And that's a tight timeline. I have faith though, you seem to be chugging alone smooveeely.

[jc43089]

Made a brass fuel pressure regulator last night.  Not really a regulator just a plug.  It turned out pretty nice, I like turning brass.

[Jdesign]

Soft metal is fun to turn. It looks really nice!

[Daggerty]

Jdesign said:

Congrats man!

And that's a tight timeline. I have faith though, you seem to be chugging alone smooveeely.

Do you mean along? Instead of alone? Or bobsled?

[Daggerty]

Congrats on the 3rd slime ball.

That tank has a lot going on.

[jc43089]

Ok, Canon Powershot in action!

Conveniently the fuse panel is completely connected by plugs so I could get it out of the way.  Not much room in here.

A little trimming to the brake pedal bracket.

New bracket for the clutch pedal, 304 SS because that is what's in the scrap bin at work.

Pedal bracket welded on.

Slight modification to the fuse box.

Also had to remount the brake pedal switch to the other side of the pedal arm.

Installed!  It looks a little low in the picture because of the angle it was taken at but feels good sitting in the seat.  My wife tested it and approves!

I had a helper for a while, new oil filter housing gasket.  It isn't that old but it was so easy to get at right now and I had one so why not.  I thought I would put new o-rings on the plugs in back of the filter housing but this one has plugs with crush washers which is much better.

After work today I will stop at the local race shop, R&S Racing in Albert Lea, to get some -3 hoses now that I know the length to get the in car plumbing finished up.  I still need to figure out a cable throttle pedal.

[B C]

I spent too much time under the dash in the pedal area on Saturday so I can really appreciate what you are doing here. Nice fab work!

[KaiserRolls]

Awesome progress.

I laughed way too hard at the way those pedals look in a van haha

[jc43089]

Not much done last night.  I installed the master cylinder supply hose and pressure hose to the firewall, I got a rivet nut setter, el cheapo china one from Amazon, it works pretty good.  I used it first to mount the clutch reservoir to the fender.