A2 1.4 TDI AMF - Simplified wire loom able to run engine in test bench/stand | how to?

dieselfan

dieselfan

A2OC Donor
Dear like-minded ?
I have been quiet during the winter, mostly due to a major refurbish of my garage. I need a better workshop to be able to fulfil my planes...

Due to that I have 5 1/2 A2 ( 3x AMFs) and that I have decided to standardize on the AMF engine and it is decided that one complete spare engine is needed....
Some collect stamps, others collect battle tanks... while I would like to spend time with my AMFs in the test bench.... and I want to have a spare engine available at all time. All my cars are long runners or very long runners, so if I suffer a real engine problem, I swap with the spare and test the failing one in the test bench. There have been to many hours under the car, outdoor in bad and cold weather... health is not the best and it seems obvious to take such a decision.

Most of the test bench is already in place BUT, I have not a clue how to make a "just-have-the-needed-functions" wire loom. I have a donor AMF 2002 but I do not have the knowledge of where to cut and where to joint the harness. I do not need any information from the dash like; rpm, warning lamps, fuel level, temperature or DIS.
What is the recommended approach ? Is it doable? Can it be bought? Any good ideas?
 
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I applaud your enthusiasm. Think there is probably more to "just bench run" an engine than jumps to mind. Fuel source that is safe, exhaust that is also safe, cooling system unless only for VERY short runs etc. You may already have the perfect solution - your donor AMF that is hopefully still installed in a car. All the systems required are there and anything that is not needed can be disconnected or removed ( climate, power steering, headlights, driveshafts, wheels etc ). You would also still have OBDII useful for fault diagnosis.

The slam panel could even be off to the side with the radiator and only the intercooler in front of the engine.

You will still need to start the engine possibly including working glow plug and be able to stop the engine.
 
Thank you G. The reason for not mentioning the "additionals" is that they are more or less in control. The mechanical work is not anything I am scared of jumping into. I mill, drill, weld, glue, turn and cast fairly ok. When it comes to wire looms I am useless..
I have a robust design for the test bench, used for 400hp diesels and 820hp petrols.
Fuel tank is an F3 fuel cell.
Exhaust suction unit approved for professional use to get rid of the exhaust.
Flywheel protector made of a broken gearbox which again let me use a standard starter.
Test bench has standard A2 radiator and IC.
Different rules over here so I will have to pay owner tax for the donor for the rest of my life if I cut the frame. If I use the test bench, and recycle the donor I get 350£ back from the government.
 
Not implying you were scared or not capable, just what I thought would have been a quicker more convenient route. You will still need electrics to run and power the injector loom, the ignition / shut off and the needed vacuum for that. ASV and turbo control systems, earths etc Possibly need both the ECU and the CCCU and then the instruments and their looms. As said before I do not think it is a very simple set up.
 
Sorry can't help you with that one.

Got to ask why you want to run on a bench? I can understand wanting to swap in a spare engine, but to need to do that the existing engine will probably be beyond repair otherwise just fix in situ.

Would have thought rebuilding some more frequently needed parts may be a more fruitful "hobby" and possibly far less regulations to worry about.
 
Why run in a bench/stand? : Typical scenario: I need an engine, only available on the private marked is sitting in a car, has been in front collision and cannot be started.... I take it out of the wreck, bring it home, into the bench, run it for 4h, I can verify the condition and then into the car, well aware that it is in good condition before I take the big job and fit it to the car. I will be able to dyno it. Plan to be able to fit a hydraulic pump too, will feed a diamond wire saw.
 
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dieselfan said:
Used design is tested and in commercial use for up to 400hp 1/2T heavy diesel engines. Why should this design not take my sweet little 75hp 330 Ibs engine?
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Go for it!
It would be most interesting to see what the donor engine produces, and then add mods, and report benefits or loss in power.
Real life data is better than claims from tuning companies.
I assume the radiator and Intercooler will be fan assisted if you will load the engine on your dyno?


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Jellybean said:
I assume the radiator and Intercooler will be fan assisted if you will load the engine on your dyno?
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Yes, my plan is to have IC and radiator assisted with one common radiator fan.
Dyno is not priority one. I will probably use stetoscope and temp sensors most of the time.
 
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