2006 Volkswagen Jetta WVO Install (Page 2)

It has taken several more days to finish the install. Mostly because of not trying to cut corning and just slap the kit in and some because some parts such as the fuel line were the wrong size and the correct size had to be ordered.

Day 4

Day four was only a half day it was spent running the header hoses and fuel line from the tank in the trunk to the front of the car. In order to install these hoses the plastic under the car and the heat shield was opened.

Here is a view of the hoses running from the rear of the car to the front. One of the hoses also has the aluminum fuel line run inside to heat the WVO as it goes from the tank to the front of the car were it is filtered and headed before being burned as fuel.

This is what the hoses and fuel line look like once install in the trunk. They get connected directly to the HotFox which has already been installed into the custom tank we completed on day one and two of the install.

This picture is the hoses all installed with the heat shield and plastic all back in place.

Here we have installed the temperature sensor in the heater line running to the heat exchanger and mounted the finial heat exchanger under the battery battery box.

To finish the day we installed some of the remaining wiring for the Greasecar controller system which will handle all of the switching and purging from WVO back to diesel. First the controller brain box was connected to the wiring hidden under the center console and then wrapped in a towel and snugly tucked next to the gear shift so it would not rattle.

The controller interface can be mounted nicely into the center console storage compartment. Although it does not look bad just placed here, later the plan is to modify the compartment so that not wire are showing. This will have to wait for the next install day.

Day 5

The next install day was used to fabricate a new front component bracket and tap into the heater core lines. The component bracket was in the way of the oil filter so we fabricated a new one that moved the fuel filter and heated oil filter over a little so that it was out of the way. Here is a photo of the new bracket with all the component mounted.

After lots of running wires, heating hoses, fuel lines and mounting additional components it was time to cut into the factory installed heating lines. These lines are used to heat the fuel as it travels from the tank in the trunk up to the heated filter and through the final heat exchanger before final being burned as fuel. The picture below show the first heater line tee we installed.

The following is an image of the heater hose tees installed in both lines before attaching the hose clamps.

Although it might not seem like much, tapping into the heater lines and connected them so that there was a complete loop from the tank to the final heat exchange as well as fabricating a new component bracket too all of day five of the install.

With the heater hoses connected all of the under car work is complete and the remaining wiring and fuel line connections can be completed with out the need for an auto lift. The final install day will be coming soon.

Day 6

It has been a very involved install, however, here is the finish install work. First we finished all the wiring for the Greasecar Co-poilit and installed two relays. One relay for the wvo fuel pump and the other for a water pump to calculate coolant and decrease system warm up time.

The co-pilot and water pump both required fuses so we mounted them inside the fuse box under the hood and connected them to the constant power bar on this box.

This is a picture under the hood after finishing the wiring and connecting all the coolant and fuel line. As you can see all the factory plastic fits back into it original place hiding most of the newly installed components.

This is the other side of the car you can see all the wiring and heat exchanger is hidden under the air and battery boxes.

Because I am not sure if I will always have enough oil to keep the tank full, we added a manual coolant shutoff value to the system. This value has proven very effect in keeping the temperatures low in the system so that the remaining vegetable oil does not cook and create plastic build up.

The finishing touch was to install the co-pilot into the car with out any wires showing. This was done by modifying the center storage console so that the co-polit can be mounted in side it. The makes it so that non of the wires not even the USB cable connecting it to the computer brain is showing. The red button was also added so that I could turn off the coolant water pump when I was not planing on running on grease. And with the co-polit in place the install was complete and ready for testing.

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