1.6L TD in a Dodge Caravan

[allsierra123]

yeah keep us posted I am always curious about gas mileage on vw vans.

[arb]

The end cap of my return lines sprung a leak. As a temporary fix,, I used this vac hose. I not have some 3/16" fuel/oil rated hose, but I didn't when I did this fix last week. I'll replace all the return lines with the fuel hose.

Here's the aux pump, not used now, with the breather hose above this. I'll be making an oil separator to put in line with this.

Here's the aluminum I'm going to use to make the separator.

Here's the aluminum tube that the in / out lines will use.


MPG - I topped off the take. It looks like my mileage is in the 40 mpg range driving 65 - 75 mph, and a little city and construction zone driving. Didn't do the long trip this weekend.

[arb]

I have developed a slight problem. At idle, by alternator sets up a resonance that has loosened the belt so it will squeal for a few seconds after startup, especially if the lights are on.

I'm thinking of cross bracing it to the mounting holes on the back side of the block near the crank.

Good news, for the first few days, I had while smoke at start-up and also for heavy loads. This is no longer the case. Even first start in the cold mornings does not produce any smoke. Heavy load - about 9.5 psi is the best I have done, does not produce any smoke. The turbo is really doing a good job of packing more O2 into the cylinders thus burning more of the injected fuel :-)

[arb]

Here's my first update since the upgrade to the forum  

We made a custom exhaust system at my brother's garage (he swings wrench for a living) and has a full hydraulic exhaust bending / forming machine. He is at work:

I needed from the muffler back. I was using the stock 1 3/4 from the dodge, but wanted 2" all the way.

Getting over the axel and next to the "frame"

We also installed a class II used hitch I had. It was a bit thin on parts of the side plates, so we used part of a 2008 F-350 dually frame to beef it up a bit. I now have a VW-Dodge-Chevy-Ford as my daily driver.

Here's the clearance for my flex joint.

We also made the front antitorque engine mount. Much easier on a hoist,

Now I will feel good about towing a pop-up camper ;-)


NEWS FLASH !!

After 2.5 weeks of daily driving 70 miles a day, I had the hose at the end of my head blow off. This was not immediately discovered as I was on the expressway in a not very friendly part of Detroit. Remember my coolant temp gauge needs the needle relocated?. Anyway, I stopped at the next exit at a gas station. The engine was rather HOT. I took 40 minutes to cool it down slowly and add water, bought 3 empty 2L soda bottles (we have a return law in Michigan) to fill with water. Starting was hard at this point. It acted like I had cooked 3 of the glow plugs. It started eventually, and ran OK with a little smoke. I drive 4 miles to the next station, this time there was much more coolant in the engine, but repeated this process over and over until I got home. Man, I hoped I had not crack my head.

I started the car at home and noticed there is exhaust blowing into the cooling system, (Photos to follow tomorrow) so I pulled the head. The head gasket was clearly blown between the #1 #2 cylinders and the coolant jacket. No cracks that I can see. Would there likely be any under the pre-combustion chamber cups  I checked it for warpage - about .0035" of an inch, end to end, with the middle being .0035" higher (concave). The Bentley says .004" is acceptable. So, using a very thick piece of tempered glass, checked for flatness, I glued 2 sheets of fine sand paper (150 grid) to the glass and took down the warpage to about .0005 - .0015 by sliding the head on the glass. I only glued around the perimeter of the 2 sheets so there would be no high spots. It looks really good now. I cleaned the block's deck last night. Hoping to get the manifolds on the head tonight and at least have it sitting in the car.

[arb]

Here's what my head looks like now that I shaved it low-tech way.

And the deck after cleaning:


Any thoughts ? Notice the vertical scorch marks in the bores. You can not feel them, so I guess it was just hot carbon. I'm hoping to attach the manifolds tonight and attach the head tonight / tomorrow, thunder storm permitting.

[jtanguay]

looking good arb.  i think you'll be okay with a new HG.  the metal HG would be nice, but not 100% sure that it will seal properly in your situation.

[arb]

Thanks. I was surprised at the couple of slightly high spots on the deck that my flat file took down around 3 - 4 on the back side.

[Rabbit on Roids]

Here's what my head looks like now that I shaved it low-tech way.

And the deck after cleaning:


Any thoughts ? Notice the vertical scorch marks in the bores. You can not feel them, so I guess it was just hot carbon. I'm hoping to attach the manifolds tonight and attach the head tonight / tomorrow, thunder storm permitting.

HOLY OMG... those are some REALLY STEEP cv joint angles. ^ ^ ^ do they click at all?

[arb]

with all the weight off the front end, yes, it is execssive. Its not too bad with the weight on it, although this engine is quite a bit lighter than the 2.5L I took out. So, I could stand to cut a few inches off the springs.

No clicking or other sounds. They actually have quite a bit more travel..

[53 willys]

Here's what my head looks like now that I shaved it low-tech way.

.

did it blow between 1 and 2?? looks like exhaust was making the bridge between the two???
I like to use scotch brite and carb cleaner to scrub the head and block with out making it untrue....cleans up real nice usually.

[arb]

Here's what my head looks like now that I shaved it low-tech way.

.

did it blow between 1 and 2?? looks like exhaust was making the bridge between the two???
I like to use scotch brite and carb cleaner to scrub the head and block with out making it untrue....cleans up real nice usually.

Yes, there was significant HG material stuck to the head and deck between 1 - 2. It was really burned to the deck, and to a lesser degree the head. Great idea for the carb clearner & Schotch brite. I too like to see nearly virgin (its appearance, and in all things) metal when I am sealing it up.

[arb]

A closer look, yes, I need to clean this before assembly.

Scotch-brite and carb cleaner ;-) Much better.

 Also, I had to hit the deck and top of the bores with schotch-brite as there was a little surface rust from the Michigan humidity.

I chased the 12mm treads in the block.

Ready for assembly.

I assembled the head next, installing the manifolds / turbo assembly. I looked at the turbo drain flange and decided not to tackle that now as it is significantly larger than what my turbo has... Next, my wife helped me install the head assembly. Its quite heavy with the turbo hanging off the back ;-) But this was still much easier than fighting the manifold bolts from the top of the engine bay. Got the head on and realized I forgot to install the tensioner pulley first !!  Man, no way I was pulling the head for that, so I backed the stud out with a 6" pipe wrench I have (Handy little thing) and installed it that way.

Now I am setting the timing. It has changed not that the head is shaved .0025" - I noticed the difference between the cam and IP sprockets was almost half a tooth.

[arb]

I set my timing last night. The IP was dead on, and the cam sprocket adjusted its half a tooth. I love that tapered system. Next I put the top cover back over the timing belt and realized I was out of Lock-tite Red.... So I when shopping. Tonight I can get back to assembly with the Red sauce. I don't like to assemble anything on an engine w/o lock-tite unless I have to. Especially our lovely king sized vibrator box.

Oh yeah, I noticed my BOV clamp was very very loose. I wonder if I'll get more than 10 psi now ;-)

[Smokey Eddy]

heh heh! Nicely documented Arb!

I tend to find 500 grit wet dry, solvent and a razor blade made easy work of gasket material and burnt on carbon.
I've never had my head off since i did the switch to the AAZ head and metal head gasket. I wonder what it will look like inside?
I too should chase my block threads. My studs did not go in all the way *evenly - so some did*

I plan on taking my head off again soon when i intercool. That way i can drill and tap a nipple on my ALH intake for the LDA to get boost from. right now i have a fitting JB welded into a rubber hose

And of course make everything spick and span like  you have done such a wonderful job doing.

 I cant believe it surface rusted that much so quickly!

[theman53]

Nice IP locking tool!!!