Author Topic: 1.6L TD in a Dodge Caravan  (Read 143950 times)

Reply #255June 03, 2009, 07:34:27 pm

ktzdsl

  • Junior

  • Offline
  • **

  • 73
Re: 1.6L TD in a Dodge Caravan
« Reply #255 on: June 03, 2009, 07:34:27 pm »
Love your unique build thread and I check every once in a while to see what new event has happened. I see where you checked the surface on your head and performed your own "surface modification." My question is what do you have at home that allows you to check the surface for "trueness"? I like your glass/sandpaper "manual" plane/lathe. I do not believe that I have anything at home that could be used as a straight-edge, but if there is, I am sure you can tell me. Thanks.
ken   
DFW area Texas
1982 1.6L NA diesel pickup

Reply #256June 05, 2009, 08:37:39 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #256 on: June 05, 2009, 08:37:39 am »
Love your unique build thread and I check every once in a while to see what new event has happened. I see where you checked the surface on your head and performed your own "surface modification." My question is what do you have at home that allows you to check the surface for "trueness"? I like your glass/sandpaper "manual" plane/lathe. I do not believe that I have anything at home that could be used as a straight-edge, but if there is, I am sure you can tell me. Thanks.
ken   


Thanks for the support guys... been out of commission this week. First, my best friend's Mom died in her sleep suddenly and without warning early Sunday morning. - She was born in 1941, so not very old for such a surprise. Then, I got an upper respiratory infection, like the flu, but not quite. Swine or Bird anyone ?  LOL...  So, I slept a lot the past few days. Feel great now and look forward to starting the diesel this weekend. I did get a new thermostat just in case that was the root cause for the hose blowing off. I'll do that before I fill it with coolant again. Too bad I used that expensive $12 / gallon stuff that goes 5 years. This time, it will be used (by me) coolant until I'm satisfied. Then I'll do a proper flush and the expensive stuff.

I have a straight edge. Its a little longer than the head. It is 4130 steel for building aircraft structural stuff and is 1/8" thick. (I'm starting my second experimental project now.) I verified it was straight with sight and the 9/16" flat tempered glass I used to resurface the head.

Just before over heating, I noticed I could exceed the clutch disc friction in 2 - 3 with full throttle and boost. I'm debating doing the clutch tomorrow too. I know I should have done this when the engine was on the floor of my garage, but I didn't have the cash then.

Reply #257June 09, 2009, 04:36:51 am

fukengruven1982

  • User+

  • Offline
  • *

  • 35
Re: 1.6L TD in a Dodge Caravan
« Reply #257 on: June 09, 2009, 04:36:51 am »
amazing work sir, cant wait to hear confirmation of its runnability... :)

Reply #258June 09, 2009, 07:30:10 am

lovinthedeez

  • Veteran

  • Offline
  • ***

  • 489
Re: 1.6L TD in a Dodge Caravan
« Reply #258 on: June 09, 2009, 07:30:10 am »
Nice IP locking tool!!!

X2
i've lost my pin so many times, its amazing what'll go in there to make it work. ;D
location:  ashland, oregon US

Reply #259June 09, 2009, 08:18:27 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #259 on: June 09, 2009, 08:18:27 am »

LOL !!  Thanks, I never had a proper pin because the tap worked great. I did buy a proper cam lock ;-)

We've had tornado weather there the past couple of days and I still had a bit of the flu, so I have not done much. Today is my birthday, so my wife and son have other ideas on what I will be doing tonight... Hope to be making smoke this week :-)  Here's what I did this weekend. The root cause was either a bad thermostat (Got a new 195 degree turbo to install) or the hose that blew off the end of the head because it was the only line I did not put a ridge on. I welded one on so this would not repeat:


Reply #260June 11, 2009, 09:22:04 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #260 on: June 11, 2009, 09:22:04 am »
Got everything reconnected last night. The exhaust was a small challenge:

Can't forget the oil supply for the turbo

Notice the hump from the flange I welded.


Now, when I cranked it over to bleed the injector lines, there was steady burping of gas into the cooling system. Humm, not what I wanted to see. When the lines were primed and secured, the engine started right up. The burping continues, but there seems to be no difference between the volume of gases from cranking to revving the engine. I would have expected that if there was a crack behind a pre-chamber that the gasses would be much more with revving.. Here's a video. Tonight I'll do the final 90 degrees on the head bolts and pray the head gasket was just not sealed yet.... I did notice this head gasket, even though its made in Germany, was a little larger than the others I've used = it sticks out a little further from the head, and I can even see some of the sealing ring for the oil return hump.
http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5124.flv
« Last Edit: June 11, 2009, 09:24:25 am by arb »

Reply #261June 12, 2009, 08:25:31 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #261 on: June 12, 2009, 08:25:31 am »
We had big rain storms last night. Almost half an inch of rain fell. Wish the guys in Australia would have been so lucky...  Hope to retorq the head tonight and see if the thing seals. If not, I might try bar's leak before pulling the head again.

Reply #262June 12, 2009, 09:34:56 am

53 willys

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #262 on: June 12, 2009, 09:34:56 am »
We had big rain storms last night. Almost half an inch of rain fell. Wish the guys in Australia would have been so lucky...  Hope to retorq the head tonight and see if the thing seals. If not, I might try bar's leak before pulling the head again.

 :-X

Reply #263June 13, 2009, 06:05:21 pm

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #263 on: June 13, 2009, 06:05:21 pm »
We had big rain storms last night. Almost half an inch of rain fell. Wish the guys in Australia would have been so lucky...  Hope to retorq the head tonight and see if the thing seals. If not, I might try bar's leak before pulling the head again.

 :-X

As suspected, the final re-torq did nothing to the HG leak. No Bar's Leak. I want it fixed correctly. S&G Imports said they will warranty the parts.

OFF WITH THE HEAD !!

Reply #264June 13, 2009, 06:37:01 pm

53 willys

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #264 on: June 13, 2009, 06:37:01 pm »
We had big rain storms last night. Almost half an inch of rain fell. Wish the guys in Australia would have been so lucky...  Hope to retorq the head tonight and see if the thing seals. If not, I might try bar's leak before pulling the head again.

 :-X

As suspected, the final re-torq did nothing to the HG leak. No Bar's Leak. I want it fixed correctly. S&G Imports said they will warranty the parts.

OFF WITH THE HEAD !!

bummer about the HG!!
glad you decided against the bars leak! ;D

Reply #265June 13, 2009, 08:56:09 pm

jtanguay

  • Veteran

  • Offline
  • ***

  • 6879
Re: 1.6L TD in a Dodge Caravan
« Reply #265 on: June 13, 2009, 08:56:09 pm »
yea that bars stuff is what those shady used car lots use  :o


This is how we deal with porn spammers! You've been warned.

Reply #266June 14, 2009, 01:12:45 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #266 on: June 14, 2009, 01:12:45 am »
OK, today I got a new HG and bolts from Parts Place Inc. They had about $3.00 higher price than S&G, but they were the only place in Metro Detroit with the parts on the shelf...

so, I  disconnected almost all the hoses and lines. I drained the coolant. I have yet to remove the timing belt from the head and pull the 10 head bolts and TC oil line. I would have had this done today, but my lovely Ukrainian wife wanted me to take her flying. It has been 89 days since I did this and she understands our FAA rules about 90 days - 3 Take offs and landings for a pilot to remain current to take passengers with them :-O

Reply #267June 15, 2009, 09:37:07 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #267 on: June 15, 2009, 09:37:07 am »
I have my German made HG now...

I thought I had cleaned the deck, but notice the left over gasket material between 1 - 2 on the back side -

Here is the block ready to accept the head again. I polished it with green scotch-bite, cleaned out the dust, then degreased it with trichlor brake cleaner. The verticle scortch lines are not as strong now, but you can still see them.

I was not going to pull the manifolds this time, but I have decided to pull them and polish the head surface again.

Reply #268June 15, 2009, 02:18:28 pm

92EcoDiesel Jetta

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #268 on: June 15, 2009, 02:18:28 pm »
Hi Arb, is your aluminum coolant flange a custom part? If not, where can I get one? I don't like the plastic ones.

Good luck with the HG!

Reply #269June 15, 2009, 03:30:31 pm

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #269 on: June 15, 2009, 03:30:31 pm »
Hi Arb, is your aluminum coolant flange a custom part? If not, where can I get one? I don't like the plastic ones.

Good luck with the HG!

It started out as a stock part - every IDI vw I've touched had the aluminum. I did some custom welding to move the pipe to one side, and a fitting for my temp sender (mechanical).  You shoud be able to find one :-)

 

Fixmyvw.com