1.6L TD in a Dodge Caravan

[hamradio]

I use bar's leaks in my car.


My AAZ gasket was seeping some after I put it in, even at 85 ft/lb.  I did not feel like going tighter with an 11mm block, so I put bar's leaks in...worked great.


FWIW, it's apparently in every aluminum gm engine...

[8v-of-fury]

i've used the stuff, haven't seen or had a problem yet with it..

why do people swear against it?

[theman53]

I have used it too. The only problems I have had is getting rid of it when you want to fix it for real and it will plug up some heater cores/radiators if they have some gunk in them already.

I use pepper more often if I have to use something to get home.

[8v-of-fury]

i used it to fix a small leak with my heater core.. in winter it would fog my windows something fierce.. fixed it right up. and it said it helps lubricate the water pump.. Never do wrong with more lube I always say

[arb]

I've used Bar's leak on some old tired cars. Always worked, so I considered it here. Glad I pulled the head. I found a couple of deep scratches on the head at the point where the metal ring in the HG seals the combustion chamber. They got there when my son and I put the head on the studs with the manifolds still attached. Very heavy that way and its a long reach on a caravan. You can see them to the right of the cup.

So, I setup my resurfacing glass / sand paper and polished off the scratches.


This time I installed the head w/o manifolds so my hands would protect the head from the studs. Worked great. It will just be harder to install the manifolds. I then installed the timing belt, and injector lines. This HG looks correct - it does not stick out too far like the one that did not seal.

[arb]

incremental work reassembling the engine. Manually cranked it to partially clear the injection lines and to be sure I didn't screw-up the valves. Sounded good! No unusual noises like last time.  Life is good. Started to bold the turbo back on. Cleaned the manifold surfaces, bolted the "T" bracket back on the block - this is the support I made for my turbo. Its at the bottom of the bock, so its a real reach from over the top. The half shaft blocks the one bolt from socket access, so hand wrenching.

Maybe more tonight... but rain is in the mix now.

[arb]

After the all day rain stopped, I got the turbo support bracket installed.

Next, the exhaust manifold. The bolt below started as the hardest to install - I reached under the manifold from the far right side. Long and difficult reach. Then I noticed, there is a space from the top to get at it. notice my EGT plug is out - This allows for socket wrench access to an intake bolt. I must remember to put it back ;-)

Next, the turbo support... I had forgotten this bolt with my failed HG change.

Got the turbo oil supply and return lines installed, the intake manifold, boost gauge feed, and the hose on the end of the head that blew off.

I might have to pull the fuel filter supply line and cut off a bit - it got folded over during the manifold work. Notice how it was pinched a bit.

Next I R&R the thermostat, fill the system and crank it over to see if the leak it fixed !!

[lovinthedeez]

is the fuel supply line the oe one.   after having a couple of fights with that pita, I just use a regular viton fuel line.  seems like once they come off the barbs, the ends are useless, requiring cutting or a clamp. kept pinching it trying to get it on, cut it, pinched it, cut it; and then it was too short.  bought two at 16 bucks in one day.  the next time i needed one, in went the viton.  I know folks say you want a clear line there, but my pump is strong, no need to worry about that.

[arb]

is the fuel supply line the oe one.   after having a couple of fights with that pita, I just use a regular viton fuel line.  seems like once they come off the barbs, the ends are useless, requiring cutting or a clamp. kept pinching it trying to get it on, cut it, pinched it, cut it; and then it was too short.  bought two at 16 bucks in one day.  the next time i needed one, in went the viton.  I know folks say you want a clear line there, but my pump is strong, no need to worry about that.

Yes, both are OE and new last fall when I put them in. I like seeing the clear and until I mashed it over, had no problems with it. We'll see how it looks this weekend, I might try cutting off a bit.

[92EcoDiesel Jetta]

I believe OE is nylon. If you are going to cut it, you will need to heat both the line and the fitting. Boiling hot water is not hot enough to soften nylon. You will need a heat gun. Reason you need to heat the fitting is so it does not cool the softened nylon as it go on the fitting. Make sure you have enough slack to play with (so it won't become too short) because you may ruin the first one you do.

[92EcoDiesel Jetta]

Oh and don't cut the nylon off the barb with a razor because it will be nicked and won't seal afterwards! Use a heat gun to soften it real well and pull it off the barb, then cut.

[arb]

Oh and don't cut the nylon off the barb with a razor because it will be nicked and won't seal afterwards! Use a heat gun to soften it real well and pull it off the barb, then cut.

Thank you. That is good advice on something I had not thought about.

Last night was snow-ball night. I was going to replace the thermostat before my start & retorq... but the alternator was blocking the bolts, so I removed it. I then noticed the anti-torq bracket / mount for the alternator / AC compressor was parially blocking the flange. No problem I though, I'd use a cut-off wheel to make the clearance. So I started to remove the bolts on the flange. The rear was first - SNAP !!!! It must have been over torq'ed because it snapped with a 6" wrench and normal force. Man, I do have a new water pump with the newer design bearing vent, but that a lot more work... Then I noticed the water pump seal had just began to seep. Notice the coolant at the edge of the photo? Its from the vent. So, the compressor and mount came off.

I removed the thermostat flange from the new pump. I guess this was a blessing in discuise. I could have been on a road trip and lost coolant through the seal. Now I'll have the confidence of a new pump and thermostat, although a 195 degree one call for with a turbo.

[arb]

Saturday started with a huge storm in the middle of Friday night. We woke up to no power. Detroit Edison had no estimate on the repairs because so many people had no power. Guess what my next project is ? Hooking up the 7.5 kw diesel generator I have sitting in the garage !!! This is the 3rd time in 18 months we have been w/o power for an extended period of time. I didn't  want to work in the dark and w/o my air tools. So, Father's day was for the assembly of my engine. Started with installation of a new O-ring for the water pump housing to engine block. The one they sold me looks just like the one for the thermostat. I had to use some Permatex to get it to stay in the groove as the o-ring was about 5 mm larger than the groove. Then I clamped it for a few hours:

All was good. I used this time to open up the access to one of the mount's bolts. Here you can see the corner blocks access to the top bolt.

So I cut it off and painted it.

Next I needed a bolt to hold the lower timing belt cover to the water pump. The stock "T" bolt was rusted pretty good into the old housing, so I used a 1/4" x 20 stainless steel bolt and ground off one side of the head.

Then I mounted the pump ! All was great - the o-ring stayed in place, the bolts were getting into their spots, then, the lower bolt that goes through the alternator bracket through the water pump snapped !! I was only using a 6" ratchet on it, and not appling a big torq. Must be it had a crack in it already. Many, I really didn't want to pull the pump again. But, the bolt is what keeps the o-ring clamped and takes loads from the alternator. Notice the fracture - half was a different event.

[Smokey Eddy]

This is the most INSANE project i've ever seen or possibly ever even heard of.
Nice work and good job on not turfing the whole thing I hope your van gets ludacrous mileage.

[jtanguay]

This is the most INSANE project i've ever seen or possibly ever even heard of.
Nice work and good job on not turfing the whole thing I hope your van gets ludacrous mileage.

yea i agree.  Arb is very determined man!  and from the looks of it, will be of great usefulness in the coming years after the US economy collapses.  during which taking a trip up to Canada might be a good idea