1.6L TD in a Dodge Caravan

[arb]

Thanks guys !! Yes, having a true multi-fuel car that gets great mileage and has not bank payment is a wonderful thing ;-)  Yes, I plan on more trips into the Canadian north :-)

This morning I started to drive it to work again !! No leaks in the HG, but the IP timing was off. I think my IP locking pin was leaning up by one tooth when I installed the belt. I'll retime it tonight. Here's what I did last night to finish the HG job. First I had to remove the stamped bolt from the water pump - an easy-out did the job. The bolt had a step right in the middle so I could not get the drill to stay centers, so my dremel was used to get the drill started. Next, I had to find a replacement 8m 1.25 bolt. I needed about 60 mm but a 70 mm was the closest I could get. I had to cut / grind it to the next length.

Next, I drilled the 3 mounting holes a little larger for the alternator / anti-torque mount to the side of the block. Made it much easier to install this time.

Then I connected all the hoses / wires and installed the a/c compressor. The car started a bit hard and there was some smoke - never had any at idle after it was warm. I also noticed I could get 4 psi booth with just revving the engine. Thought it was timing but thought I would be sure driving down the road this morning. I did run the engine for a while last night to bring it to temp, then I did the final 90 degree torque on the head bolts. One thing that broke when I was trying to start the engine was the momentary contact switch I have for my pimped GP - the lever snapped off. This morning I simply connected the 2 spade connections onto each other. I feed the switch with a separate lighted switch so its fail safe. This worked this morning.

Here is the video of the idle. Did not sound too bad, but not too good either.
http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=102_5174.flv

[arb]

Is there still smoke/steam coming out of the radiator?

No smoke, bubbles, gas coming from inside the radiator. That was part of the reason for the video, but you can't see the surface of the fluid. After I stopped this morning after driving a few miles, I noticed a little - _little_ steam coming from the front of the radiator. I assumed this was from the coolant I spilled on it when filling and not a leak. This is a new aluminum radiator.

My leak was the HG not sealing. My vendor refunded the bolts and HG as it was mis-packaged. He thinks it was from a hydro head but was sure it was not for my 83' mechanical so the sealing line showing from the front of the head was because of this.

[Smokey Eddy]

The idle just sounds fast to me? maybe its just the quality of the video...

[arb]

The idle just sounds fast to me? maybe its just the quality of the video...

Very perceptive !! It would not idle at all, so there was a 2L Coke bottle sitting on the throttle peddle holding it to about 1400 rpm.

Last night I pulled the covers and retimed it again. As suspected, the IP pulley was 1 tooth off on the belt. I made about a 1/4 tooth adjustment to the cam pulley too. WOW !! She runs better than before the melt-down. I drove it to work today w/o issue. Felt strong. Tonight after work I will try to tow our pop-up camper with it. I am not worried about the engine, but the clutch might not be up to the job....
http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=102_5177.flv

[Vincent Waldon]

Whoo-hoo !!!!!   

[jtanguay]

be sure to keep an eye on coolant temps or add one of those products to keep temps stabilized while towing.   

[88jetta350]

I hope you don't plan on leaving that POS Fram filter on there...

Tsk, Tsk, Tsk... 

[arb]

The only fuel filter Autozone could get me didn't have the integrated water separator. Murray's Discount Auto could get me this Fram with the separator... What brand do you use? Does it have a separator?

[jtanguay]

the fram filters aren't that bad... its just the oil filters you gotta be worried about... as they will bypass the filter at high pressure. 

a CAT 1 micron fuel filter would be an excellent choice, and i think you could modify a flange to make it fit rather than spend the $200+ for it    but its not required. 

[arb]

the fram filters aren't that bad... its just the oil filters you gotta be worried about... as they will bypass the filter at high pressure. 

That's what I thought - I don't use their oil filters, but fuel I thought they did OK.

A CAT 1 ? I'll have to look at that.

[rabbitman]

napa fuel filters have the water separator.

[arb]

napa fuel filters have the water separator.

Thanks. I'll be sure get one of theirs in the fall. They are just across the street from the other shops.

[jtanguay]

the fram filters aren't that bad... its just the oil filters you gotta be worried about... as they will bypass the filter at high pressure. 

That's what I thought - I don't use their oil filters, but fuel I thought they did OK.

A CAT 1 ? I'll have to look at that.

a lot of guys at TDIclub praise the CAT filters

[arb]

The diesel caravan is running strong and sounding good. Last night the engine developed a slight low speed sound almost like a scrapping. When I looked under the hood, the forward mount for the TB cover had slipped off the grommet - I must have missed the washer that prevents this. I'll post photos later.

[arb]

23.6 mpg pulling this camper, 2 kayaks, a canoe, and 620 pounds of people 65 - 75 mph !!!


Wow. This was the true stress test. The 1.6 was enough for the job and performed well. Lucky for us, there was no stop and go construction traffic as I still don't have the radiator fan connected.
Here is the cover bolt that slipped through.

And the repair.


My brother did a quick front end alignment Friday just before the trip. He plays that rack like a master violinists. I had 1.86 degrees of toe out. Not too bad for only having a tape measure to do the alignment after I put the new manual rack & pinion in. Now I have exactly 0.00 toe. He thinks its worth 4 mpg. Feels like it driving it. Very smooth and stable on rough roads. The diesel machine took us on an awesome trip.


On the way back, I noticed a slight vibration in the left front end between 55 and 59 mph. It was only pulling the trailer, and would come and go with side loads on the car (steep turns). Could be an exhaust pipe vibrating in resonance against a support. It was not there today on my drive to work. I have new wheel bearing / hub assemblies for the front. This will let me use my 15" wheels (aluminum rims) rather than the 14" steel you see.