Fixmyvw.com

Author Topic: 1.6L TD in a Dodge Caravan  (Read 143940 times)

Reply #465April 09, 2010, 10:49:09 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #465 on: April 09, 2010, 10:49:09 am »
those are a really common(especially with newer cars) inner joint.
I am not sure if they are superior to a CV or not, but they dont seem to like high angles like a CV joint does...

my neon uses that style joint, and they are for sure easier to service(but when they fail they really fail!) although there is little warning before they go boom(no clicking for a while to tell you something is wrong like a CV will)

glad to see you figured it out, and hopefully you will be back on the road for a long time before you break down again.

-Owen


The new shaft is on my right side which has almost zero angle at the inner, unlike my drivers side, which has maybe a 15 - 20 degree angle all the time. That one is maybe 26 -30 years old. Its outer boot just started to throw grease through a crack, so its time to pull it and figure out how to take apart an outer CV joint....  any one done this ?

On my oil separator - it and the new shaft are working GREAT !  My oil loss has gone to zero.  Next refinement will be to connect the rad fan to power for the first time, and then maybe install an inner cooler. Last summer I had a few boiling moments in stop & go freeway traffic.

Reply #466April 12, 2010, 03:36:11 pm

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #466 on: April 12, 2010, 03:36:11 pm »
I need to do a measured MPG test (remember I have no working Dodge instruments - odometer, fuel gauge, etc) - I filled it up yesterday and it had way more fuel in it than I estimated it should with my estimated 40 mpg from the first few months of driving it... Something that has changed, when I put this new (used but resealed for WVO) pump on, my throttle cable began to stick a little at the half way point. The throttle arm of the IP does not stick, so its on the Dodge side. If I hold full throttle for a few, it will go to full throttle, but I seldom do this. The acceleration became about what my first Rabbit NA was SLOW. So, I'm obviously not burning the fuel I used to.

Time to measure (my Garmin will give me accurate miles).

Reply #467April 13, 2010, 11:26:13 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #467 on: April 13, 2010, 11:26:13 am »
My daily driver didn't today... Was just about to pull on to the freeway when my oil pressure dropped below 20 psi !!  I pulled over and saw dripping. I have a leak. I'm guessing turbo supply or return line.  I added the 2 quarts I had in the car, and limped the 3 miles home, hyper-mileage style coasting (engine off) most of the way....  Maybe the rain will end and tonight I can find the leak.

Reply #468April 13, 2010, 11:30:27 am

8v-of-fury

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #468 on: April 13, 2010, 11:30:27 am »
Man this thing is nothing but problems eh Arb? It sucks because it happens, but its good because it happens to someone it is not going to be a crippling blow to lol. you know?

Hope you get it all solved out and running tip-top-shape :)

Reply #469April 13, 2010, 11:37:55 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #469 on: April 13, 2010, 11:37:55 am »
Man this thing is nothing but problems eh Arb? It sucks because it happens, but its good because it happens to someone it is not going to be a crippling blow to lol. you know?

Hope you get it all solved out and running tip-top-shape :)

Yeah, its a bit of a pain because when its running, it is soooo  good. Especially the mpg. With all the new parts, I'm getting closer to a new ride with each new part ;-) Most people I know would have thrown in the towel long ago. I just LOVE these engines, though.

Reply #470April 13, 2010, 11:39:45 am

8v-of-fury

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #470 on: April 13, 2010, 11:39:45 am »
Couldn't have happened to a better person! Every time I see an old Caravan, I kinda laugh to myself and wonder if it has axle problems. Then I think of how cool a diesel caravan is ;) You redefine MINI-VAN and make it cool. lol

Reply #471April 13, 2010, 01:06:55 pm

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #471 on: April 13, 2010, 01:06:55 pm »
Couldn't have happened to a better person! Every time I see an old Caravan, I kinda laugh to myself and wonder if it has axle problems. Then I think of how cool a diesel caravan is ;) You redefine MINI-VAN and make it cool. lol

Thanks Jeremy !!  This summer if this these systems stablize long enough, I'll be looking to customize the body and paint it. Not sure exactly how yet, but the head liner and seats will be part of it... Maybe something to do with changing the rear hatch and both bumpers to something metal.

Reply #472April 14, 2010, 09:13:30 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #472 on: April 14, 2010, 09:13:30 am »
I filled the pan with oil, checked that there was no oil in the coolant, started the engine and could not find any oil leaks.. I noticed a small leak at the coolant line on the oil cooler, and my rear anti-torq engine mount had broken on the firewall mount. Since I still had not fixed the broken front mount, my engine would have been flopping back and forth quite a bit. I noticed a lot of fresh oil on the "K" frame (the reason this platform is called a K car) just below the turbo... nothing dripping while. So I pulled the front mount and cleaned it. After I fix both mounts I'll run it to operation temp and check again for a leak.

Reply #473April 29, 2010, 10:50:55 am

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #473 on: April 29, 2010, 10:50:55 am »
The oil leak was the drain line to the turbo. The short rubber hose split when the rear anti torque mount failed, this time on the firewall, allowing the engine to roll back pushing on the turbo drain. There's only an inch or two between it and the "K" frame.

This shows the new hose between the elbow and the steel tube as part of the flange on the turbo.



Here is how the mount broke..



Here is how I changed it - I have a stack of 3 or 4 layers of radiator hose at all 3 unions of the mounts / bolts.



I decided to modify my large vise by welding a wing on it to clamp my welding ground to. Works great.



Here is the mount for the firewall after it has been expanded. The bolts have been welded to the mount as well so I can install / remove without someone's help on the other side to hold a wrench



Here is the bottom and how it is much stronger - there is a plate welded to the bottom so there is about 3/8" of steel welded inside and out.



Here is the oil separator on the firewall.


I also changed the cooling system a bit ( 210 - 215) . I was over heating a bit during stop and go traffic on the expressway - speeding to 75 mph and then stopping, over and over creates a lot of heat. I found that my lack of heat in the cabin last winter was due to lack of coolant flow through the heater core, and therefore lack of flow through the oil cooler. It could be I was boiling some coolant in the oil cooler because of this. I ran my head line directly to the oil cooler, with a "T" for the VW expansion tank. I also connected one of my aux power switched on my new instrument panel to the Rad fan for when I'm stopped. Never got above 205, and was usually at 195 - 200 this morning. Very happy about this as camping season is almost here. I did have a little bit of coolant drips on the ground when I stopped at work, under the radiator cap area... I think the cap is not sealing correctly.


Reply #474May 04, 2010, 11:26:37 pm

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #474 on: May 04, 2010, 11:26:37 pm »
EIGHT DAYS !!!!  8 DAYS !!!I MADE IT 8 DAYS !!

Did someone say they have a spare good 12mm 1.6L head available ? So, today I drove it hard in stop & go traffic on the I-696 speedway. This means one minute you are racing full throttle to 70 mph, the, just as your engine temps are soaring, come to a full stop for the gawkers to look at who knows what, then back to 70 mph again. And so it repeated for 2 hours straight, then a brief stop before returning home. Made it 5 miles in the stop & go and noticed the temp steadily climbing through 228 F. Stopped in a hood north of Detroit, noticed some coolant on top of the valve cover. Humm. No apparent leak. Checked the oil, a bit more than a quart low. Topped it off, let the engine cool off, opened the rad & expansion tank. They were about 1.2 quarts low. Topped them off. By now, I was at 160 F. Started the engine and turned around. Then I noticed a trail of coolant !!! Killed the engine, popped the hood. More coolant on the valve  cover. Started this cold engine - immediately the expansion cap became a slow fountain as combustion gasses pushed coolant out the cap, killed the engine, stopped immediately. Restarted engine, fountain again. Crap.

I knew the head was on borrowed time after a failed what every caused it to warp twice and I honed it flat twice... Just wish the first time I had used studs rather than the throw away stretch bolts. The $199 they want for a full stud set would have paid for itself by now.

Time to maybe get a new head or one w/o cracks. The lower end looks so good, I'll pass on overhaul for now.

At least there was a little old lady working on her porch where I parked it. I asked her if I could leave it there over night. She looked at me funny and demanded "What do you want" in an eastern accent. I asked her "Paruski ?" and her face lit up and asked me if I spoke Russian too, in Russian. So I shouted to the car "Wifey, Eaddee Seada!" which means come here... turns out she is also Ukrainian. Go figure. The car will still be there tomorrow night, probably under guard !

Reply #475May 05, 2010, 01:52:00 pm

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #475 on: May 05, 2010, 01:52:00 pm »
My wife is asking me to justify replacing the head… so,

Of last 386 days, 254 days running (36.3 weeks) and 132 days down time.

Each week, I drive 450 miles in my commute. This car has cost $1,184 in diesel, the replacement car cost $3,518 in gas, so it has saved me $2,334 in real money this past 13 months.

Here are the details boiled down to events:

Aug 12 2008 build start
April 27 2009 first daily drive
237 days to build

May 26 2009 first head gasket due to hose failure - no thermometer
30 days running

June 2 2009 fixed
8 days repair

June 12 2009 - defective new head gasket
10 days running

June 18 2009 - defective thermostat seal
June 24 2009 all fixed, back on road
12 days repair

July 6 2009 bent alternator bracket - fixed same day
July 22 2009 - only old hose failed
29 days running

July 27 2009 - fixed hose
5 days repair

July 28 2009 - head warped from hose failure w/o thermometer
1 day running

Aug 10 2009 back on road
14 days repair

Aug 24 2009 Injection pump leaked
14 days running

Aug 31 2009 back on road
8 days repair

Sept 1 2009 - IP bolt loose - fixed same day
2 days running

Sept 3 2009 damaged timing belt - still driving
Sept 8 2009 fixed belt
Sept 16 2009 boost problems - fixed same day
Sept 24 2009 new alternator defective - replaced same day
Setp 25 2009 front engine mount failed
24 days running

Sept 27 2009 fixed
2 days repair

Sept 29 2009 CV joint failed
2 days running

Oct 8 2009 fixed as well as some loose bolts
10 days repair

December 23 2009 used CV failed
77 days running

Jan 5 2010 fixed
14 days repair

Feb 23 2010 used CV failed, ordered new
50 days running

March 20 2010 - fixed
March 20 2010 -new failed
April 5 2010 fixed
42 days repair

April 13 2010 - oil leak due to engine mount failure
9 days running

April 29 2010 fixed
17 days repair

May 4 2010 - head gasket / head crack
6 days running

Reply #476May 05, 2010, 02:04:56 pm

theman53

  • Global Moderator
  • Veteran

  • Offline
  • ****

  • 7837
  • Personal Text
    Holmes County Ohio - North Central Ohio
Re: 1.6L TD in a Dodge Caravan
« Reply #476 on: May 05, 2010, 02:04:56 pm »
I hope that you get it fixed for "good" this time. BTW there are ARP studs in the for sale section 100.00 new in box shipped in US. If I didn't already have mine they wouldn't have been there :D

Reply #477May 05, 2010, 02:41:12 pm

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #477 on: May 05, 2010, 02:41:12 pm »
I think I'll pull the engine and overhaul it to be sure I'll be good for years :-) Only reason, my oil pressure starts at 100 psi and after its a full temp has gradually dropped to 40 psi at speed, and only 15 psi or so idle, so the fuel pump or bearings are aging.

THANKS !!  I NEED the studs !!!

Reply #478May 05, 2010, 02:59:05 pm

arb

  • Guest
Re: 1.6L TD in a Dodge Caravan
« Reply #478 on: May 05, 2010, 02:59:05 pm »
Reading at the head port, 10 psi per 1,000 rpms is great oil pressure.  It sounds like you're doing even better than that.  No need to rebuild based on those pressure. 

Thanks Andrew. I remembered higher on my last rebuild, but it was not turbo ;-) When I pull the head, if the lower end still looks good, I'll only replace the head.

Reply #479May 05, 2010, 10:44:35 pm

rabbitman

  • Veteran

  • Offline
  • ***

  • 2787
Re: 1.6L TD in a Dodge Caravan
« Reply #479 on: May 05, 2010, 10:44:35 pm »
With my 36mm oil pump I had about 45psi without a turbo, I added the turbo and it didn't change, then I removed the turbo and it still didn't change.

Probably if the oil pump is big enough and the bearings are good then it shouldn't change with or without a turbo.
'82 Rabbit, I put on a euro vnt-15, 2.25" DP, 2.5" exhaust, the result.....it whistled.

I removed the turbo, made a toilet bowl 2.5" DP, the result....it was deafening. Now it has a homemade muffler up front and a thrush in the rear, the result.....less loud.
Watch: AGENDA, GRINDING AMERICA DOWN

 

S-PAutomotive.com