Diesel conversion problem

[wildenbeast]

I am hoping some of the diesel gurus can help on this one.  I posted this on the Samba as well...

I am in the (long) process of finishing a conversion to a 1.9TD engine in my Syncro Adventurewagen. Everything is running, exhaust installed, etc.

The problem; the coolant lines that go to the rear heater get hot but the coolant lines going to the front heater do not get hot.

Background:
1.9TD engine- brand new longblock
rebuilt shortblock with different exhaust manifold to accept larger turbo
this turbo: http://dieselvw.com/AAZTurbocharger.htm
saab 900 intercooler
all coolant lines have been bled
boost set to 11psi

I have already replaced the radiator thinking that was the problem. If anyone has any ideas, please let me know. The other alternative seems to be a bad head gasket but this doesn't make sense with a brand new longblock.

[arb]

Do you have photos / diagrams to show how you plumbed the lines to the engine ?

[zukgod1]

As mentioned above I believe you have a restriction in the heater core or lines as well. Fluid is like air, it will take the path of least resistance..

If you have access to them maybe you can unhook them from the core, hook them together with a small piece of pipe or something then see if you get flow. If so your core is plugged for sure.

[wildenbeast]

Thanks for the replies.  Here's some further info:

We have bled the system many ways and are convinced there is no air in the system.  With a hard acceleration, we are producing black smoke- so there is not a lack of fuel.  Something is not circulating correctly as we are getting hot coolant in the radiator but the thermostat is not opening.  Also, coolant is pressurizing quickly.

[jtanguay]

Thanks for the replies.  Here's some further info:

We have bled the system many ways and are convinced there is no air in the system.  With a hard acceleration, we are producing black smoke- so there is not a lack of fuel.  Something is not circulating correctly as we are getting hot coolant in the radiator but the thermostat is not opening.  Also, coolant is pressurizing quickly.

have you confirmed there is no valve??? i would imagine there to be a valve for the summertime when you don't want heat... and the coolant will take the path of least resistance as stated above, so if given the chance, it won't flow right to the back if not plummbed correctly.

[wildenbeast]

The reason we thought it was the engine was that we had another long block in there originally and the cooling system was working properly (plus we bled the system a number of times as well as performed numerous checks that were mentioned above). We just pulled the head gasket and it was the problem- we made an assumption that the head gasket was factory installed to spec (torqued properly) since it was in a brand new long block. This was unfortunately not the case and a new one will now be installed (along with new bolts) tomorrow. Anyway, I just thought I would update everyone on the status...