First of all, this is my first post to these forums, and I have *already* learned so much from just poking around and using the search function, so I want to say thanks to all of you involved for contributing to such a great resource!
Long story short, I bought an '82 diesel vanagon a few months ago. The engine is the stock 1.6 N/A, so it's about as slow as you might imagine, but the engine was rebuilt about 50k ago and was running very nicely.
I say 'was' because on my latest trip the engine lost compression and coolant started spewing into the cylinders and out around the headgasket.
The engine was running a bit hotter than normal so I'm at least partly to blame, but unless the van's temp gauge and idiot light aren't working right, it wasn't really into what I'd consider dangerous territory.
I pulled the head off and the bolts weren't torqued down nearly as hard as I expected - and I have a suspicion that they were re-used, since one of the 12-point heads was stripped in the direction of removal. The gasket wasn't even blown through, it just got loose enough to leak around the sides. I figure the head was, unfortunately, the path of least resistance when the coolant got hot..
I don't have any experience working on these diesel engines but it isn't too hard to notice that something's wrong with the head on cylinder #2:
Any idea what happened here? The hole with melted aluminum leads into the swirl chamber, but as far as I can tell not through the water jacket. There was just as much carbon on this part of the head as elsewhere, so I suppose it could have been that way for a while, but I'm assuming this is a BAD THING and I should probably not be re-using this head.
I managed to get ahold of another 1.6d engine from a vanagon for almost nothing, and pulled the head off it, but aside from the fact that the engine was 'running' I know very little about it. It has a lot more carbon build-up and pretty large cracks between the valves (bordering on, if not over, 1mm/0.20in) - however, the valves do seem to seal ok.
Here's a picture of the worst crack on that one:
I don't particularly want to go all out and get a completely new/rebuilt head, since I can see myself replacing the engine with a 1.6td or 1.9 down the road, but I also want to do things *properly* and not be tearing it apart again in a few months.
I'm wondering what you all would do if you were in this situation. Get the second head pressure tested and a valve job done? Rebuild one of them? Get a different head? Give up?
Thanks in advance
-A