1980 Caddy TD Build

[dh13]

Well I figure I will start a build for my newest project. I recently picked up a 1980 diesel caddy. I had no intentions of keeping this truck, I was going to fit the head gasket and sell it.... Looks like that is not the case now. When I bought the truck it needed a head gasket, timing belt, and some other misc stuff done to it. I finished up the head gasket project a couple of weeks ago and have been accumulating parts for the next stage of my project.

I have almost all the parts to turbo it as of now. I am in the process of cleaning and rebuilding the turbo, I have cleaned and painted the exhaust manifold and painted some of the turbo parts.

Last week I was driving the truck and the clutch started slipping. I am now looking for a 5 speed for it. I will be swapping the transmission before I do the turbo. I think I have found a FK transmission, which is not the exact transmission that I want but I will be swapping the 5th. gear before the transmission goes in. I want to run a .75 or .80 5th because I do quite a bit of highway driving.

I will stop rambling and post some pictures for your enjoyment.

Just got home with it

[dh13]

I bought a T3 and manifold even though I don't want to run it. I know the T3 is a slow spooling turbo and for what I will be doing with the truck ideally a K03 or K14 would be the best. I will be running only stock boost pressures and because I want the engine to live.

Here are some pictures of the cleaning process

Box of turbo parts, T3, manifold, injectors, and turbo pump lines


Dirty turbo






The tear down process



Oily? I still haven't figured out if this is because of the turbo seals or from blow-by issues on the PO's engine?


Before


After


Before


After


After cleaning up the exhaust housing I found these




I am in the process of cleaning up another housing so that I can use it instead of the cracked one. It will take me some time because I have to re-tap 12 bolts/studs that are broken.

glassbeaded the exhaust manifold


Painted


Well today a local wrecking yard was having a sale, $2 per part, I figured I would go see what I could find. I was looking for a transmission but of course the only one I found was a 4 speed. I did find some good parts that I will be able to use or sell later.

I got a gti front bumper beam, (2) struts, (2) door grabs, axle, 8v manifold, exhaust flex pipe, and some other misc parts.


The 8v intake manifold I will be cutting and fabbing up a turbo manifold because I was not able to buy a factory turbo manifold.

On Saturday i found a TD injector pump for sale so I bought it. my original plan was to mod a N/A pump, but because I found this for the price I could not pass it up. My truck as oh now has a early style pump that has a different governor system in it then the later style pumps do, so the TD pump will be a nice addition to my project.


   
Thats all for right now

DtHm

[dh13]

I didn't get too much done this weekend. Or anyways I didn't get any noticeable progress done. I found some SS so that i could start building my exhaust once I get around to that point. I also picked up some new hardware for the turbo while I was at it.

I tore down the second turbos' center section. I marked the compressor wheel, nut and the shaft so that I could install it back the way it came apart so that it will still be balanced. I am going to try to order a rebuild kit from a place here in town. The shaft doesn't have all that much play but I can see that the bushings are starting to wear a little, but overall it was in great condition.

I also finished re-threading the first exhaust housing and starting making a new base plate for the wastegate and down pipe.

The new hardware. I forgot how expensive this stuff is getting.
 

I went to a used metal place in town and found some scrap pieces that will help with building my DP. I plan on building the DP with a divorced wastegate flange setup.


First turbo halfway assembled. 



I know its not much but its something to look at.

I have a feeling that after I get the turbo and all installed I will be finding a K03 and manifold fairly quick. Like I said before I don't plan on running tons of boost, so the T3 is not my first choice. The K03 seems to be what I am looking for, but for the time being I will run what I have and see how I like it, or dislike it.

[dh13]

So I finally got out into the shop. I was able to get the motor and transmission pulled. Now its time to start working on the Turbo build!

Heres some pictures

The beginning


Everything unhooked


My choice for a cherry picker




Out


Time to clean up the bay


NA soon to be TD!


Wheel gap!

[GEE-BEE]

You will need another 3 bolt AAZ ex manifold for the K03 Turbo, along with a different downpipe...

let me know down the road if you want to sell the truck ?

I have a brand new 1980 dash and cluster in the factory box....

GB

[dh13]

You will need another 3 bolt AAZ ex manifold for the K03 Turbo, along with a different downpipe...

let me know down the road if you want to sell the truck ?

I have a brand new 1980 dash and cluster in the factory box....

GB

True, I will wait to see how I like it with the T3 first.

I can let you know. I have another one that I might want to sell. Its not deal but It does have a supercharger.

[stewardc]

That's a nice find you have there. The truck looks nice and straight and relatively rust-free. Keep us informed on the progress.

[dh13]

That's a nice find you have there. The truck looks nice and straight and relatively rust-free. Keep us informed on the progress.

Thanks. I will post when I have more. I am trying to get everything for the motor right now. I am currently trying to get the headgasket situation figured out.

I will post as soon as I get some work done.

[diffdude]

We could have twins.

[burn_your_money]

Nice truck. I love the early westy front end.

[dh13]

I got some progress done this weekend. Although plans have changed since my last post, as they will many more times. My original plan was to turbo the NA block that came out of the truck. I got to thinking what the heck am I doing.. I forgot (well not really I just don't know what I was thinking) that I had a complete or 99% complete TD engine in my shop that I was given to me by the college that I attend.

So the plan now is, Use an already Turbo'ed engine and build it. My intent of this build is not to make a "TON" of power, but rather make more power than stock, and be robust enough to last for many years to come.

So basically I started the weekend by removing the NA block from the engine stand and replacing it with the TD. I wasted no time and started tearing into it. Like I said I was given this engine, and have no history or any information about it. The only thing that I do know, is that this engine is from a quantum.

Here are some pictures of the tear down.

This is a mechanical lifter TD


Looks like the NA engine will be put to better use somewhere else.
















Looks like someone over tightened that timing belt.. 


Freeze plugs gone. Down to a bare block!




I will post build plans in next post.

[dh13]

So I have decided that I have a lot of research to do still. I thought that I had a fair grasp on this Volkswagen thing... Well I decided today I have a lot (and I mean A LOT) more to learn.

But I know I read or was told that the 1.6TD and the AAZ have the same issue with the crank nose failure?

I was looking at my NA crank nose and it looks like this



I know that there was an early style nose, much like the 1.5L crank (which this might be a 1.5 crank I have no idea) and there was the later style and the TD style.

I just want to make sure that I am aware that the TD crank like this one;



is prone to failure much like the AAZ crack?

Am I correct on this issue? It this is the case I will be adding at least one dowel pin to the nose of the crank for extra security.



Build Plans:

So now that I have a true TD I can focus on other things. Like I said above I am not out for ridiculous numbers as far as horse power and tq. are concerned. I want a reliable motor and a fun toy. Although I will take as many ponies as I can get  . These are my plans as of now.

First things first, I need take the block to my machinist and find out if the bore is good for standard size pistons. I am pretty sure the pistons that were in it are not usable.

If I do have to bore it and buy new pistons that is $400 less I have to spend on other thing, which sucks, but that is life.

List of things I know for sure

* ARP head studs
* ARP rod bolt kit
* Stock head gasket ( I gave up on a MLS and all that stuff)
* For now stock T3 turbo
* Governor Mod
* 10mm head (if I can find one for a reasonable price)
* Valve grind
* A little porting work

I think that is all for right now.

Although does anyone think that ARP main studs are a good option or will just reusing the stock bolts be reliable? I might sound stupid asking that, but I truly don't recall reading anything about main studs/stock bolts.

I will post more after my trip to the machine shop.

[dh13]

I'm finally getting some time to sit down and post. I have been running around with my head cut off trying to find all the parts that I am missing. I think I have finally found 95% of the parts that I need for my swap/build.

I finally heard back from my machinist, he hot tanked and magged the block. Turns out the block is good and we can go ahead. The beginning of this week I dropped everything off to him so that he could do the machining and all the balancing.

I bought a Ahu sprocket and I am having the crank machined to accept it. (I don't feel confident with my machining skills to do it myself.) I will have pictures and information when I get it all back from the shop.

Here are some pictures of what I have been doing.

This is only about 1/3 of the parts that I bought. Just to name a few things. KS 0.5mm turbo pistons, 36mm oil pump, VR seal kit, arp head and rod bolts and losts more.


Decided it was time to take the head apart. I will be using a different machinist for my head work.


Some slight surface rust on the cam. I still haven't found one yet though.


I decided to clean up my oil pan and add a nice skid plate. I plan on bagging thing truck so I want to be safe.








I am slightly embarrassed about the welds. I can weld really good I swear.




Since I can't really do any motor work, I decided to take some time to clean up the engine bay.






I am going to paint the truck soon. I just don't know what color to paint it. I am thinking UPS brown with metallic clear. It should look pretty good. The only other color I am thinking is a factory vw green. I don't know the exact code but it is a lighter metallic green (bali green?).

I will post more when more comes along. 
 

[theman53]

i like this color.

[GEE-BEE]

I vote for the green with a white engine compartment...

Looking Good !

I have a extra positive battery wire if need be and a set of 15 x 6 BBS wheels in fresh silver Powder coat

GB