OK,
I have an 82 VW Westy (originally had the 1.6 non TD in it). I purchased this from someone who had put in a 1.9 AAZ and did a decent job.
The van ran well but as always - still a bit under powered. I built a boost controller and raised the boost from 10 to 15 psi and slightly increased the fuel.
It ran much better and I kept a close eye on the water temp gauge and made sure it never went into the 2/3rds zone. I don't have an EGT sensor or an intercooler and knew I was messing with trouble but tried to be "nice" by watching the water temp (silly me).
I drove it back and forth to work and on several camping trips in the Sequoias with no issues.
A few months ago I was heading up the long steep grade from Riverside to Barstow (CA) and about 200 yards from the top it went "pop" and abruptly died. My temp instantly pegged. To keep this short, I was able to re-start it within 15 minutes. It ran rough and there was white smoke as I limped it over the top and down to a cafe at the bottom of the grade.
I am finally tearing it down and couldn't wait to get the head off so I could see where it had failed. My problem now is - I don't see anything wrong
The head bolts were 100+ ft lbs when I broke them loose and I have inspected every line left from the metal HG (3 notch) - they are all continuous as far as I can tell.
There was no water in my oil and no oil in my water.
I'm stumped.
BTW - when I was removing the manifolds one bolt was missing from the turbo where it bolts to the manifold - if anyone has a spare (12 point head) i'd appreciate a PM. Also the bolts that held the intake on to the head were slightly over finger tight - I'm amazed it even ran like this.
Anyway, I am hoping a few of you Gurus can tell me what I am overlooking. The van started several times after this happened and other than quickly overheating and billowing white smoke and feeling like it ran on 3 - it did run.
Could the head be cracked and I can't see it? I even separated the metal HG so I could look between the plates - spotless.
Any ideas?