1.6 not running anymore

[TD100]

 Hello,

 First post here, but long time viewer. A while back I put a NA 1.6 w/ a VNT in my Toyota T100 after the V6's head gasket went up for the last time. It's been running nicely for the past 2 months or so until about 2 weeks ago when I noticed a much louder knocking sound. I figured I had the fuel turned up too far as I had been tweaking it for more power, so I screwed out the fuel screw about a .25 turn when the engine completely died on me. You could hear the pistons still pumping though and as they slowed down, you could her little metallic sounds pinging around inside. It would not start up anymore, only the starter turns over. Took the starter out today and noticed I could spin the flywheel w/ my fingers very easily. Broke crank I'm assuming? Too much boost? The engine was boosting around .5 psi at idle and I could never get any kind of smoke out of the exhaust. Any smoke that was visible was always a light gray. The VNT's only control was the flipped spring mod turning it into a pressure diaphragm instead of vacuum, which worked very well.

 I have a 1Z w/ a Disco pump waiting to swap into this truck and only used the 1.6 to verify my adapter and motor mounts worked, so I'm not worried about fixing it. I'm really just trying to figure out what exactly went wrong w/ this one so I do not kill anymore of my 1.6s for future swaps.

 Thanks for the time and you can check out some of my pics at http://www.geistsystems.com/ 

 -Rich

[veedubcanuck]

Sounds like you sheared the crank to flywheel bolts to me.

[rallydiesel]

Did you use new flywheel bolts?

[TD100]

 ..sure did as I was not sure if they were reusable even though they looked fine.

 At least that's an easier fix then what I was expecting.

 I'll dig into this and post what I find. Thanks for the help!

[arb]

When you spin the flywheel, does the pulley on the other end of the crank move ? What did you torque the flywheel bolts to? Bolts are very weak in shear - crank bolts get their strength from the compression between the crank / flywheel.

[TD100]

  ..no, the pulley does not move while spinning the flywheel which is why I thought the crank was broke. FW bolts make me a lot happier though.

 No clue on how much I tightened them ether. I guess what I thought was tight, obviously was not enough. I'll loctite them in this time too.

 Just went out and put it in gear -flywheel does not move. In neutral -flywheel moves. Guess it's the bolts.
Thanks again everyone!

[rallydiesel]

You definitely need to torque them properly. Also, are you sure they are the proper bolts? New oem bolts from the dealer already come with blue loctite on them. Whatever you used, probably weren't the proper bolts.

[TD100]

  ...the bolts I used were not OEM flywheel bolts as I modified a V6 Toyota flywheel to fit the VW crank. This entailed opening up the flywheel's bore to fit the larger VW crank and indexing 6 new holes to match the off-set VW bolt pattern. OEM bolts would not work as the V6 flywheel is much thicker then the VW one and this would make the bolts too short. The bolts I used were grade 8, I did use loctite (very little), but I doubt I torqued them down very well.

 This procedure is sold as a kit by some companies to swap VW diesels into Toyota trucks and Suzuki Samarai/Side Kicks, but only w/ 4 cylinder drive trains. Nothing is available if you have a V6, so I made my own bell housing adapter, modded the fly wheel, machined a new pilot bearing and fabbed new motor mounts. This is all R&D at the moment. Everything worked on the first go around, just need to keep the flywheel on

 Again, appreciate the help.

[Rabbit on Roids]

i kinda like the picture of the intake piping hooked up to the turbo intake AND the engine intake. lol

[TD100]

  ..LOL! Yeah, it's really ghetto but I needed something to mock up just to get things running. It works surprisingly well though. Still need to decide on what to do for the intercooler, but at least there is plenty of room..

[Rabbit on Roids]

i was messing around with my volvo 740 cooler, and it would have fit beautifully in front of the radiator in my 4runner. and i know your T100 is wider than my truck, so the cooler should work. they have 2 different style intercoolers in the volvos. one has the in and out on the top of the tanks, the other one has the in and out at about the middle of the tanks. and both are cheap and plentiful at junk yards. i picked mine up for less than 20 bucks.

[TD100]

  ...oh, I see the image you were talking about now (1301). Yeah that's when I said "that was too easy", then looked at it again. LOL. Need to delete that one..