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Our first Vanagon - A Turbo Diesel for a USA roadtrip
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Syncroincity
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PostPosted: Fri Oct 17, 2014 8:05 pm    Post subject: Reply with quote

The tachometer conversion thread is back online;

http://www.vwdiesel.net/forum/index.php/topic,3741.0/topicseen.html
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BlueTucker
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PostPosted: Fri Oct 17, 2014 10:39 pm    Post subject: Reply with quote

Waldi wrote:
26 is ok.
I would change the rod bearings in any case. The main bearings if they look bad.
Measure the shaft if it wasnt polished before.
You can brake an old piston ring to clean the ring groves from carbon.


I found one main bearing is missing a small chunk. But the crank looks perfect. I will be replacing the mains and will measure the rods.

Not sure how I missed this. The other bearing in this journal was fine.
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BlueTucker
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PostPosted: Fri Oct 17, 2014 10:45 pm    Post subject: Reply with quote

Syncroincity wrote:
The tachometer conversion thread is back online;

http://www.vwdiesel.net/forum/index.php/topic,3741.0/topicseen.html


Cool, Thank you!
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BlueTucker
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PostPosted: Thu Oct 23, 2014 5:13 pm    Post subject: Reply with quote

Well bad news. All back together. Runs fine. Smokes bad. No intake hoses hooked up at all. Just a open intake manifold. Ran it until normal operating temp and it is still smoking. Looks like the garage-hone and re-ring was a bust. Need to leave on a trip and have no motor. Anyone want a vanagon? Smile
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vanagonjr
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PostPosted: Fri Oct 24, 2014 10:55 am    Post subject: Reply with quote

BlueTucker wrote:
Need to leave on a trip and have no motor. Anyone want a vanagon? Smile

Well, when I read the following 3 things together, I thought "Hell, more guts than me." At least when coupled with a Vanagon, with a bicycle I would not have just thought - GO!

BlueTucker wrote:
10,000+ mile trip across the USA. Leaving end of next month. We have limited funds to do this trip:)

I think the thing to focus on taking the trip itself - get a mini-van, plenty of room to sleep, and cheap to buy. I saw two 50+ year old woman in Alaska in a mini-van with Cali plates, setting up the bed to crash in a Walmart parking lot. A Vanagon is not essential to travel.

Of just use a tent and fuel efficient car. Heck I did not get my 1st Vanagon ready for a 1-month trip with family (a blessing in hind-sight) and we took an Escort Wagon, roof top box and tent. If a family with 2 kids under age 5 can travel with a tent for a month and never stay in a hotel, so can you! Very Happy
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BlueTucker
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PostPosted: Fri Oct 24, 2014 5:46 pm    Post subject: Reply with quote

vanagonjr wrote:
BlueTucker wrote:
Need to leave on a trip and have no motor. Anyone want a vanagon? Smile

Well, when I read the following 3 things together, I thought "Hell, more guts than me." At least when coupled with a Vanagon, with a bicycle I would not have just thought - GO!

BlueTucker wrote:
10,000+ mile trip across the USA. Leaving end of next month. We have limited funds to do this trip:)

I think the thing to focus on taking the trip itself - get a mini-van, plenty of room to sleep, and cheap to buy. I saw two 50+ year old woman in Alaska in a mini-van with Cali plates, setting up the bed to crash in a Walmart parking lot. A Vanagon is not essential to travel.

Of just use a tent and fuel efficient car. Heck I did not get my 1st Vanagon ready for a 1-month trip with family (a blessing in hind-sight) and we took an Escort Wagon, roof top box and tent. If a family with 2 kids under age 5 can travel with a tent for a month and never stay in a hotel, so can you! Very Happy


Some encouraging words! Thank you! The lady has given up hope. However I have secured a job in Colorado for the winter and we have some funds for a few weeks in Thailand before mid December. Will be planning this soon. I however am not one to look defeat in the eye and lay over. I was quoted $520 to bore the block and grind the crank. May have to buy some new oversize rings and bearings. Would be another two weeks but a perfect longblock. We will see
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vanagonjr
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PostPosted: Fri Oct 24, 2014 5:59 pm    Post subject: Reply with quote

Atta boy! OK - remember Gas 2.0 ABA motor is another option - Danfromsyracuse can tell you what you need to know. Relatively cheap too. Seriously, consider this route.
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?Waldo?
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PostPosted: Fri Oct 24, 2014 7:32 pm    Post subject: Reply with quote

I would measure the crank to see if it is within spec.

If you have the block bored you will need to fit oversize pistons. Pistons are $350ish with rings.
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BlueTucker
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PostPosted: Fri Oct 24, 2014 9:03 pm    Post subject: Reply with quote

[quote="Andrew A. Libby"]I would measure the crank to see if it is within spec.

If you have the block bored you will need to fit oversize pistons. Pistons are $350ish with rings.[/quote

Found 1mm over size are $299 with rings and pins. Are there any ones to stay away from?

Any idea if any gas engine exhaust manifolds fit these heads? I'm pretty sure the turbo is gone so I may run it NA until after the trip. Finding a vanagon diesel manifold is going to be tricky. I can weld or modify if needed.
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BlueTucker
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PostPosted: Fri Oct 24, 2014 9:06 pm    Post subject: Reply with quote

Figure I would also share the inside finished (mostly). Turned out well.

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?Waldo?
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PostPosted: Fri Oct 24, 2014 9:27 pm    Post subject: Reply with quote

I would go with either Kolbenschmidt, Nural or Mahle. If you find a set of those for $300 that's a good deal.
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Gizmoman
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PostPosted: Sat Oct 25, 2014 7:03 am    Post subject: Reply with quote

The interior turned out very clean.

As for the oversize pistons, you get what you pay for. Please take no shortcuts when it comes to the engine.

Finding one that runs already may be a reasonable choice.
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BlueTucker
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PostPosted: Sat Oct 25, 2014 2:56 pm    Post subject: Reply with quote

Gizmoman wrote:
The interior turned out very clean.

As for the oversize pistons, you get what you pay for. Please take no shortcuts when it comes to the engine.

Finding one that runs already may be a reasonable choice.


Well I talked the lady into doing the motor. Will be ordering pistons and needed parts here later. Need to get that motor out and ready for machining
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vanagonjr
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PostPosted: Sat Oct 25, 2014 7:15 pm    Post subject: Reply with quote

BlueTucker wrote:
Figure I would also share the inside finished (mostly). Turned out well.

OK - now that I see how much work, and how nice a job you did there, forget what I said about the mini-van! Laughing

Get that puppy going!
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Flint reversed 1.8T W/Passat 5-Speed
LiMBO (late model bus club) www.limbobus.org
LiMBO is on Facebook too! https://www.facebook.com/groups/
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?Waldo?
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PostPosted: Sat Oct 25, 2014 7:24 pm    Post subject: Reply with quote

You said it's very smokey. Did you drive it enough to seat the new rings?
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BlueTucker
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PostPosted: Sat Oct 25, 2014 11:23 pm    Post subject: Reply with quote

Andrew A. Libby wrote:
You said it's very smokey. Did you drive it enough to seat the new rings?


It ran for awhile stationary. Torqued head bolts. Ran for another 30 minutes stationary. Then took it out onto the highway. Did a quick trip floored. Slightly uphill. Could barely reach 45mph. Smoked like hell the entire time. Honestly, I am happy that we decided to do a full rebuild. Money well spent. I am also trying to source a new turbo if anyone has one laying around. Even if it's a good "core" for a rebuild. Mine is trashed.
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Waldi
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PostPosted: Sun Oct 26, 2014 1:40 am    Post subject: Reply with quote

Check compression.
I still smell a injection pump problem.
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BlueTucker
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PostPosted: Sun Oct 26, 2014 11:10 am    Post subject: Reply with quote

Waldi wrote:
Check compression.
I still smell a injection pump problem.


Even with blue smoke? Not white. I was adjusting the enrichment screw and could get blackish smoke to come and go. Then was left with heavy blue smoke.
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Waldi
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PostPosted: Sun Oct 26, 2014 11:38 am    Post subject: Reply with quote

What about the valve seals ?
If u had checked the compression before disassemble the engine and after, you could be sure for one thing.
But for example if your compression is more less good, the car should run better like now even with blue smoke.
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singler3360
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PostPosted: Sun Oct 26, 2014 12:23 pm    Post subject: Reply with quote

vanagonjr wrote:
BlueTucker wrote:
Figure I would also share the inside finished (mostly). Turned out well.

OK - now that I see how much work, and how nice a job you did there, forget what I said about the mini-van! Laughing

Get that puppy going!


Agreed. That is a very nice custom interior job. I'd hate to be stuck in a Walmart parking lot in a mini-van knowing this nice interior was sitting at home or sold off. I guess going to Thailand would lessen the impact but stay with this project as long as you can; you will love your van far longer than a year once you sort out the rebuild.

Once upon a time Justin at GreaseWorks.com provided consulting services. I know he's away from his business mostly this year, but it may be worth contacting him to see if he's available for consultation. He's a guru of the Vanagon TDI conversion and is also an all-around good guy. He's also active over on the Yahoo Vanagon TDI group still and might be able to give you some pointers there as well.
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