Date:         Thu, 27 Sep 2001 17:58:00 -0700
Reply-To:     Michael Snow <mwsnow@HOME.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Michael Snow <mwsnow@HOME.COM>
Subject:      Re: Dan's Diesel Rebuild Part 6
Content-Type: text/plain; charset="iso-8859-1"

I'm pretty sure that I've seen something posted here about enlarging the
head bolt holes in and older head for the larger bolts.  I don't know what
would happen if you used the small bolts in a 'large bolt' head.  Notice how
the washers on the newer 12mm bolts fit so nicely into the recess in the
head casting.  I don't know if you can duplicate this with the 11mm bolts.
Proceed with caution until you are sure.

Whatever you do to make the head and bolts work, the engine is installed
from the bottom.  My mechanic buddy and I use an angle iron frame and a
come-along to hoist the engine into position.  The factory way is to use a
floor jack with a special support plate to lift the complete engine assembly
into place.

Intermediate shaft bearings are a job for the machine shop.  The shop that I
use charges $40 to install new ones.  Have the shop inspect the intermediate
shaft, too.  Bad bearing may indicate bad shaft :-(

The Vanagon installation does use a crankshaft pilot bearing.

Mike Snow
(no known relation to Dan)


> Diesel Folks:
> I have forwarded below a message posted to the Vanagon list
> (vanagon@gerry.vanagon.com) by Dan Snow.  I thought our diesel
> list members
> might be able to help Dan get his diesel Vanagon running.  Please
> reply to Dan
> (dieselvanagon@hotmail.com) directly, as I am not sure he has
> subscribed to the
> diesel lists yet.
> Thanks for helping in advance,
>
> Maynard Southard  OvO '79
> '82 Westy Diesel "Reinhardt"
> '82 Vanagon GL Diesel
> '93 EV GL "Klinger"
> '00 Golf GLS TDI "WooHoo"
> '84 Jetta GL TD "Donor"
>
> -----Original Message-----
> On Thursday, September 27, 2001 2:54 PM, Dan Snow
> <dieselvanagon@HOTMAIL.COM>
> wrote:
> > ...the adventure continues...
> > Last night my diesel consigliere and I went to the backyard of
> one of his
> > friends to retrieve my new diesel engine. It has been languishing in a
> > broken-down 1980 dasher diesel. It had no head, and the transmission had
> > been removed. The engine was teetering on two motor mounts. It
> turns freely,
> > and there is no ridge on the cylinder walls where the rings
> stops. That's
> > good.
> >
> > We jacked up the car and unbolted the motor mounts. We dropped
> the engine
> > out the bottom and dragged it to the car. The
> friend-of-a-friend with the
> > Dasher threw in the old head (more on that later) and the old injection
> > pump, which to my diesel buddy is like candy.
> >
> > We brought the engine back to his house and stripped it bare.
> We took out
> > the crankshaft and pistons. Happily, all the bearings and crank
> surfaces are
> > as smooth as glass. We will put in new bearings anyway. The one
> downside is
> > that the head bolts for the dasher are not the ones in my
> Vanagon. This may
> > cause problems because I am planning to install the head from
> my Vanagon.
> > The Vanagon bolts are slightly too big to fit in the threads of
> the dasher
> > block. But, because the dasher block PO threw in the head, I
> have the head
> > bolts that do fit the block.
> >
> > 1)Will it cause me problems to use the Dasher bolts in the Vanagon head?
> > 2)Will I have to machine the Vanagon head to fit the bolts??--hope not.
> > 3)Since we stripped the block down to nothing, will the engine
> gasket kits
> > include all the seals I need? OR will I need more.
> > Also, the one place there appeared to be significant wear was on the
> > intermediate shaft bearing closest to the timing belt.
> > 4)Is that a machine-shop replacement item?
> > 5)Also, am I mistaken, or did I see the infamous pilot bearing
> in the dasher
> > engine? I guess this is a longitudinal application so it might
> make sense
> > that there is one there? I plan to clean the block and paint it
> this week
> > before reassembly.
> >
> > That's it--The next step is to get the block ready for reassembly, then
> > reassemble and attach the head. I think I will leave it at that
> until I get
> > it installed, or at least right next to the van ready to install.
> >
> > Right now the plan is to consruct a derrick in the luggage
> compartment out
> > of 2 x 4's and a chain hoist. We will pull the engine up and
> out, and lower
> > the new one in. Any alternative plans?
> >
> > Thanks...
> >
> >
> >
> > Daniel Snow
> > PhD Student
> > UC Berkeley
> >
> > '82 Vanagon Diesel
> > '78 Puch Maxi Luxe Moped
> > '01 Xootr Scooter
>