[OT] Diesel HG help needed

[drew at scirocco.cs.uoguelph.ca (Drew Mac)]

Mark F. wrote:
> As some of  you may have read in another post the head gasket (I'm
> assuming at this point) has blown on the 1.6L NA diesel in my 82
> Caddy.  As this is the closest to roadworthy vehicle I have at the
> moment I need to get it back on the road ASAP.  Anyone got advice for
> a diesel newbie on the differences I'll experience vs. the same job on
> a gasser?
>

You'll need some patience, and some special tools.  There are a few 
differences in procedure between the gassers and diesels - most notably 
cam to crank to pump timing is critical - so you have a special tool to 
lock the camshaft at TDC, and a special tool to lock the pump at TDC 
(and to make the job easier, I have a "special tool" to lock the crank 
at TDC so it doesn't roll around when the belt is installed.)  I've done 
this job once or twice (or 50 times?), and it's pretty straight forward 
if you follow the book.  The cam gear is a friction fit on the camshaft, 
there's no keyway (who needs an adjustable cam gear when you have 
infinitely adjustable cam timing?)   The procedure to install involves 
locking everything down at TDC, loosening the cam gear bolt and knocking 
the cam gear loose on the cam, then installing the belt with no slack 
between the crank and the IP.  With everything lined up, you unlock the 
pump, tension the belt (45 degrees, not 90, between IP and cam gear) and 
then tighten the cam gear bolt.  Remove the cam gear locking plate (if 
you forget, you'll bust the locking slot out of the back of the cam) 
roll the engine a few times, and double check that everything lines up.  
Last step is to check pump timing, which requires a special adapter and 
a dial guage.  You can skip this step generally, unless the pump was 
removed or wasn't timed properly in the first place.

Your head is going to be scrap (sorry to say)  If the engine is a solid 
lifter I have a VW-rebuilt head still in the box, or if it's hydro 
lifter, Carrots original 1.6 TD head can be available - if you're 
planning on rebuilding the turd, that is.  If you're upgrading to TD, I 
have some A1 specific bits you'll need - notably the downpipe and airbox.

> If anyone has bentley scans of the particular pages, please email them
> - I'd like to get started asap on it, and don't have a Bentley just
> yet (I'll try finding one on Ebay or the Vortex later)
Sounds like Cathy can hook you up with the Bentley, you'll need the 
tools (I think Adam has the timing tool, not sure on the cam plate and 
pump locking pin)  You can fabricate/fake these two out - I've used a 
craftsman deep 7/16 3/8 drive socket for the pump pin and I have seen 
people use appropriately sized pieces of flat iron for the cam plate.


Let me know if you need any more info or tools...

Drew