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First thing this morning I went down to my NAPA FLAPS and found everything I need to effect repairs on the stripped coolant pipe fastener thread. They had an 8 mm 1.25 helicoil kit, and I was also able to pick up two injector seal kits. I returned home and removed the coolant pipe from the head. Just for fun, with the pipe removed, I attempted to screw the hex bolt into the head. To my surprise, I found good threads when the bolt was in about 3/4 of the way. So I threw away the gasket for this fitting, and spread some Permatex RTV gasket maker compound around the pipe flange, circling both the pipe opening and the bolt openings. I then refitted the pipe and found that without the fiber gasket I was able to get a good purchase with the defective fitting. Now we'll see just how good this Permatex gasket is!
Late afternoon, I started back to work.
Then I learned an important lesson: Install the alternator prior to the installation of the air intake manifold tubes! You would not believe how difficult it was to get that bottom bolt through from the back of the alternator bracket, through the alternator and out the hole in the front of the bracket! I finally had to ask my daughter, whose hands are smaller than mine, to help. In a matter of minutes, she had the bolt through and I was fitting the nut. After threading and tensioning the belt (this one goes over the oil filler tube), I began making the electrical connections. At this point, I immediately realized that somehow, during my fussing with the alternator, the little green wire that comes out of the alternator and attaches to a connector on the front of the power steering pump had broken off. Luckily I found it on the ground. Unluckily, I don't have a clue where it attaches to the alternator. Guess I'll ask the fine folks on the Vanagon Mailing List. I'll bet they know! July 8, 2002: We're back home after nearly 3 weeks away, and it's time to finish reassembling this guy and see if he runs. I'll be putting the finishing touches on this section of my site over the next several days. Today, we have a heat index of 108, and I'm not going to do anything until maybe this evening, so please be patient. July 9, 2002: 1:45 PM: OK. One of the kind gents on the vanagon.com mailing list told me that the broken alternator wire just attaches to an alternator ground. I stripped the insulation off the end and found a nut and washer that would fit over one of the small bolts holding the alternator case together and -- Voila! -- It's reconnected. Finished attaching various and sundry hoses, gapped the spark plugs to 0.7 mm per Bentley, jabbed some antiseize compound on them and installed same. Bentley recommends torquing to 14 ft lbs. I couldn't use my torque wrench to tighten them down, so I just guessed... Turned them in until they stopped, then gave them another quarter turn or so. Back later... July 10, 2002: 5:30 PM: Well, today I put the finishing touches on my reassembly. Installed the spark plug wires (had to unscrew the caps on the top of the plugs so they'd fit), put the air filter/AFC assembly into place, and attached the last few connectors. I then installed a new washer on the oil drain plug and screwed it in appropriately (moderately) tight (don't over do this). Pulled a brand new oil filter out of the box and filled it to the point that it wouldn't spill out when I screwed it in, then installed it, following the instructions on the side of the filter. After that, I tightened the two coolant drain plugs (one under each head), reusing the old washers. I didn't put fresh washers on, because I am filling it initially with plain water and expect to drain it and refill with antifreeze/distilled water mix after I check things out and make sure my head is through leaking. That's when I'll install the fresh washers. After putting in about 3 1/2 quarts of oil, I pulled the garden hose over to the back of the van and filled the coolant expansion tank. What's that!!! Water coming out of the water pump! SH*T! Sure enough, the rigid pipe that runs from the right rear of the engine to the coolant pump, threading between the pulleys and the engine, was leaking right where it goes into the pump with just that O ring to seal it. Hmmm.... I'll deal with this later. Right now, let's see if this sucker runs. I reconnected the ground (negative) terminal on the main battery after first lightly touching the cable to the post to ensure there was no humongous spark that would be indicative of a serious short circuit somewhere. Then, after checking to make sure there were no tools left in the engine and that nothing was in the way of the belts and pulleys, I lifted myself into the driver's seat and inserted the key into the ignition switch. What a joy to see those idiot lights come on when I switched the key to the ON position. With delight I gave the key a twist to start the engine. ---------- Nothing. I switched on the headlights and tried again. Nothing. And the headlights didn't dim. Plenty of battery. Looks like I screwed something up. I put the trickle charger on the battery and went into the house. Back to the Bentley. 6:20 PM: Hmmm... Went out to close the rear hatch. Just for the fun of it, I put the key in the ignition and gave it a twist. EUREKA! The engine started and ran for 5 seconds before it died. Now THAT'S what I call PROGRESS! |
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