Well here is a long overdue update. I've been spending the past couple of days trying to get the turbo taken apart. WHY DIDN'T ANYONE TELL ME THAT THE IMPELLER BOLT IS REVERSE THREADED?!?!? THERE WASN'T A SINGLE FAQ THAT MENTIONED THIS!!!!!
Anyways, I learned that the turbo is in trouble, the previous guy damaged the impeller in a way that I couldn't see it until I had the snail off. I'm thinking that he made the same mistake that I did. There were other things going on inside the turbo that I couldn't see that make more sense now.
Here's the turbo teardown:
You can see that the inside was coked up, it's all nice and clean now. I am going to be getting a turbo rebuild kit for this, and now that the impeller and turbine are out I might try to get a pair that is more suitable for low RPMs of diesels.
But wait, I did more on this warm and comfortable day. I decided that I wanted to hammer out how I was going to route all the coolant lines. This is something that has been vexing me for a while, but soon to be no longer. The easier ones were done first as I had the materials to get this job done. Note that nothing is tightened down as of yet and I will be working on proper mounting hardware.
For the heater core plumbing:
Solid line that is going to go over the valve cover, near the washer lines, brake lines, fuel lines and part of the master harness. I am going to make some sort of bracket to make this all nice and neat by the time that it's done.
and here is the lower heater core port to the rear of the water pump. Note that I stuck the valve in the heater core to always open so the direction of the flow will be fine being the opposite as if it were a gas equivalent. The flap door will keep the cooler air coming in when I don't want heat, it's been resealed for better efficiency
and here is how I am going to find the right radiator hoses for this thing. One thing that sucks major *** on this one is that the ports on the motor are slightly larger in diameter than the ones on the radiator itself. The diesel uses bigger hoses. I should be fine though as I do have a backup plan involving a stainless steel reducer if I really need to. What I did to get the right shape of the hoses is to take something bendable but solid (like solid copper wire) and make the approx shape and length that I need. The white wire is for the upper hose and the black wire is for the lower hose:
I also figured that due to financial constraints I am probably going to be starting this engine up for the first time as a non-turbo. I am going to be doing it this way so I can
#1 make sure that everything on the inside is torqued down right. I don't want another rod through the side of the block.
#2 find leaks. Oil or coolant leaks while NA are a lot less damaging than for turbo.
#3 Verify that I don't need to send the injector pump to the repair shop because of leakage. If I do that'll be a few hundred dollars.
#4 Verify that the injector pump timing is spot on. If it's a little bit off and the EGTs are high while it's NA, the damage would be much higher under boost.
#5 I can let it idle while at home for a few hours (once verified that it's solid) then do an oil change to help keep the internals nice and clean, especially since it sat for quite a while.