4 - Fuel and Exhaust

     

4.1 Exhaust flange               4.2 Head Intake and Exhaust valves                           4.1 Air filter               4.2 Turbo Boost               4.3 Fuel tank gauge replacement              Table of contents

4.1 Exhaust flange 

		The exhaust connection. When you upgrade to A turbo diesel this exhaust flange ends up in slightly the wrong place, you can get it on with some effort but you need to have the pipes bent and reformed to line up properly.

4.2 Head Intake and exhaust valves

A Head, showing the exhaust and air intake valves. This the best I head I have ever seen, no cracks between the valves. Cracks are a common problem but not the sign of a wrecked head. As long as they are narrow and small the head may still be ok. This is not the head I used in the Red van rebuild project but from the first Engine I acquired that turned out to have totally worn block. If you are buying a used engine make sure it's been rebuilt by a reputable mechanic or if you buy an engine for a rebuild check the walls of the cylinders for wear. take the time to pull the head before buying. In my opinion anything beyond a very, very small ridge or no rideg at the top of the cylinder is not worth the money to rebuild as you are going to have to invest in machining and oversize rings and pistons

4.3 Air filter
			AIR FILTER A couple of configurations, the one on the left off a chevy truck, actually fits nicely, I punched a hole in the side to receive a fitting for the cam cover breather hose .The right one is the original hose with an off the shelf K&N filter. Clean air and lots of it that's the key.
4.4 Turbo Boost
			Boost pressure. You need to drill a hole in the top of the intake manifold, then thread it and insert a threaded hose barb. Run the hose thru the firewall and hook up a gauge. Low and behold the turbo produces up to 10 lbs of boost when working hard.

4.5 Fuel tank gauge replacement

			Fuel sender replacement. This a difficult job, you have to cut a hole in the floor or pull the tank, I opted for the hole. The original sender is in a completely inaccessible place so I just abandoned it. You need to clean up the area around where youare going to drill to keep debris falling into the tank to a minimum.
			I drilled a new hole in the tank spliced an extra length of wire on the old sender wire and put a new ground lead. Use a marine fuel tank sender as they are cheap,. Use a vacuum cleaner while drilling to suck away the debris from the drilling operation.