After I thought I had finished up the work on the SDL Timing, I ran
the car a little then found it had an air leak in the fuel lines and
bad glow plugs. I wanted to check the GPs before I put the intake on
but SWMBO had run off with the vehicle housing my good multimeter, so
I wasn't able to check them then.
So today was the day. Put in a new starter, then the GPs. Since I
didn't have a ALDA shim the last time, Today I had time to try to
create one out of something. I tried a copper seal from the oil
drain plug for the 603. It was too small ID and OD. Wondered if I
could stretch it out using a needlenose. pulling it oval, turn 90
degreed, then pull oval again. after may a dozen pulls, I rounded it
out, and found it was still a little small. So a few more pulls,
round it out, and it was a snug fit in the base of the ALDA. It went
together nicely.
So, to recap:
First: replaced ball joints and UCAs.
Then:
Replaced AC condensor
then had to move the timing chain forward a link to retard the valve
timing a tooth. That corrected the timing. Then I had to remove the
IP to correct IP timing.
While the IP was out, I put a new oring in the shutoff valve,
tightened the cover plates
New GL-5 antifreeze. WP and Idler are good!
Put in new Beru GPs in #3 and 4, as they are next to impossible to
change with the manifold on.
Found original fuel lines on the engine: prefilter to heater, and
heater to Main Filter. Marked "86"
replaced fuel hoses in the engine bay.
Replaced the other 4 GPs
Replaced starter
Replaced a few hunks of vacuum hoses
So, a "simple" replacement of the condensor ended up in quite a bit
of work spanning several weeks (some delayed due to weeks of cold
rainy weather)
Road test today: Sounds way better. Runs smoother. no lifter
click. Takes off better from a start. Does not chirp tires. Does
not smoke on floored 0-65 MPH runs, so the ALDA is not over-fueling.
So far, fuel consumption appears to be better. Leak from shut off
fixed. Fuel leaks around IP appear to be stopped. Accelerates well
at 65 MPH. It is NOT a 240D! (They have their place) So far it
seems like it may get better mileage. Time will tell.
Seems like there may still be an air leak in fuel lines. Will find
out tomorrow. Probably should replace the one remaining line under
the hood and the hoses at the tank.
May still be able to use a little more ALDA shim.
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