Replacing the IP in Klaus - a heart transplant.....

[jbrianfoto]

Well, I was gonna do this to Spouse first, but she needs allot more work than Klaus, so he went under the wrench today. My son Matthew and his best friend, Eric, helped me out all day long. I let them do as much as I could stand (I'm a control freak, real hard to let someone else do the work).

Got all the parts laid out nice and neat, pulled Klaus into the service stall (our backyard covered gravel spot next to the basement doors).



We started working down the list of items to remove (According to the FSM). Took out the fan, vacuum pump, intake manifold, unhooked all the lines and crap from the IP, got the basket installed. Matthew and Eric worked on getting the big stuff off the top of the engine - I had them remove the valve cover too so I could better explain how the cam/valves/cylinders all work together.



While they were working on that, I took the new IP and connected the new fuel lines and the new check valve, thumb tight.



When it got further along, it came time to attach the IP locking tool into place. I had practiced on the new IP and found that the tool (got it on eBay from a third party manufacture, it was not an MB tool) - the slot was VERY thin and shallow. It would not grip the indexing tang, no matter how hard I tried. So I put it on the vise and cut the groove a little deeper. It is still a pain, but at least it works now. We tried and tried and tried for about an hour, but getting that tool locked was very difficult. I kept having to rotate the engine around whenever I would miss the target. Finally got it, I was so thankful. Most importantly, I showed my boys that sometimes you just have to keep trying (and to never get mad and throw tools or to cuss).



The old and new IP's sitting together.

Learned that you have to pull the cruise control actuator out of the way before the IP can be removed totally. I forgot to order a new O-Ring (for between the IP and the engine block) - so I'll be able to finish this job next weekend.



JJ pointing to where the IP used to live. There is a gob of old WVO crud back there - am going to do my best to clean it off - I got the biggest chunks with a screw driver.

[BayouFlyFisher]

That is so cool that you are taking the time to show those boys how to work on a car! My step dad did that fit me 55 years ago and it has served me well ever since. He remains my hero to this day!

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[Mölyapina]

Originally Posted by jbrianfoto

Most importantly, I showed my boys that sometimes you just have to keep trying (and to never get mad and throw tools or to cuss).

Good for you! Throwing tools and cussing never actually fixes anything . I generally work on the car alone, as I am the only one in our family who does that sort of stuff, so I've taken to singing to myself (mostly hymns, I love hymn music) to keep my spirits up.

Happy Easter to you! He is risen .

[Diesel911]

I like the black and white Photos. Especially picture 2 reminds of a early 1960s do-it-yourself manual. Even the dress of the 2 Guys would fit in back then.

[Diesel911]

Originally Posted by Jooseppi Luna

Good for you! Throwing tools and cussing never actually fixes anything . I generally work on the car alone, as I am the only one in our family who does that sort of stuff, so I've taken to singing to myself (mostly hymns, I love hymn music) to keep my spirits up.

Happy Easter to you! He is risen .

That reminds Me I got mad once an blindly threw 10 inch Cresent type Wrench. It hit the Tire on the Truck and shot up on the Roof.

I clearly paid for that Tantrum having to drag the Ladder out of the Garage and go up on the Roof to get the Wrench.

In My case it was the Wrench that had risen.

[Mölyapina]

Originally Posted by Diesel911

That reminds Me I got mad once an blindly threw 10 inch Cresent type Wrench. It hit the Tire on the Truck and shot up on the Roof.

I clearly paid for that Tantrum having to drag the Ladder out of the Garage and go up on the Roof to get the Wrench.

In My case it was the Wrench that had risen.

[jbrianfoto]

Originally Posted by Diesel911

I like the black and white Photos. Especially picture 2 reminds of a early 1960s do-it-yourself manual. Even the dress of the 2 Guys would fit in back then.

Thank you, that's actually how we dress around here on the weekend. I am also a photographer (so is my Dad and was my Grandfather). I actually stopped for a break and set up my 60 year old 8x10 view camera to take a few portraits of Eric.



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[jbrianfoto]

Originally Posted by Diesel911

That reminds Me I got mad once an blindly threw 10 inch Cresent type Wrench. It hit the Tire on the Truck and shot up on the Roof.



I clearly paid for that Tantrum having to drag the Ladder out of the Garage and go up on the Roof to get the Wrench.



In My case it was the Wrench that had risen.

Ha! Made me laugh. Thank you.


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[jbrianfoto]

Whew! Got the new squeaky clean IP installed in Klaus this weekend. It wasn't a fast job, had to buy some long Allan sockets, but it's done for now. Took about 30 minutes to get all the air bled out of the hard lines, but now he cranks right up and the best part......wait for it...wait for it.....the TURBO works again!

We took him for a quick 20 minute drive. Noticed some black smoke when I try to floor it, but otherwise not too bad. I'm assuming the black smoke may mean I need to slightly adjust the IP's position. Am going to read thru the subject here on the forum and see what I can learn.......because I have one more car to do this to, Spouse got moved into the workshop space this afternoon as soon as Klaus drove out.


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[Maxbumpo]

Black smoke - probably accumulated carbon in the pre-chambers, head, piston. Drive the car like you stole it for a while, or if impatient perform an Italian tune-up. I'll bet the smoke clears up just fine.

[jbrianfoto]

Originally Posted by Maxbumpo

Black smoke - probably accumulated carbon in the pre-chambers, head, piston. Drive the car like you stole it for a while, or if impatient perform an Italian tune-up. I'll bet the smoke clears up just fine.

I think you were right. The black smoke went away after I drove it into work today, I95 north, usually between 70-80. Thanks for the tip!


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