6.9 now runs, but...

[TJ 450]

I got it running nicely today, abeit without suspension. I just diverted the hose into the reservoir. However, there are two very annoying and dissapointing problems.

1. One of the sump hose flanges is leaking.

2. Slight coolant leak at manifold gasket (front).

We all know what this means... it will all have to come off again.

In hindsight, I really should have used hylomar on the gaskets!

So, that's a real PITA, although it is running very nicely and the lifters are nice and quiet. I'm in the process of uploading the videos now.

Tim

[TJ 450]

Here we go...

6.9 Starting

Tim

[Big_Richard]

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[TJ 450]

Nah, no sealant on the manifold gaskets or the flanges on the sump, although there wasn't any before. Although the surfaces are not new anymore, so it makes sense to use sealant and I will.

Yes, now I can have the sump powdercoated and all the rest, which will be awesome.

Tim

[Big_Richard]

.

[TJ 450]

Hahaha my mistake, I meant the oel tank. 

[Big_Richard]

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[TJ 450]

I might remove some parts for plating too, but I need to back off from the 6.9 for a few weeks (as far as spending money is concerned, anyway). At least I know the engine runs well and sounds sweet, no smoke on startup either.
Fortunately, the only parts that are going to cost me $$$ here are another set of manifold gaskets. Those flange gaskets on the sump flanges are only a few bucks, plus I already have the genuine sealant.

Tim

[TJ 450]

Here's a vid of the exhaust. The slight "pop" is just the camera adjusting the audio level. There is no hint of any missfire.

6.9 Exhaust

Tim

[koan]

2. Slight coolant leak at manifold gasket (front).

We all know what this means... it will all have to come off again.

First time I had the inlet manifold off it had a small leak when replaced, at the rear which disappeared with a bit of extra torque.

Using a sealant on the gaskets shouldn't be necessary, I decided not to last time but maybe I will this time.

Engine sound really good - front and rear, hope mine comes up as well when I eventually get it back together.

koan

[TJ 450]

That's interesting, Koan. Do you remember where you found the torque specs for the manifold? Maybe I got it wrong to begin with. It is a small but obvious leak.

Upon investigation, the small oil leak is due to me attempting to install the flange back-to-front and distorting it slightly, I then changed it around but the damage was obviously done. I'll have to remove it and inspect the damage.

Tim

[koan]

That's interesting, Koan. Do you remember where you found the torque specs for the manifold? Maybe I got it wrong to begin with. It is a small but obvious leak.

Coming back to me now, there isn't a figure in the engine manual or the technical data book. I found a table or torques for metric bolts in to aluminium on the interweb and used that. As best I can recall it was in the order of 20 Nm.

Fingers crossed for the flange

koan

[TJ 450]

Yes, I think I used 20 lb-ft, but I will inspect and retighten them all to be sure. The coolant leak appears to have stopped, as I tightened the two bolts either side of the offending port (LHF), although it will probably show up again when the system is under pressure.

Hopefully the flange will just need a fresh gasket and sealant, fingers crossed anyway.

Tim

[s class]

20 lbft and 20Nm are not the same thing. 

[TJ 450]

20 lb-ft and 20NM are not the same thing. 

Yes, 27.09NM, which is clearly far too tight.

The coolant leak is not going to right itself (this is a car, not a living organism  ), so...

After running the engine to operating temperature and letting it cool off for a bit, I drained the engine oil, then the coolant.

I have now stripped all the K-Jet gear off as well as everything down to the A/C compressor at the front.

I observed that the thermostat housing flange is cracked, the source of one leak.

I will be purchasing the required gaskets and will be redoing these jobs so it does not leak again in the foreseeable future.

There will also be parts sent out for cad plating.

Tim