17-06-2014, 11:45 AM
Will,
If you have the non-ac aux belt setup, you have to pull off the three allen bolts to pull the entire bracket off the block from underneith. This is a 5 min job mind, but don't try keeping the PAS pump in place because as soon as you get the sump off you realise you need to move the sump around to get it off (which the PAS pump stops you doing - as I found out
) this is just for non-ac but not sure about AC setups.
when removing/replacing pistons never ever ever force them. Just light taps as if you were cracking a ping pong ball with a lump hammer or hammering a drawing pin into the wall with a sledge hammer, and remove the lip on the top of the barrel before pushing them out so you don't crack the rings if your gonna re-use.
standard stuff;
dont mix the shells from pistons
dont mix the pistons from barrels
dont mix the front/back orientation of the shells (very bad!)
ake sure the head gasket is the right way round
when removing the head dont forget the dowel on the side of the head that goes into the engine mount.
Blow out the bolt holes on the block otherwise it can crack the block if there is oil in them when you replace the bolts
Copper grease them if angle tightening them this makes them hell easy
Dont forget the dowel in the head when the head goes back on
Dont forget to do all the shitty little stuff on the head while its off if your doing a proper build like testing injectors, glowplugs, pressure testing, skim, leak offs, fireseals and injector seals - which I do none of when I do mine :p
Defo the right idea doing the rods while the head is off, made the job easy just a few extra steps.
Just make sure you have all your shit you need to complete the job and it can be done in an afternoon, just depends on how much work you want to do on the head while its off.
I did mine just replacing the head gasket and re using everything else, but really should replace;
oil & fluids & filter
Shells
bolts
rings
leak off pipes
fireseals
injector copper seals
Depends how much you wanna spend, lots have people have done this with varying levels of replacement haha
If you have the non-ac aux belt setup, you have to pull off the three allen bolts to pull the entire bracket off the block from underneith. This is a 5 min job mind, but don't try keeping the PAS pump in place because as soon as you get the sump off you realise you need to move the sump around to get it off (which the PAS pump stops you doing - as I found out
) this is just for non-ac but not sure about AC setups. when removing/replacing pistons never ever ever force them. Just light taps as if you were cracking a ping pong ball with a lump hammer or hammering a drawing pin into the wall with a sledge hammer, and remove the lip on the top of the barrel before pushing them out so you don't crack the rings if your gonna re-use.
standard stuff;
dont mix the shells from pistons
dont mix the pistons from barrels
dont mix the front/back orientation of the shells (very bad!)
ake sure the head gasket is the right way round
when removing the head dont forget the dowel on the side of the head that goes into the engine mount.
Blow out the bolt holes on the block otherwise it can crack the block if there is oil in them when you replace the bolts
Copper grease them if angle tightening them this makes them hell easy
Dont forget the dowel in the head when the head goes back on
Dont forget to do all the shitty little stuff on the head while its off if your doing a proper build like testing injectors, glowplugs, pressure testing, skim, leak offs, fireseals and injector seals - which I do none of when I do mine :p
Defo the right idea doing the rods while the head is off, made the job easy just a few extra steps.
Just make sure you have all your shit you need to complete the job and it can be done in an afternoon, just depends on how much work you want to do on the head while its off.
I did mine just replacing the head gasket and re using everything else, but really should replace;
oil & fluids & filter
Shells
bolts
rings
leak off pipes
fireseals
injector copper seals
Depends how much you wanna spend, lots have people have done this with varying levels of replacement haha
![[Image: 22f2b6b2-758b-4c1c-96fb-6fa9c6059b13_zpsf306b56b.jpg]](http://i585.photobucket.com/albums/ss299/Ha11elujaz0rs/22f2b6b2-758b-4c1c-96fb-6fa9c6059b13_zpsf306b56b.jpg)