03-11-2016, 10:35 PM
I'm not made for working on cars all day every day, 4 hours turns out to be my limit.
I'm a little further ahead than the photos show but in all honesty it'll be touch and go as to if I get it back together and running in another 4 hours tomorrow morning before leaving for work at lunch time.
Anyway I got the head off quite quickly this morning, the injectors came out nice and easy and the head bolts came away with no trouble. I cleaned up the face of the block with wet and dry on a block of wood, left it like this as I didn't think it was gonna get any better.
One of the many joys of the day that made a 1 minute job into a 30 minute one was removing the cam pulley. The cam shaft has a hex on it to get a spanner on, I rounded this off. I could get good purchase with the grips but not enough leverage so slid a bit of small diameter exhaust over the grips which worked. I'd never of got it done in the bay with the fact I was having to apply body weight to the exhaust and the leavers.
Other Joys have a press in water fitting, I don't have a press and there's no way I could get any real sort of tool on it. In the end I heated up the head and slid a big 21mm spanner round the pipe and hammered on the spanner, right pain in the arse. The other pain is removing every bloody stud out the head especially the exhaust ones that appear to have started corroding in.
Anyway head is on. All the 18 head bolts are torqued up, this was a pain in itself as there is 2 different types of bolts and they were supplied with different heads so it meant constantly swapping sockets on the breaker bar. I've than pictured got a little further, the inlet manifold is on, water inlet, injectors are in and piped up, glow plugs are in and the cam belt is on and correctly timed. I don't think it was correctly timed before (the car has had some less than brilliant mechanics work on it before) I'd counted teeth and copied what was there when I swapped the belt but now having worked out what the timing marks are I'm pretty sure that was a tooth or 2 out causing the rough idle.
I'm a little further ahead than the photos show but in all honesty it'll be touch and go as to if I get it back together and running in another 4 hours tomorrow morning before leaving for work at lunch time.
Anyway I got the head off quite quickly this morning, the injectors came out nice and easy and the head bolts came away with no trouble. I cleaned up the face of the block with wet and dry on a block of wood, left it like this as I didn't think it was gonna get any better.
One of the many joys of the day that made a 1 minute job into a 30 minute one was removing the cam pulley. The cam shaft has a hex on it to get a spanner on, I rounded this off. I could get good purchase with the grips but not enough leverage so slid a bit of small diameter exhaust over the grips which worked. I'd never of got it done in the bay with the fact I was having to apply body weight to the exhaust and the leavers.
Other Joys have a press in water fitting, I don't have a press and there's no way I could get any real sort of tool on it. In the end I heated up the head and slid a big 21mm spanner round the pipe and hammered on the spanner, right pain in the arse. The other pain is removing every bloody stud out the head especially the exhaust ones that appear to have started corroding in.
Anyway head is on. All the 18 head bolts are torqued up, this was a pain in itself as there is 2 different types of bolts and they were supplied with different heads so it meant constantly swapping sockets on the breaker bar. I've than pictured got a little further, the inlet manifold is on, water inlet, injectors are in and piped up, glow plugs are in and the cam belt is on and correctly timed. I don't think it was correctly timed before (the car has had some less than brilliant mechanics work on it before) I'd counted teeth and copied what was there when I swapped the belt but now having worked out what the timing marks are I'm pretty sure that was a tooth or 2 out causing the rough idle.