19J Cylinder Head Rebuild

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Have a really good look at the block when the head is off. You may be able to see where the leak into the cooling system from the cylinder or exhaust port was. A leak of this kind will often discolour the coolant - is it a bit "dirty" looking?
Not too bad, but a bit dark in colour. I think there's only a slight crack in the old head that opens up when things warm up on a run, as in town driving there was never an issue. Head gasket itself seemed fine- which it should be as the head was only off in 2013.

Have you taken a good, close look at your pistons? 19Js are notorious for cracking them.
Gave the tops of the pistons a bit of a clean and they seemed pretty good. Some very light pitting in no.2, but looked undamaged otherwise. The engine doesn't breathe heavily unlike some 19Js so hopefully the bottom end is in a good state.

Nearly there, Pete! :)

Careful as you refit the injector pipes, spin on the unions and then wiggle the pipes around to settle them in the spigots before tightening the ends. It is quite easy to lock a stress into the pipes during tightening, which sometimes causes them to snap later.

General condition and underbonnet view is better than a lot of the 2.5 tds I see. Nice to see! :cool:
I would get rid of the Bearmach filter and get a Delphi, and clean up the turbo actuator a bit, but that is just being a pedantic old git! ;) :)
It's getting there and hopefully should have things back together tomorrow :) The coat of paint on the head helps tidy things up I think. Got the injectors fitted this afternoon before it got dark, and also the oil feed to the back of the head before I forgot ;)
 
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Got it back together and all working :D There appears to be a slight leak from the exhaust system- most likely between the turbo elbow and the front pipe- but nothing serious. And one of the hose clips could do with replacing. But it's alive again :)
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Got it back together and all working :D There appears to be a slight leak from the exhaust system- most likely between the turbo elbow and the front pipe


Quite likely blowing out of one of the slots cut in the downpipe to allow it to slide over the elbow! :) Gun Gum, and if necessary a sliver of thin steel inserted in the joint, will deal!
 
You took a bit of a gamble there, the older 19j's suffered from cracked blocks as well, glad to see it sorted though.
 
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