At Last The Big TD5 job

steve2286w said:

Looks a monster of an engine, I wish I had an engine stand when I did mine , forever rolling it around, Landry looks good nick underneath , what symptoms did you have with bad cam and how was it damaged

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I will post pictures of the cam I am wondering if the lash adjuster is responsible but lets see

So lets get some weight off this brute


clutch looks fine I fitted it a couple of years ago



Oil seal looks to be in good condition no sign of oil running down the casing
I am finding the strip down of even simple bits is not easy, they always seem to have a bolt hidden behind another component, probably need to work out a routine if you were working on these all the time.



These buggers are well nipped up, bless my lovely 1/2" cordlesss impact gun




Time for lunch

Great work!

Looks alot more oil tight than mine lol

Well continued to tear off the outer bits untill it is all ready to put on the new engine stand



Built up the stand
The brackets are very difficult to match up to the engine end (flywheel end) and I did not like it a bit when I let the crane off, the stand is suposed to be good up to 1000 lbs thats nearly half a ton, but I dont think so, the TD5 was plenty for it, so I put the damper pulley bolt back in and supported the free end, lets check again when the head comes off.



Piulled of the rocker cover and had a bit of a fright, one of the locknuts on the injector rocker arm adjuster was missing (cylinder 3 can you see it in the picture below) must have gone down the sump, hope it's not damaged anything.
That must be down to me need to start and double check on things like that.
So had a good tidy up and put stuff away, come back tomorrow.

I had mine mounted using the two lowest and widest holes and the top two. But I had already taken the head and sump off so was stable.

Watched

That bolt missing reminds me of a time I did a Classic Mini's valve clearances.

It would forever need them doing every month IIRC, so to negate the bolts coming loose I put a locknut above each of the standard nuts and thought that would stop them coming loose!

2 months later it came back with the standard rattle,, off came the rocker cover and the nuts were gone

Had to drop the sump and fish them out

Ahh makes me laugh..


Hopefully it went down there without playing ping pong


I never liked those engine stands ever since doing a Ford York diesel it bent the MOFO into a banana the minute the jack was released!!

I'd pull the nead before allowing the stand to take the weight..

Cracking on nicely, would the stand be more stable connected to the bottom two wide bolts , sometimes easier to fix the plate when off the stand

steve2286w said:

Cracking on nicely, would the stand be more stable connected to the bottom two wide bolts , sometimes easier to fix the plate when off the stand

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I might try that, I tried different ways to try and get the thing to balance, but the arms and slots just dont seem to go onto the TD5 easily. I want to try and get the head off tomorrow and then try the block on the stand, hope to get the sump off then, as you may see from the pictures space is quite a problem, I wanted to fold up the crane when the engine is on the stand.

brianconwy said:

I had mine mounted using the two lowest and widest holes and the top two. But I had already taken the head and sump off so was stable.

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Hope mine will be better with the head off, seems the TD5 is quite lump.

I did a thread weighing all the bits on my 200tdi, must have have to much time on my hands, it came to about 250kg

brianconwy said:

I had mine mounted using the two lowest and widest holes and the top two. But I had already taken the head and sump off so was stable.

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Would it reach easier with the fixing plate turned 90 deg , hard to tell from pics but then you prob get the width with the arms more vertical

When I first attached mine (300Tdi) to the engine stand I'll admit to being a tad scared and so very conscious of where my toes were and if they were under it!


My bolt set up, but obviously different block.
It looks precarious and dangerous at first, but you soon realise it's very secure.



So long as you've bolted it on properly, I suppose

steve2286w said:

I did a thread weighing all the bits on my 200tdi, must have have to much time on my hands, it came to about 250kg


Would it reach easier with the fixing plate turned 90 deg , hard to tell from pics but then you prob get the width with the arms more vertical

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I tried it both ways problem seems to be the arms are not long enough to span the bolt holes. I am going to have a fresh run at it tomorrow.

Well back at it again this morning, slowed down a bit for two reasons
1. need to take care and get ready for the head coming off,
2. I'm knakered this is a young man’s game.
Tried the engine stand every which way, and finally settled on this, its not perfect as I can only engage three arms and clamp the fourth one, but I will keep the crane on it until I get the head off, I thought about making two more arms for future use, and then I thought sod that I think this may be my last engine overhaul.



OK after I managed to get started then took out the rocker shaft and injectors



Now you can see the damaged cam lobe, interestingly it was more pronounced than this when I first found it about two years ago, and the roller on the rocker arm was chuffed, but I managed to get a used rocker arm and put it on as a stop gap, since then the cam surface appears less scratched and I think the roller has kind of rolled it down, but no hiding the real damage here.



one bit of luck I found the locknut off the injector arm adjuster, it had lodged in the head near the injector.

My old mechanic was 73 and was still heaving and hauling heads and engines around

That cam looks destroyed!!

Afternoon
Rigged up the crane and unfastened the cam sprocket.


Then slowly backed off the head bolts in stages and removed them, ten started to free off the head a bit reluctant at first but it soon let go, its important to get the allen screw out which goes through the timing chain guide



now we can see what we are up against bores look fine with the hone marks clearly visible oops should I have left this alone ? top of the block looks rusty in the picture but its fine I wiped it with brake cleaner before the picture and wiped the top and the bores with an oily rag immediatly afte.
I was going to check the piston protrusion but I will start all of that tomorrow, it had a 2 hole laminated gasket fitted but I want to check all 5 pistons to be sure they are all in tollerance.
So hope to start the cleaner work tomorrow.

Henry_b said:

My old mechanic was 73 and was still heaving and hauling heads and engines around

That cam looks destroyed!!

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I retired a year ago and this sort of thing is not every day, also the TD5 is such a brute, I remember doing a moggy 1000 clutch and laying under the car then lifting the gear box onto a block and holding it up to the engine, would not like to meet the man who could do stuff like that on a TD5,

Cam is well buggerd, I have been worried about emissions and I wonder if it could affect that or is this too small to do that, I an also worried that I have a bad injector or two, I have tried to get onto some decent second hand ones but little success.

raywin said:

I retired a year ago and this sort of thing is not every day, also the TD5 is such a brute, I remember doing a moggy 1000 clutch and laying under the car then lifting the gear box onto a block and holding it up to the engine, would not like to meet the man who could do stuff like that on a TD5,

Cam is well buggerd, I have been worried about emissions and I wonder if it could affect that or is this too small to do that, I an also worried that I have a bad injector or two, I have tried to get onto some decent second hand ones but little success.

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It would cause the motor to run rough..

How bad was it? in terms of performance?

Doing a P38 transfer box is fun 110lbs having to wiggle underneath with that on yer chest and then heaving it back onto the gearbox!!

enough to make ya see stars half way through

I know the TD5 cylinder heads weigh a fair bit..

Those bores look good!

Henry_b said:

It would cause the motor to run rough..

How bad was it? in terms of performance?

Doing a P38 transfer box is fun 110lbs having to wiggle underneath with that on yer chest and then heaving it back onto the gearbox!!

enough to make ya see stars half way through

I know the TD5 cylinder heads weigh a fair bit..

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Its been a bit off for some time and never sounded smooth to me like one cylinder was out of sync with the other 4 but oddly enough the last month or so was sounding better, I was also suspecting the injectors as it smokes when cold, and they told me it was high on emission at the last MOT, but that cam was always on my mind, I would have done it sooner if I used it more.
The gear box and transfer box is not only a heavy cumbersome thing but the weight is so badly distributed that it is an accident waiting to happen,