Try again….

Well I went and collected the crane.. turned out the place was Aladdin’s cave. Got the crane, pillar drill, Britool (old) breaker bar which is a lovely heavy thing, a metal tool box and an old record vice. Win.

Have started stripping bits from the bay. Looms pretty much out the way, just need to remove earths and starter connectors.

Only had a td5 viscous wrench so have ordered a new one.

Next stop is an engine stand and some lifting gear.

Found a green spring kept plug at the back, no idea what it’s for but wasn’t plugged in.

Can you knock the rubbers out of the mounts once engine is under the cranes support to gain room to bellhousing bolts or do you have to remove whole mount?

@RAW111111 edc stuff will be yours mate - l’ve been very gentle with everything. There may be some bits of wiring in the main loom that I can’t remove though. Not sure what your plans are with that.

Hi mate. Thanks for taking the edc bits off for me. I’ve got all the wiring diagrams so I could make up any bits that are hiding in the main loom if needed. Could the stray connector have been for the EGR perhaps? Thought all the disconnected bits of that were down by the n/s battery tray though so maybe not.

Rich

I’ve no idea mate. I remember my 90 had a random one tucked away too. I’ll check wiring tomorrow and also take a picture. Engine is coming out august 19. I may try and make it light as possible before then

resto_d1 said:

Well I went and collected the crane.. turned out the place was Aladdin’s cave. Got the crane, pillar drill, Britool (old) breaker bar which is a lovely heavy thing, a metal tool box and an old record vice. Win.

Have started stripping bits from the bay. Looms pretty much out the way, just need to remove earths and starter connectors.

Only had a td5 viscous wrench so have ordered a new one.

Next stop is an engine stand and some lifting gear.

Found a green spring kept plug at the back, no idea what it’s for but wasn’t plugged in.

Can you knock the rubbers out of the mounts once engine is under the cranes support to gain room to bellhousing bolts or do you have to remove whole mount?

@RAW111111 edc stuff will be yours mate - l’ve been very gentle with everything. There may be some bits of wiring in the main loom that I can’t remove though. Not sure what your plans are with that.
View attachment 293750

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Drop engine mounts & lower gear box down.
Plenty of long extension bars then do the trick

Couple more hours grabbed in the rain today. Got most ancillaries stripped off and out, crank pulley didn’t budge with the battery gun so will give it a whirl with the air gun tomorrow.
Theory is, removing the head will make it easier to lift if I have to do it on my own. I can manage getting the block out no probs but might be a bit twitchy doing the lot in one.
Plan was to get a turners head but I think I’ll get this one checked over and crack tested first. There’s a reputable firm 15 mins away.

Always read conflicting information on whether you can skim a 300tdi head? Or was that td5
@RAW111111 - did you say you’d replaced that vac pump when I picked her up?

Still need to get an engine stand. No pics unfortunately apart from the close ups so I can remember how things are routed.

However, here’s a pic of one of my bargains!!

resto_d1 said:

Couple more hours grabbed in the rain today. Got most ancillaries stripped off and out, crank pulley didn’t budge with the battery gun so will give it a whirl with the air gun tomorrow.
Theory is, removing the head will make it easier to lift if I have to do it on my own. I can manage getting the block out no probs but might be a bit twitchy doing the lot in one.
Plan was to get a turners head but I think I’ll get this one checked over and crack tested first. There’s a reputable firm 15 mins away.

Always read conflicting information on whether you can skim a 300tdi head? Or was that td5
@RAW111111 - did you say you’d replaced that vac pump when I picked her up?

Still need to get an engine stand. No pics unfortunately apart from the close ups so I can remember how things are routed.

However, here’s a pic of one of my bargains!!

View attachment 293989

Click to expand...

Yeah, the vacuum pump was new while I had it.

Rich

You already know which bolt was the fiddly one!!!

110psi and my gun couldn’t get the crank pulley bolt to budge. Probably a weedy gun to be fair.
I bought one of these wacker impact bars. After buying it I then wonders how I would torque it back up without the crankshaft locking tool?

resto_d1 said:

You already know which bolt was the fiddly one!!!

110psi and my gun couldn’t get the crank pulley bolt to budge. Probably a weedy gun to be fair.
I bought one of these wacker impact bars. After buying it I then wonders how I would torque it back up without the crankshaft locking tool?

View attachment 294041View attachment 294042

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I can’t remember if these are normal direction threads?

As for locking tool… old drill bit in the wading plug hole for the gear box. Locks the fly wheel… or remover starter and lock the starter ring

Oopps

Dippypud said:

For those ordinary members of LZ who struggle to know WTAF tony109 is talking about, here is a small clue of the type of Conspiracy Wormhole he's diving in .... (if you're not bothered, scroll on dude/dudette) ...

What Is the ‘New World Order’ Conspiracy?

The “New World Order” conspiracy is having a renaissance after Putin’s invasion of Ukraine.

www.vice.com

Click to expand...

@Dippypud you posted this in wrong thread or is more wine needed

Hicap phill said:

@Dippypud you posted this in wrong thread or is more wine needed

Click to expand...

Thanks, I was skimming threads and miscounted the back-pages ... back to the beer ...

Hicap phill said:

I can’t remember if these are normal direction threads?

As for locking tool… old drill bit in the wading plug hole for the gear box. Locks the fly wheel… or remover starter and lock the starter ring

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Think it is a normal thread, just FT!!

I have the timer kit for doing the pump and everything so no issue there. It was more being able to lock it in place when I re torque but I could manually put the autobox in 4th and low. Think it’s 80nm. Even though it’s taking 300 to undo

Bit more. Stat housing bolt was cross threaded. I was so patient, unwinding then winding, adding oil as I went. Then patience disappeared and I gunned it off. I decided on a new head anyway as I want the engine to be totally fresh.

On that note, I’ve no idea about oversize tolerances etc should the block need more than a hone. I know it’s all doable. Just got to read the 300tdi rave and hope it’s right!

Nick of time!

Finished up here, ready for next time…

Right then. Any experienced eyes want to take a butchers as I’m not entirely sure what story this tells (I’ve never rebuilt a diesel!)

The head - id say 2&3 have hairlines. Doesn’t really matter as I am getting a turners one:

The block. Star marks on the pistons. Normal? Head actually had very little face damage off the coolant ‘triangle’ so a shame. It’s done 200k though so she deserves treats.

Honing marks still present. Assume carbon ‘lip’ marks where ring one reaches in the cylinder?

Auto stick freed up. Didn’t know how much free play would be in the cable when I tilt engine to do bellhousing bolts.

Ordered some fine pitch m12 high tensile bolts so I can lift the block out via the head bolt holes. Bloody expensive but I’d rather not risk a head bolt bending/snapping when lifting!!

How's it going, any updates

Firebobby1 said:

How's it going, any updates

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Not much done but few bits bought. Been working non stop. Should be a bit calmer this week so hopefully get some time on it. Also got a weekend without many commitments next weekend so should get the block out.

Bought a few ancillary bits and some factory optional extras - oem nudge bar with the LR lights.

Will start on the bay, inner wings etc when engine is out. Obviously got to get the dash out too.

Hoping the lifting tackle can clear the front. I have got the car fairly low but could go lower if I removed front springs. I think it should make it.