Well I finally started the "BIG JOB" !

As some of you that have read my posts may know I have a number of "little" jobs to do on my 53 plate TD6

Replace the following :

Intercooler
Intercooler hoses
Glow plugs
Rocker cover breather
Water pump
Thermostat
All fan/aux belts
Oil and Filter
Diesel Filter
Correct spec anti-freeze
EGR blank and K+N Air filter (yes I know the purists dont like em and evidence out there that they not much cop - but I like em - lol)

Remove and check :

All 6 injectors as I have diagnosed 1 is "bleeding off or leaking"

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So here is what I managed to get done inbetween 5 MOT's and a service today !!



















Cylinder 5 Injector certainly looks "leaky" !

good job !

2.0_hippo said:

good job !

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I aint finished yet - lol lol

If you've got time for photos you're not working hard enough.

bix said:

if you've got time for photos you're not working hard enough.

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+1

you might as well fit a facelift front while the existing is off !

lol

2.0_hippo said:

you might as well fit a facelift front while the existing is off !

lol

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You buy it and I will fit it - lol

I was thinking of grafting a P38 front end on it - well it would be a bit different

That looks like 'fun'....!!

Keep the piccies coming! Sure to help others seeing how it is all put together and what parts are what...

Good Luck Dave...!!

Bix said:

If you've got time for photos you're not working hard enough.

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2.0_hippo said:

+1

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If I didnt take pics what would you lot have to talk about ?

RS2000CUSTOM said:

You buy it and I will fit it - lol

I was thinking of grafting a P38 front end on it - well it would be a bit different

Click to expand...

ound:

Saint.V8 said:

That looks like 'fun'....!!

Keep the piccies coming! Sure to help others seeing how it is all put together and what parts are what...

Good Luck Dave...!!

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I need help in how "it is all put back together"

So far got 4 glow plugs out and ALL 4 are forked !!! (they felt very fragile)

Still got 2 to more to undo or break yet

RS2000CUSTOM said:

You buy it and I will fit it - lol

I was thinking of grafting a P38 front end on it - well it would be a bit different

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Why not, a L322 mule had a P38 front end. Well lights and grill. It actually looked rather good.

Hi, Looks like you've taken on a lot there! Just a couple of questions, how long did it take to get the front off and I notice there is a lot of carbon build up in the exhaust and inlet ports will you decoke them or is that ok to leave.. Great thread

If the head was being removed then I would have fully decoked the head and ports etc but as I cannot safely remove the carbon with head in-situ it is best to leave it alone except the carbon I can get to with a hoover

The reason for this is if I try to remove the carbon and loose fragments go into the cylinders then this will contaminate in one hit both the cylinder and the turbo on the way out to the exhaust

The removed manifold will be cleaned though - certainly shows the damage caused by having an EGR valve fitted to an engine

To get it to the stage seen in the pics took me apprx 2 hours BUT I have the vehicle on a ramp and my workshop has air tools etc - the job upto yet though has been within the realms of a home mechanic with suitable tools (only specialist tool so far was a mobile air-con mate of mine to empty the air con gas)

Injectors out and sent away for test/repair (clearly Inj 5 has "issues") and replace water pump and stat are jobs for today

Looks like a Group N Rally Filter youve got stuck on to that thing! Looks absolutely Huge!

Ruthlessgk said:

Looks like a Group N Rally Filter youve got stuck on to that thing! Looks absolutely Huge!

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Same size as the original

Result ! ALL 6 injectors out and am now on way to get em tested

I like a big sucking filter !! lol

Plenty of room to poke around now



The "caked-up" inlet manifold is all clean (horrible job !) and ready to go back on once I get my injectors back from being tested/checked/overhaul if needed

How many belts are on that thing?? Was happy to go from Classic 3.9 lots of belts to 4.6 petrol serpentine belt (one belt) but you have lots on there!! suggest new ones all round on rebuild. Must say you seem to be doing a great job. Carbon is probably due to short trips baybee???

stopover said:

Carbon is probably due to short trips baybee???

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lol

Mosy likely that it is due to the "soon to be removed" EGR valve dumping exhaust gas into the inlet - long or short distances makes no real difference

As for the belts there are only 2 and yes both are being replaced