Right, this could bet a bit long winded, the engine as left on my last post was awaiting Gaskets and head bolts, these had failed to be posted, so lost over a week waiting for some clown to realise that they had sold them so best post, I with my Son in Law had taken the opportunity to clean up the head faces and lap all 16 valves in, the job was made easier through the use of a battery powered drill and virtually no marks on the valve seats, refitted with new oil seals, the engine we decided due to weight and virtual impossibility to get to the two upper bell housing bolts was fitted bottom half only, this made the job a little more bearable, I kept the timing pin in the flex plate as I could find no reliable information if the liners were wet or dry, I was not taking the chance of them moving!! This made the alignment and fitting of the flex plate to torque converter bolts a little harder as we had to wait to fit the head, but was well worth it, on fitting the head do not forget the EGR pipe mounting on the back, we did and the clamp could in no way be fitted, hey ho, lets hope that doesn't come back to bite when it fractures due to vibration!! You will have to appreciate all the work has to be done in about 1 1/2 hour slots every day due to the pain I am in, its not something you can put your big boys pants on and ignore, nore is the frustration of having the strength of a baby!! People helping and in fact doing the work I owe a great dept for their help and patience.
The gaskets arrive, the old gasket had the holes missing (the metal had corroded away) where it would of given you a clue to its thickness, so we plumpt for a 2 hole gasket, torqued it down, SO SIMPLE THOSE FEW WORDS, 'TORQUED IT DOWN' my god on the holies of holies who in a drug induced coma thought of degree tightening, yes I realise you have to get the metal bolts into a state of plastic elasticity, but some one please tell me whats wrong with using a torque wrench? (I think a whole new post could be dedicated to that subject) we took the timing pin out and turned it over, no lumps bumps or bangs, so were good there, took the opportunity to refit the four flex plate bolts, how can co much torque be transferred through such little bolts? right we learnt not to get to complacent as this engine bites if you dare to relax!! we refitted all 16 hydraulic tappets with their fingers, that design must have looked brilliant on paper, I can see some Italian singing his head off as he thought of it, and the people trying to put together his jigsaw wanting his head!! 6 times the cam carrier was offered up, five times one or two of the fingers fell off, (on you tube there is a chap using a sheet of sheet steel in between the fingers and cam carrier, pulling the sheet out like a magician with a table cloth) we finally got them under control, the mood was extremely heavy and quiet, until the last bolt was done up and no gaps, phew!! now you set to fitting everything as the book says its a simple matter of reversing the process!! Bugger is it. (EXCEPT THERE IS NOT A BOOK I CAN FIND ON THIS ENGINE YOU GAIN SNIPPETS ACROSS THE NET) we did find the water system a little complex, finding the second water pump was a surprise, but the piping that went with it well..........................on to the injectors, as the engine came without, causing the above problem we set to to try to get ours out, first thing clean the area methodically, not having an airline to hand we adapted a hoover with a piece of fuel pipe strapped to the end of the hose, this enabled us to remove sand, yes SAND the whole top of the engine was one mass of sand, the only conclusion we could come to that A/ someone has let their kids burry the Jeep on a beach, ooorrrrrrrr B/ its been for a swim, neither options were favorable, would the injectors move let alone come out NO, time to introduce a bit of thinking and make up a hook affair that could be connected to a slide hammer, result out the little buggers came, we removed the rubber silicone? O rings cleaned them up, now up to now I had kept the new copper sealing washers for the injector seats in my wallet, I hand them to my Son who drops them into No1 and 2 with No3 being dropped never to be seen again into the open mouth of the exhaust pipe, not a word was said, we looked for the best of the old 4 found one and quickly put it into the correct orifice!! then we move on to the exhaust manifold and turbo, nice and straight fwds? Oh NO this on really tried the patience of all there, the supply oil pipe would not go where you needed it, due to the waisgate rod, now we had a flight of inspiration decided to remove the pipe from the oil gantry fit it to the turbo then fit the unit as one, remember me saying this refit had a habit of biting back? this was just such an occasion, there was no way without having some serious surgery performed on your hands would you be able to reach this fitting to even try to do it up, plan 2, tie a piecs of wire through the banjo hole after refitting the supply pipe back to the oil gantry and physically pull like hell to persuade it to bend and convort through to where you wanted it, job done!! having wrestled the wiring loom back over the top of the engine, trying to remember if it were the Water pipes or wires closest to the engine etc etc, onto the Rads, Water Intercooler by gumm that's a big one, air con and finally power steering, who hoo, all in, I will take this opportunity to say please remember where all the fixings came from, we even took pictures and got it wrong, then it was a simple matter of refitting the headlights grill and bumper, all of which were a bloody nightmare!! onto the Fuel Filter, I had noticed on removal that most of the fuel pipe was severely perished, so we bought new and renewed, we also renewed a fair bit of the heater water piping as the alloy piping had almost worn through by being wrongly fitted, fresh oil, oil filter, primed the system and tried to start, the filter head has a quaint little pump in it, very old school, but it worked, well it would try to start and fail, to cut a very long story short we found the bottom O ring between the clear inspection and the fuel filter was too thin, refitted the old chunky one and bingo, after priming yet again she started and staid running, sounds bloody good as well, one slight water leak where a hose clamp had failed to be tightened, I think that was my fault!!
If any one wants a Cam Carrier and Head off the old engine please message me, you will also require patience complete loss of your sanity and if married a divorce, if you just want to do the rear main oil seal and use the engine as is please message me £300 in any form its yours you take the lot.
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