Engine overhaul experiences

It takes a bit of getting used to, but gets quicker each time (I’ve dug down about four or five times now).

I first stripped down to investigate ‘blowing’ last year. Turned out the Exhaust manifold was cracked in several places.

Having re-assembled, I then had to replace the manifold when I had the replacement (I managed to do that while camping one week - lucky nothing went wrong!).

I stripped it again to do the head gasket, but managed to slip the cam belt one notch when tightening the cam shaft pulley without realising. Hence, stripped again to resolve the problem. I’m sure I’ve been in there at least one other time also, so you develop a knack for the fiddly bits and ‘learn’ where everything fits and sequence of events.

I need to dig in yet again as I suspect a water pipe leak (for sure some jubilee clips are required and some pipes badly corroded) and I think the Cam Belt tensioner (idler pulley) needs tightening up a bit.

Problems encountered were:-

How to undo pulley bolts without rotating engine (Jammed wrench against body work while fitted to other bolts).

Removing Crank pulley without puller. Snapped of scrap bolt trying to push the pulley off. In the end I managed to fit a spanner between the center bolt already undone a few turns and an outer pulley bolt with oversize washers fitted. Then applied big hammer against the spanner!!!!

Major grief identifying and then aligning Crank timing marks. Ended up painting lines on outside of pulley and across sump face.

Rest was usual problems on any job...this can’t be removed because that is in the way. That can’t be removed because other bit in the way...and so it goes on! Especially useful (but I don’t have one) is a ‘C’ 14mm spanner to remove turbo to exhaust manifold bolts.

- Ray Woolmer 19 March 2002