Injectors misbehaving but trying to understand the numbers

[MattBLancs]

Yes, grinder with thin cutting disk made short work of it, but also massive lethal burrs and such a din. Got sick of the noise mostly so tried the Aldi snips and actually cut really easily. It's very, very thin just about enough strength for being a heat shield (or cooker hood chimney) but not a lot beyond that.

It's only been in the garage awaiting being recycled into something new for about a decade - so I was made up from that perspective!! the coupe came with a flash twin outlet stainless exhaust, so seems fair enough to do a bling heat shield to match! think MOT man will have a good laugh at me about it!

[darbuck]

Yeah I am not as quick to reach for the grinder because of the noise. Sometimes you need it but it's more for heavier metal. I'm sure MOT man will reflect on it first .

[darbuck]

Well it just took another turn when I went to put the intake back on I noticed one of the rocker arms on cylinder 3 was lying on its side in the head so I had to pull the valve cover off again . I have now ordered a replacement which should be here early next week. So the past couple of days work is undone, this engine doesn't seem to want to be fixed or at least cylinder 3 doesn't. Cleaned up put tools away until then and I think a few beers tonight are on the cards. Back in work on Tuesday so enjoy the last few days of my holidays if you could call them that. I did trade my hawk and trowel for an engineering gig during the last recession so go in there and have a rest.

[MattBLancs]

Glad you spotted it rather than missing it and trying to start it like that - try and hold on to the positives, that was a lucky save there! Keep on going am sure you will overcome it!! But stick some more pictures up if you get chance, helps us come along on your journey/saga/trials and tribulations!

"Holiday" = extended period of DIY, no? Certainly is my definition

[Rp0thejester]

DIY stands for Do It Yourself, unless a woman is involved then it stands for Do It Yesterday, you donkey

[darbuck]

Yes totally agree that could have been catastrophic and a lot more bits would have needed to come off. Will do, waiting on the rocker arm so have it covered up the winds are very high here at the moment so keeping the polythene over it is a bit of a nightmare seems to be holding the way I have it now though. Holidays have become extended periods of DIY, that would be a better way of putting it .

[darbuck]

Rebuild back underway had Torrential rain here for the past few days. Water got under the polythene somehow and into no4 cylinder so had to pull egr and glow plugs again!! Blew out the cylinders with compressed air . I have everything back together just have to button up the intake and make sure I am not forgetting anything. I hope to have it back in by the Monday. I had to buy a new small torque wrench 5 -25 Nm. For the valve cover. I had to work fast between showers so pics are few and far between. I will try and get a few more there are a couple of bits I am not sure of their position so may need help identifying them

[MattBLancs]

Sorry if stating the obvious, but elastic "bungee ropes" like these:

Euro do dah

Are good for strapping stuff down against the wind.

My approach: if in doubt, keep adding more!

Logs and bungees!

[darbuck]

Hi Matt, the polythene had holes I didn't see in it so unfortunately wouldn't have made a difference I am more or less there now anyway. I keep meaning to pick up some bungees I used to have lots of them but they seem to have disappeared.

I got the upper intake, egr to intake pipe and vacuum and high pressure diesel pumps back on last night.
I have a bit of loom I am trying to figure out placement on, I think I found pics last night that will show me where it goes.There are so many little bits to get right on these engines.
I have an issue, you may say I have many.
I broke the yellow clip that holds the crank case ventilation hose to the intake when I first took it apart but forgot about it and can't find a replacement online.
I wonder if Marc could post up a part number?
I will get a few more pics in a bit of the current state of play. I didn't get pics of the reassembly because of the rain.

[KennyW]

Darren,

Marc may miss the request for part no in the text. Put it on the part request post.

Keep up the good work.

Kenny

[MattBLancs]

Oh dear, polythene sheet with holes no good (though appreciate the various bits and bobs on the engine likely good at puncturing an intact bit of sheet!)

Bungees are good at "wandering off" if you don't keep an eye on them, very true!

[darbuck]

Yeah I posted in the parts request Kenny thanks. Yeah bungees go for a walk quite easily. Tiny holes but easy missed.
Note to self build a bloody garage.

[darbuck]

This is where I am now lads and ladies. I have it all timed up and starter back in. I have lost 3 bolts and a pipe clip for the hose to the heater matrix. If anyone knows the part number or any other suggestions please let me know. The turbo pipe that runs under the engine is split as well at the joint under the engine I am trying some Tiger seal but I am not sure it will bind it properly.

[MattBLancs]

This is where I am now lads and ladies. I have it all timed up and starter back in. I have lost 3 bolts and a pipe clip for the hose to the heater matrix. If anyone knows the part number or any other suggestions please let me know.

Can you take a picture of the area in question? I'll try and look on the parts Asia site when I get chance. Presume not those pictured (11th and 12th pictures) above gearbox (near starter Allen head bolts) = think standard M8 about 25mm long would do for them. One is threaded hole in gearbox, the other: captive nut in bracket (clearance hole in gearbox protuberance)

The turbo pipe that runs under the engine is split as well at the joint under the engine I am trying some Tiger seal but I am not sure it will bind it properly.

Would think the oily nature of turbo pipework would make an adhesive struggle. Not used Tiger Seal myself so not sure on its capabilities.


All looking lovely and clean - especially considering sat on a tyre on the floor for all you've done!

[darbuck]

Hi Matt, the bolts are M10 x30 I think that are missing they go under the into the gearbox standard thread 1.5 I think if memory serves me right. Tiger seal is a polyurethane sealant very strong and oil resistant as a bonus it's sitting in the shed clamped I will check when I get home. I'm not concerned about the oil it's the air pressure of the turbo blowing it apart that concerns me. I will track one down online later I think. To clarify I am looking for the part number for the clip in the photo, sorry for the confusion. They're is my current engine stand and the crate is my stool .
It serves its purpose and will have to do until I get a driveway across to my shed that I am converting to a garage temporarily until I can build one With high ceiling.
I want to buy a 2 post lift when I get around to it. I've suffered enough winters on that driveway. A driveway is going in this year even if it's only gravel.