Well good news it’s all back together,
5 hours yesterday just to get the EGR valve back on with poor light somehow making it harder to do the work even though I was literally working blind
The day finished with uncertainty as I had to torque up before the silicone gasket set to the new gasket. My iPhone deciding that it wasn’t going to shine a light for the video to confirm everything was located correctly, as it was down to 18% battery power.
Today started late while trying to locate the neighbours endoscope, it wasn’t the simple one I remembered borrowing before. The idea I thought would be a good one, but wasted time messing with my laptop trying to load software that failed and broke my hinge when the neighbours wife got all excited and slammed the screen down to see what make laptop it was, before I could say NO the hinge doesn’t work
That new job aside, I ended up getting confirmation of a (in)/correct assembly, with the iPhone in the end, yes here comes the bad news
- Skull’s - gasket located incorrectly
BUGGER it’s about 80 degrees out, the bolts have apparently both let go of their respective holes!
The decision was made to continue and hope for the best … today’s 5 hour shift, re-fitting the c-clamp on the exhaust to inlet flange, remember the metal shim! This was done to a fashion from above the engine. Nothing seems easy…it’s now expected and accepted….then the coolant pipes
B first, the suspect pin-prick one, lubed up with KY jelly on the inside and wrapped in amalgamating tape on the outside, with 2 jubilee clip on the suspect area, trying to tighten these with only one arm available in the space takes more time as it tries to spin away from you
Hour of fun…no problem.
Onto pipe
D just lubed up with KY, jubilee clip located prior to inserting. I initially decided this would be inserted PRIOR to fixing the ERG valve as the pipe was hard to remove, but it never happened that way in the end….
Solution was to remove the 3x 13mm bolts on the gear linkage anchor plate fixed on top of the gearbox to give some much needed room for the pipe to slip on easier with a straighter run and the easiest jubilee clip of the job to be tightened up. Refit the gear linkage anchor plate and bolts you doughnut.
Back on the top area of the engine now for EGR solenoid plug fitting and lock tab engaged.
Just the air box to be fitted, MAF fitted and lock-tab engaged. Intake piping located and secured with large R-clip. Battery Earth re-connected …. DON’T forget the coolant, I’ve reused the old long-life as I still don’t know if this is a rehearsal for when (I mean IF
) the EML light re-appears (dodgy gasket
)
Initially started up fine and whilst warming and topping up the coolant on what appears to be an easy self-bleeding coolant system, an 11 mile shake down run during rush hour (no pressure) revealed no coolant leaks and no warning lights and a couple of burbs of coolant added to restore correct levels.
Tomorrow is either a longer run to test the EGR valve and see if any warning lights reappear …Nighty Night
It looks like a right 'mare and then some 
That's made me smile