As you will all know by now, I bought Max's Elite Estate 3.0 Auto as a non-runner project, and did some reasonably major engine work to get it running. It had to be a bit of a swift one, because A) I need an Estate quickly for the dogs, and B) I didn't want it Hanging around due to nowhere to work on it.
Symptoms
The main problem with the car, is that it was losing coolant. The coolant loss was down the back passenger side, and was running down the block onto the floor.
This car was OOF'd at the last cambelt party, laidback did the brakes, and Mark DTM removed and resealed the oil cooler, and coolant bridge doughty seals. Sadly the leak didn't go away. Shortly after this, I changed the thermostat seal and front transfer pipe seals. This improved the leak, but it was STILL there.
It gradually got worse, to the point it would dump all it's coolant in about 20 miles.
Diagnosis
Max's garage recently diagnosed a head gasket leak on the 2-4-6 bank, and I was inclined to agree with them. So - seeing as it needed a head gasket, I decided to go all out and do a top end rebuild.
I rebuilt two heads, using new valve stem seals, cleaning everything thoroughly, and grinding the valves back in using some fine paste.
I flattened the exhaust manifold mating faces on the heads, and the manifolds, and fitted new exhaust manifold gaskets and studs / nuts all round. Sassanach helped me helicoil 2 broken threads on one head.
Armed with my nicely rebuild heads, I attacked the car.
When I arrived, the plenum, inlets, DIS and coolant bridge were off. Otherwise it was complete.
Day 1)
Removed bagpipes, aux belt tensioner, cambelt cover, water pump, cambelt, inlet bridge, cambelt cover(rear), camcovers, camshafts, all 4 sprockets, NS SAI pipe, Thermostat and front transfer pipe.. exhaust downpipes... basically everything in the way of the heads. I then undid the head bolts (a scary moment, they DIDNT feel good!). I then removed both the heads, and rebuilt the drivers side one and cleaned all the mating surfaces. (Had already done the passenger head).
I then re-fitted both heads (using new HGs obivously) to the car. Got the camshafts back in, rear cambelt cover on, cam sprockets all back on, and the cambelt kit back on and the valve timing set. Also got stat and transfer pipe in, and that barsteward rear transfer pipe too.
At that point, I was working with a torch inbetween my teeth, so decided to call it a day once the cambelt was on. I then had a few beers on the train home.
Day 2)
Woke up with sore head, after only 4 hrs sleep.
Arrived at Max's, and starting putting all the bits together. Inlet, coolant bridge, DIS, leads, plugs.. blah...
Pics are below. I must admit, at one point I thought "oh dear, I've taken on a bit much working alone over 2 days here)....
But it's all turned out well.
When I fired her up, she literally started on the first turn, with no fault light. That pleased me immensly
I drove her home 40 miles, and no problems at all. Temp stable, and NO coolant loss, so it's fixed it
General Pics of rebuild below:
Passenger head coming off:
Both heads off, and new HG being offered up to make
sure it's correct. NOTE: The crank was set to 60deg BTDC before head fitting! I had been moving pistons up and down at this stage for cleaning purposes. Also note the corrosion in the water jacket on the 246 bank, where there's been no antifreeze in it.
Now onto the head rebuild.
2 4 6 head before rebuild:
Removing Valves:
All valve components in bags, to ensure they are fitted in their original locations:
Here is the head with no valves!
Cleaning Valves:
Removing collet, Valve spring,stem seal and seat washer
All valves cleaned, lapped back in, and fitted with new stem seals:
The FUBAR head gasket. (One of). This was caused by running with no antifreeze, I guess:
Offering up new exhaust manifold gasket following cleaning of the faces. Note the helicoils in the bottom right two holes..
I obviously used new gaskets for downpipe to manifold too, and new studs/nuts all round.
Must say, I'm quietly pleased the rebuild went so well, without so much as a minor glitch really.
My next couple of days off hopefully won't be spent working like a mad thing under a bonnet of an Omega!
PS - I got a few funny looks / comments, doing a Head gasket change on a V6 at the side of the road
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Topic: Pictures of my recent engine rebuild... (Read 2751 times)