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[Doctor Gollum]

Beer time

Well earned I'd say! 

Definitely 

[ronnyd]

You guys amaze me. I'm just not methodical, (or patient) enough to embark on anything like that James.  I do clean mine now and then though.

[JamesV6CDX]

Some more progress today

Firstly, I finished fitting the camshaft housing / carrier, whatever you want to call it. All the journals cleaned and lubed, and all the shells torqued down evenly and correctly.



With the cam locked in position via the locating bolt, I took the engine off it's mount, installed the crankshaft pulley, then brought the crank round clockwise to TDC, and then fitted the cambelt kit:





Interestingly, on every rotation, the M8 bolt fits correctly in the diesel pump, so, it was set up incorrectly before I took it apart. I'm not actually sure what the consequences of this are, as I've always thought High Pressure / Common rail diesel pumps weren't "timed" - but the workshop manual is clear that it should be in that position, so it must be for a reason.

Upper and lower covers fitted:



Manifold, with turbo, refitted (Note, all the turbo gubbins / actuators etc are not done yet)



Air Conditioning pump and various brackets fitted, including one which contains an aux belt idler. Aux belt refitted



Engine back on it's mount;



Oh, and the dipstick tube!

[JamesV6CDX]

I should add -

No I didn't change the water pump. It looks in good a nick as the rest of the engine, and isn't cambelt driven I didn't see any value changing it for a pattern part that probably won't last as long as this one.

Secondly, I didn't change the cambelt kit either. That was a concious decision. I'm not throwing money at things like that, until I see the thing actually running and driving.

I am out of my comfort zone with this engine, the damage in that chamber was extensive, and I don't hold great hope. It's still good fun putting it all together though, and trying to make it better

[Broomies Mate]

I should add -

No I didn't change the water pump. It looks in good a nick as the rest of the engine, and isn't cambelt driven I didn't see any value changing it for a pattern part that probably won't last as long as this one.

Secondly, I didn't change the cambelt kit either. That was a concious decision. I'm not throwing money at things like that, until I see the thing actually running and driving.

I am out of my comfort zone with this engine, the damage in that chamber was extensive, and I don't hold great hope. It's still good fun putting it all together though, and trying to make it better

I don't think anyone can say you haven't made the right choices.  Once driven for a few thousand miles, and you've got confidence that the engine is good, you can address those items.

You've so far done a sterling job, and the attention to detail is a credit to you.

[Doctor Gollum]

It should feel a damn site happier than it was

[STEMO]

Derivatives of this engine are in so many cars. It's a well proven unit and I'm hoping you'll be fine. Good work, lad 

[dave the builder]

Interesting on the M8 bolt in the diesel pump, the older engine (2008) the bolt only went in easy every 5 ish rotations .

you can always go back and replace the tensioner and idler and belt in a few k  ,once your sure it's OK

I had to replace a NON OEM waterpump (leaking,bearing play) at about 105k so you could be right about keeping the original

I tend to buy gates kits and waterpumps

I agree ,make sure it runs and there are no other problems ,THEN spend

or sell quickly 

[JamesV6CDX]

Derivatives of this engine are in so many cars

I really wish I was more confident with cars that are not Omegas. I had to stare at this one for half an hour earlier and work out where the correct loom routing was likely to be - and even then only did it based on what I thought was best, not knowledge. V6 Omega, I wouldn't have had to think twice.

I really admire mechanics that can just turn their hand to any car, without having to think about it

[Doctor Gollum]

I find it helps to take loads of pictures as you dismantle something. Takes alot of the guessing out of refitting everything

[JamesV6CDX]

I find it helps to take loads of pictures as you dismantle something. Takes alot of the guessing out of refitting everything

Funny you say that, a couple of the photos on this thread were a great help to me today 

[Raeturbo]

Derivatives of this engine are in so many cars

I really wish I was more confident with cars that are not Omegas. I had to stare at this one for half an hour earlier and work out where the correct loom routing was likely to be - and even then only did it based on what I thought was best, not knowledge. V6 Omega, I wouldn't have had to think twice.

I really admire mechanics that can just turn their hand to any car, without having to think about it

                    I don’t think you do too badly considering it’s not even your chosen profession

[JamesV6CDX]

Not much progress today, due to the rain. But, glow plugs are fitted, including one new one for no4.

Forgive me not changing all 4 - they don't do much in these engines, and for £20 each, it's pointless at this stage. They're also easy enough to get at.

I've got the injectors all in, and secure, including the replacement one for No4. I've refitted the rocker cover, injector to camcover seals. Also got the fuel rail reinstalled, and all of the diesel pipework, including the pump-to-rail feed, the injector pipes from the rail, and the leak off / return pipework. In addition, fitted some of the inlet stuff, Eg throttle assembly, EGR valve.

It was getting dark by the time I took the last one, but here are a couple of shots from today.

Injectors in:



Current state:

[Doctor Gollum]

Be firing it up after breakfast 

[JamesV6CDX]

Be firing it up after breakfast 

Oh mate I wish - there are a sea of electrical connectors, particularly all in the region of under the alternator, which I need to fathom, plus some at the back of the engine. Plus I need to refit the exhaust, intercooler bits, etc. Oh and work out all of the vacuum hoses!

With that said - now the engine is almost back together, the loom just seems to be falling into the right places, and the connections to the various sensors/components are pretty unambiguous for most.

I reckon a leisurely days tinkering, (plus a battery charge, and it will be shit or bust time!!

I ordered some fresh fully synth oil for it today. I know I'm not throwing money at it until I know it works, but oil and filter is the exception - it would be a moronic sin, to pour used oil back into that freshly assembled engine