TD5 Head Strip....

**Psimpson7** · 30th October 2008, 02:33 PM

Right so part 2. this covers teh stripping of the head. Please excuse the fact that I haevnt got a nice bench. I will haev everything a lot better set up when I reassemble it.

So firstly, remove the lifting eyes:

Then remove the water outlet with temp sender:

Next unbolt the 6 bolts that hold in the rocker shaft.

Lift it out

It will now look like this:

remove the bolts that hold down the injectors, and lift out the clamps. I arranged everything so Iknow where it came from.

Remove inlet manifold

remove fuel block

Undo the bolts holding down the upper section of the head. undo them evenly in a sensible order to release spring load evenly:

Lift it off

This will expose the Camshaft, lift it out.

Now remove rollers that go between cam shaft and valves. Bottom of picture. 10 of them. place somewhere, keeping order.

Once they are gone it will look like this:

Now pull out the pedestals they sat on:

Next pull out the pedestals that the injector clamps sat against:

Now remove the injectors. This is actually quite easy adn you dont need an injector removal tool. Thanks JC for the tip. I used an allen Key as a little lever and gently prised them out uner the bridge.

Lift out injector:

Head is now basically bare enough for skimming (need to remove heater plugs and maybe studs but thats basically it.

Its actually a really nice engine to work on

Cheers
Pete

**andymach23** · 30th October 2008, 08:03 PM

Hi Pete

This series is excellent. A brilliant reference. The photos are well lit so are very clear. Looking forward to the next installment.

Cheers

Andy

**Psimpson7** · 30th October 2008, 08:15 PM

Thanks very much Andy

Skimming is going to be done tommorow so basic reassembly of some parts may happen tommorow. Havent actually ordered much yet beyond oil and filters but hopefully will get all the bits next week to start the proper reassembly.

Rgds
Pete

**Outlaw** · 31st October 2008, 12:37 AM

so to ask so i'm clear and learn something more

What is skimmed and what does that entail?

**Blknight.aus** · 31st October 2008, 05:57 AM

think of it as feeding the head through a really really accurade deck planer to make it all nice and flat.

the machineries different the concepts the same

**Psimpson7** · 31st October 2008, 04:23 PM

Well I had the head cleaned, pressure tested and skimmed this morning by PA Gilberts in Southport. Had 5thou taken off it to clean it up nicely.

Also dropped in to the Bruce Lynton LR dealership (basically next door) it turns out that all their engine machining goes there and started to look at part numbers.

Ended up buying near enough everything from them there and then. Got a discount on the head bolts too ($22.76ea+gst) which was nice. Only thing they didnt have in stock was teh dowels so they are on order adn will be with me on Monday.

Head check, clean and machine was $187 and parts were $676 so far. If anyone can think of anything I have forgotten please say! I will be getting all teh water pipes and so on too.

Cheers
Pete

**justinc** · 31st October 2008, 04:38 PM

Originally Posted by Psimpson7

Well I had the head cleaned, pressure tested and skimmed this morning by PA Gilberts in Southport. Had 5thou taken off it to clean it up nicely.

Also dropped in to the Bruce Lynton LR dealership (basically next door) it turns out that all their engine machining goes there and started to look at part numbers.

Ended up buying near enough everything from them there and then. Got a discount on the head bolts too ($22.76ea+gst) which was nice. Only thing they didnt have in stock was teh dowels so they are on order adn will be with me on Monday.

Head check, clean and machine was $187 and parts were $676 so far. If anyone can think of anything I have forgotten please say! I will be getting all teh water pipes and so on too.

Cheers
Pete

I'M STILL waiting for a reply Email RE parts

, so I'm glad you were able to get it all at one place, sounds like good prices, RRP on Headbolts alone is about $440!
And By the looks of that list, it's all there!
5 thou is excellent, looks like a good finish too.
You're going well Pete, and your explanations and pics are excellent! Good tutorial!
JC

**justinc** · 31st October 2008, 04:46 PM

Pete,

Just remembered, don't forget to adjust injector bump clearances when reassembling. AFAIR you sit the cam lobe for the injector at full lift, screw the adjuster in until it bottoms out, then out 2 full turns and lock it up. repeat for others.
It may not need adjusting as you haven't changed cam/injectors/rollers etc BUT it is so simple to check and the results if it is wrong can be expensive. I've had to pick particles of broken injector springs out of heads with a magnet before now

JC

**harry** · 31st October 2008, 04:56 PM

good report pete,
the only thing i have to ask,
is
why havn't you taken the valves out and given them a tidy up as well?
seats and faces, guide wear etc?

**Psimpson7** · 31st October 2008, 04:59 PM

Thanks Justin. no worries! Will start to do a basic clean and reassemble of some stuff today. Will look at the injector bump clearances.

Yep finish on headis very good. happy with that. Guy did Sam's Vitara a while back and that was good also hence using him. His workshops are immaculate too.

Harry, its only done 98000km and I dont think needs it.

Rgds
Pete

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