Thread: Off it comes...D2 TD5 headgasket swap

Not yet, reassembly has not started yet, getting the head back on monday. I am aiming to get it running by tuesday, if I can get the dowels in time, had to order them in as Southern Cross LR didnt have them in stock.

In the mean time, been taking the steering knuckle balljoints out, had to make a special tool for that too. Will post up pics and make a how to, as I could not find any info anywhere on removing those balljoints. So I was very excited when I got them out.

Dearot, I'm sure you can buy something similar to that pedastal thing I made if you looked hard enough, makes it very easy.

Strangy and Pete, did you get the injectors professionally cleaned before you put them back, or did you just refit them as is?

No, The diesel mob here reckon I could do just as good a job as them, using a soft cloth .
They were unable to clean or test any EUI from any make. Apparently cheaper to replace the injectors than the time, effort and investment in the equipment to test and clean!!

I looked at the injector pattern on the piston crown and they were all uniform and clean so I just accepted that they were ok.

Cheers

I wiped my tips with deisel and a lint free cloth, coper washers fell off so put them in the head 1st. and then slid the injetors in.

Hendrik may I add a little bit here.
Unlike above, my copper washers were firm and a little care was required to refit.
I used a little engine oil (smear not a splash) on the washer and then used the injector retainer bracket (also with a smear of oil), to push the washer home. This applied uniform pressure over the entire washer surface so as not to bend, scratch or warp it going back on.

There isnt much pressure required and I just held the EUI in one hand and the bracket in the other.
If you place the bracket on a bench and push you may strike the injector tip.

cheers

Thanks for that, I just have to get the washers off first, mine are on really tight, how did you remove them?
Well the machining place has finally done the head, picking it up this afternoon as well as the steel dowels which I am hoping has come in. Everything has been cleaned and ready to go in.
If all goes to plan, I am hoping to have it fitted tonight and torqued down, so a big night ahead...but looking forward to it all.

Thanks for that, I just have to get the washers off first, mine are on really tight, how did you remove them?

Hi Hendrik, getting close now.
I used a small set of adjustable pliers (from a Toyota tool kit!) which were ideal.
These are really just like "multi grips", only smaller and easier to manage on delicate stuff. i used the middle part of the jaws (the oval shaped bit for big things)

A good clean first which helps get rid of some of the soot which binds them.

My tool has small directional teeth on it , so i carefully gripped the edge of the washer and slowly twisted in the direction of teeth. As soon as the washer moved it was all easy from there. If you use something like this, be careful not to get the teeth biting into the injector body.

I would not be tempted to use anything to prise them off.

Make sure you dont grip it too hard to avoid compressing the washer harder onto the nozzle. Dont stress if that happens, it isnt the end of the world it just makes it a bit more time consuming.

Cheers

Well the head is pretty much assembled, just need to torque down the upper section and fit the rocker shaft. Thanks for the tip about the injectors Strangie, I found a similar tool in our Courier and that made it very easy to get the washers off. What took the most time was refitting the valves, a bit fiddly but got there in the end. Will try to have it going by the end of tomorow, and then reassemble the front end..lots of work to do still.

It goes I'm so happy.
Reassembly went very smoothly, the hardest job was taking off the oil filter, still as hard with the head off believe it or not.
Will post some pics soon. All I need to do now is reassemble the final drives on the front diff then it's drivable.

Originally Posted by Hendrik

It goes I'm so happy.
Reassembly went very smoothly, the hardest job was taking off the oil filter, still as hard with the head off believe it or not.
Will post some pics soon. All I need to do now is reassemble the final drives on the front diff then it's drivable.