Right, following on from my thread at the end of last week, I now have teh head off the 90 and I thought it may be useful to post the procedure for people to at least get an idea of how to do it. I managed to get it in our garage by letting the tyres down so decided to have a go at it on my own at home
I will have 3 or 4 stages to this.
1. Removal of head.
2. strip and rebuild of head
3. refitting of head.
I will also say that I have tried to capture this accuratley but I may have missed something. Be warned!
So lets make a start.
Remove Bonnet.
Remove Fan cowl
Remove Engine cover
Remove intercooler pipe
Remove Radiator hoses and drain coolant.
Remove
Remove Breather hose
Remove Injector loom plug.
Remove Rocker cover. 10mm socket is required. Also unbolt dipstick tube
Remove Top radiator hose, and air inlet hose including AFM.
Remove Turbo heat shield. 3 bolts as marked. (one into bracket mounted onto turbo may have come adrift of rivets)
Remove Injector loom. Push clips on each injector and push fit round connector.
Remove exhaust manifold. 13mm socket and ratchet with extension. May be necessary to remove rotor filter cover to get easier access.
Remove water pipe
Remove wiring loom from water temp sensor, unbolt 2 clips on front of head, disconnect glow plugs, MAP sensor and any other sensors that are in this area (EGR etc) Thread loom out of inlet manifold
Remember to plug all oil pipes and turbo etc.
Disconnect fuel lines. One from fuel cooler can be connected to the one on the head as highlighted to keep it clean. I unbolted the entire fuel cooler to make disconnection easier, rather than risk breaking the clips
Remove Fan from engine, and manually rotate engine to align the 2 coloured links and pulley groove. Lock the pulley in position with a bolt down from the top. See next 2 pictures.
Remove Cam chain tensioner.
Remove Vacuum hose.
Now remove everything highlighted here. Can shaft front cover, the bolt on the OSF corner, the nut on the NSF corner, and the allen key that is the guide for the can chain tensioner. Once you have removed the front cam shaft plug, remove the 3 bolts that hold on the cam shaft pulley.
Double check everything is disconnected and lift off head. I recommend an engine crane but I did it with Sams help and we lifted it off.
Gasket looks perfect. Dowels have a slight amount of damage but not much.
If you do decide to do this yourself be careful. Its nota ctually that difficult but, my car has no aircon and is a Defender so it is easier than an Aircon spec Defender and a fair bit easier than a Disco.
Anyway, the head gasket looks fine, and I cant see any issues with it but I will clean everything up tommorow and go from there. Still happy I have stripped it as i dont like not being 100% confident in a car.
The saga will contiue.
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