The dirtiest TD5 engine you ever saw, but I still need your precious advice.

[Robthebob]

This is a 2005 TD5 EGR bought as a mistake under advice of a friend who considers himself an expert in 2012 from Sisters of Mercy in Haiti where I live (sorry, not an Ozzy guy). End of june the engine stopped as the engine had oil in the water system. Thick black oil coming out of the water tank. A mechanic tried a quick fix which didn't work, then took off the radiator to get it cleaned (which was done) but then never showed up again to put the radiator back and finish the job. After some research I found out that a fault in the cylinder head gasket could be a probable cause of the symptom. I then documented myself as much as possible and took the head down. Some bolts made me sweat but worst of all was to discover the dirt underneath the visible parts. I will not be able to do a clean job in this moment. No new engine but just a good clean and replacement of all gaskets.

One more question: how do I rotate the engine to clean the cylinders and get it back where it is to mount back the head?
Thank you all very very much.

http://robertostephenson.com/TD5_problems

[justinc]

This is a 2005 TD5 EGR bought as a mistake under advice of a friend who considers himself an expert in 2012 from Sisters of Mercy in Haiti where I live (sorry, not an Ozzy guy). End of june the engine stopped as the engine had oil in the water system. Thick black oil coming out of the water tank. A mechanic tried a quick fix which didn't work, then took off the radiator to get it cleaned (which was done) but then never showed up again to put the radiator back and finish the job. After some research I found out that a fault in the cylinder head gasket could be a probable cause of the symptom. I then documented myself as much as possible and took the head down. Some bolts made me sweat but worst of all was to discover the dirt underneath the visible parts. I will not be able to do a clean job in this moment. No new engine but just a good clean and replacement of all gaskets.

One more question: how do I rotate the engine to clean the cylinders and get it back where it is to mount back the head?
Thank you all very very much.

http://robertostephenson.com/TD5_problems

Hi and welcome!☺

The only way to rotate the engine safely is a 2 person job. Somebody needs to lifr rhe camshaft sprocket up to maintain tension on the chain while rotating the engine. Clockwise direction when viewed from the front.
Aaand i hate to break it to you but i would say that the oil cooler is actually at fault here.. not the cylinder head 😢.

Jc

[Robthebob]

Hi and welcome!☺

The only way to rotate the engine safely is a 2 person job. Somebody needs to lifr rhe camshaft sprocket up to maintain tension on the chain while rotating the engine. Clockwise direction when viewed from the front.
Aaand i hate to break it to you but i would say that the oil cooler is actually at fault here.. not the cylinder head 😢.

Jc

Hi Jc, thanks for the answer. How do I return to the exact actual point when rotating the engine? and what makes you think that this is more of a oil cooler fault? Anyway I can confirm this? And if, is this the part to buy? TD5 Oil Cooler Repair Kit - Paddock Spares

[djam1]

Hi Jc, thanks for the answer. How do I return to the exact actual point when rotating the engine? and what makes you think that this is more of a oil cooler fault? Anyway I can confirm this? And if, is this the part to buy? TD5 Oil Cooler Repair Kit - Paddock Spares

Cant help with the answer to the engine rotating but it will definitely be the oil cooler, you can see from your photos that the wrong coolant has been used
The other thing I would be looking at is the coolant galleries in the head where they pass near the fire ring my head was toast when the wrong coolant was used.
The Cooler repair kit you mention is on the right path I personally prefer to buy quality parts though.

[Robthebob]

Thank you Djam1, would a Britparts replacement be a better choice?

[Robthebob]

I also need your answers, if you have any, about:
When taking EGR off, what to do of the blue pipe lines? see photo http://robertostephenson.com/TD5_pro...617_large.html

And the EGR cooler water hoses, can they be connect together once the cooler off?

Is it ok for the breaks fluid reservoir to be mounted with an angle? as you see in the photos: http://robertostephenson.com/TD5_pro...043_large.html and next photo ?

The exhaust manifold had 2 gaskets fitted. Should I just put one new one? Check photo at link and following. There is much corrosion on the manifold wall, would this be ok anyway? http://robertostephenson.com/TD5_pro...154_large.html

One of the manifold studs unscrewed from the block. How do I fix it back in? http://robertostephenson.com/TD5_pro...121_large.html

Any advice on how to clean cylinders and head from rust and deposits? check photo at link and following: http://robertostephenson.com/TD5_pro...828_large.html

Thank you all!

[nismine01]

If you turn the engine over twice, piston #1 up twice the timing marks on the cam gear and the chain will line up again.

Just check their position before you start for a reference when done.

Cheers

Mike

[JR1]

I'll second the oil cooler. Had a small hole in mine recently. One week of flushing the engine, professional clean of the (recently replaced) radiator, new hoses and $3500 later, we were running again.
The hole was tiny -only seen after cleaning the cooler and was originally not noticed. Good luck.

[PhilipA]

When taking EGR off, what to do of the blue pipe lines?

If you are taking off the EGR , then you may as well remove the solonoids and block off the vacuum line from the brake line to the solonoids. If you remove the electrical plugs from teh solonoids then yhe ECU does not fault.

The exhaust manifold had 2 gaskets fitted.

The exhaust manifold is probably warped. check the face of it with a straight edge and machine it flat. At the same time either slot or open the end and next stud holes in the manifold to 10MM.
You can just screw the stud back in, BUT it is always best to replace the studs or they can break without warning. Mercedes studs also fit and are stronger.
I don't know if it is 2 gaskets as I think there are two halves to the stock gasket and they come apart when old.
The waterways certainly look really bad. You should clean up the head and block with scotchbrite and maybe clean the pistons with a blunt scraper. I have never seen such crappy waterways but maybe soak them in degreaser for a couple of days?weeks?
It looks like the LR has not done any hard work for a long time , thus all the carbon in the head and combustion chambers. Is there a mechanic anywhere with a hot cleaning bath?
I managed to clean out my inlet manifold with a high pressure cleaner so maybe that is a start.
Regards Philip A
I suggest that you get the sisters of Mercy to pray a bit also.LOL

[djam1]

Wow that is expensive!

I'll second the oil cooler. Had a small hole in mine recently. One week of flushing the engine, professional clean of the (recently replaced) radiator, new hoses and $3500 later, we were running again.
The hole was tiny -only seen after cleaning the cooler and was originally not noticed. Good luck.