Max needs a new Head Gloom

[missfixit70]

Good news MH we shall expect a full write up with photographs of course

[maxheadroom]

Good news MH we shall expect a full write up with photographs of course

Bugger better get my spanners back out

It was a very satisfying job and when it started today well I was like a dog with two tails
To be honest it wasn't that hard, just took my time taken it a part and putting it back together.

Had two nuts left over and then realised they were the two I replaced as I couldn't find them

Should have taken pictures as they would of helped when putting it back together
only broke two things, the ring off my dip stick and the fuel return pipe from the injectors very brittle from the heat but replaced that and all seems well

[missfixit70]

Main thing is you got it sorted & we have us another head fixing expert

[maxheadroom]

Good news MH we shall expect a full write up with photographs of course

Well how I re-assembled my head (well what I can remember, I have had a sleep since)

I put the glow plugs in, temperature sensors in, the inlet and exhaust studs in, oil fill pipe and water pipe on the drivers side on the bench (dinning room table actually very understanding wife )

Out to the car now…

Set No. 1 piston at dead top centre. Check fuel pump mark was lined up with timing mark.
Fitted head gasket in place.
Applied silicone as manual to water pump end of head.
Lower head on with the timing mark on the belt pulley set.
Greased/oiled all the head bolts threads and under the bolt head flange.
Tightened bolts hand tight and then four times to torque settings 22 ft/lbf (Bongo manual says 4 times, Ford ranger says 3)
Then put a paint mark on all the bolt heads and turned in sequence 90º
Then once more to a further 90º turn.

I think I then fitted new cam belt and new tensioner, re-checked timing marks.
I then re-fit exhaust gasket and manifold.
First poured oil over the cam and re-fitted the rocker cover to the manual including silicon sealant and new gasket.
Fitted all the hoses etc and alternator basically everything on this side of the engine.

Now to the other side of the engine…

Fitted injectors.
Buzz bar for the glow plugs.
Then the inlet manifold and new gasket. Don’t forget to re-fit the plate that holds electrical bumf and vacuum pipes the plate is held with two of the manifold bolts. (not that I forgot )
EGR was the re-fitted with two home made blanking plates (galvanized steel plate just a bit thicker than the old gaskets)
Re-fitted the vacuum pipes.
Re-fitted the fuel return and injector pipes. Be careful as I managed to snap the rubber fuel return pipe, as it was very brittle. Replacement found and fitted.
Fitted the air intake pipe that runs behind the engine and re-connected it to the turbo and air filter.
Re-checked the timing and then re-fitted the cover.

Connected all the water pipes and flushed engine out with hosepipe and then fitted new thermostat. Refilled coolant system with water.
Checked oil levels
Fitted the centre cover with hand brake, gear stick and any other electrical plugs and bits I could see

Stood back and went for restart bugger battery not charged enough as it had been stood for a while.

Charged battery and went for blast off I think it was about six turns of the key and hey presto the engine sprang into life. One very happy and satisfied Maxheadroom.
I had two nuts left over and thought ah that was the two I replaced holding the air pipe to engine as I couldn’t find them in the first place.

I just took my time and if in doubt log on here or lush projects etc.

I hope this is of help…..

any questions please do not hesitate to contact mikeonb4c

Thought I would copy and paste this from ADAMD thread just in case it's of help to others

[maxheadroom]

Well took the Bongo to work today as it needed it's fourth MOT, I did think it was the third as I have had it three years but of coarse I had to MOT it when I imported it
So this was it's first real test drive since fitting new head and steering rack seal. Seal is fine, so well happy. Bongo is running great and it passed the MOT with flying colours Well impressed with the emissions they where 0.33 1/M, so cleaning the inlet manifold out of all that black tar like cr*p and blanking off the old EGR seems to have worked well
Heres to the next 83K

[missfixit70]

Nice one Nic Now you just need some decent weather to get out & enjoy it

[maxheadroom]

Now you just need some decent weather to get out & enjoy it

to right but the weather is not looking good this weekend could do with getting away
got some great friends in Somerset that need a visit.
Oh I feel a party coming on roll on summer

[Northern Bongolow]

congrats max.
well chuffed for you, bongo on and on.

[mikeonb4c]

Well took the Bongo to work today as it needed it's fourth MOT, I did think it was the third as I have had it three years but of coarse I had to MOT it when I imported it
So this was it's first real test drive since fitting new head and steering rack seal. Seal is fine, so well happy. Bongo is running great and it passed the MOT with flying colours Well impressed with the emissions they where 0.33 1/M, so cleaning the inlet manifold out of all that black tar like cr*p and blanking off the old EGR seems to have worked well
Heres to the next 83K

Great result Max - I'm seriously impressed

[SiF]

Should have taken pictures as they would of helped when putting it back together
only broke two things, the ring off my dip stick and the fuel return pipe from the injectors very brittle from the heat but replaced that and all seems well

Hi

Is the fuel return pipe you broke the little black tube that goes from the diesel return pipework manifoldy thing to what I'm guessing is the fuel pump/valve. It has a spring clip at each end ? If it is I've just totalled mine as I wasn't expecting it to be so brittle, I am hoping that normal diesel fuel pipe can be used to replace it or is this a specialised part and is so does anyone have a part number...

many thanks

Simon

[maxheadroom]

Should have taken pictures as they would of helped when putting it back together
only broke two things, the ring off my dip stick and the fuel return pipe from the injectors very brittle from the heat but replaced that and all seems well

Hi

Is the fuel return pipe you broke the little black tube that goes from the diesel return pipework manifoldy thing to what I'm guessing is the fuel pump/valve. It has a spring clip at each end ? If it is I've just totalled mine as I wasn't expecting it to be so brittle, I am hoping that normal diesel fuel pipe can be used to replace it or is this a specialised part and is so does anyone have a part number...

many thanks

Simon

item 93-4104 for anyone who needs to know.........

http://www.lushprojects.com/bongopartsm ... mgno=.html

Simon pm sent

[Bob]

Splendid bit of work, jolly well done.

[bigdaddycain]

Glad to see you back on the road max....