 | Home > Maintenance & Modifications > A day in the life of Miffy the 110... |
 
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410  
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I think this might be step one  With some sort of drill guide. The dead has been done now so got to continue...  |
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11th Jul 2021 10:56am |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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In other less destructive news from yesterday...
The fuel tank breather has been repaired and the relays that control the fuel pump, glow plugs etc have also been replaced. I opened all the relays up and 1 out of six was in passable condition. The rest all showed pitted and worn electrodes. Definitely worth checking. And lastly, just before I broke a rocker shaft bolt the old girl turned 220k miles 
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11th Jul 2021 12:00pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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So doing a little recon on what to do next with the head. I have contacted an engineer about removing the sheared bolt (maybe bolts once the other 5 are out). I am not sure whether the head is going to require a skim, mind you considering Miffy's head has already been skimmed (+/- 24 months ago) I am do not think that is possible again...
So, assuming that he head should be skimmed and cannot be again the options become limiting. Source a good second hand later model head or go the whole hog and speak to Turners about an AMC head... The latter is more costly up-front, but might be the more prudent option longer-term. What to do, what to do... Full AMC replacement looks to run to £1665 inc VAT and P&P... |
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12th Jul 2021 11:06am |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Hi Clay. Thanks mate it has been an expensive day so far today. I have removed the rocker shaft and begin the strip down this evening... Four sheared rocker shaft bolts... Four... They were so incredibly tight. The first bolt is still sitting up on my desk.
Click image to enlarge The injector bolts were also incredibly tight, I was sure they were going to all shear off as well. They didn't. but it was a close thing, really close. You all know how a bolt feels just before it shears... 
Next step is to drain the coolant (time for a flush perhaps ), unplug the glow plugs, drain the fuel, dig out the AC fan loom which for some reason is wound through the arms of the intake manifold, then it is one to the BIG  holding the head on...
Please please pretty please come out ok... As for the head gasket I noticed that there is a 1 hole on at the moment (and since the head was skimmed in 2017) but scrolling back through photos Miffy had a 2 hole from the factory. So head skimmed and garage upped the thickness of the gasket by one thickness to accommodate the loss of head material in the skimming process. Good to know. I have ordered a 1 and 2 hole gasket and will measure the piston protrusion once the head is off. The 2017 gasket change was a head gasket failure, this time around it is a clutch of sheared bolts... For those who are interested the order of thickness with TD5 head gaskets goes 2, 1 and then 3. Thinest to thickest. Completely logical
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15th Jul 2021 8:27pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10568 
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I have everything crossed for you when you tackle the head bolts
 1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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15th Jul 2021 8:44pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Think I may need it... Plan B... What would Plan B be if they resist removal
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15th Jul 2021 8:57pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10568
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Can't help you with the plan B but there would be a lot of this
I do hope they all play ball for you  1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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15th Jul 2021 9:11pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Thanks Clay. I am sure they will put up a fight and if they do, well after a lot of censored language and the feeling of dropping your guts a Plan B will make itself known I am sure... Perhaps a V8...
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15th Jul 2021 9:22pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10568
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You just never know how these things will turn out, hope it's still a Td5 for you
1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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15th Jul 2021 9:56pm |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3626 
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Beer. Helped out massively in my recent AC install! |
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16th Jul 2021 6:03am |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Right then, parts are arriving thick and fast. Well Turners are, LRDirect are being a little slower.
This weekend is going to be glorious so all hands to the pumps, make hey whilst he sun shines etc etc etc... Just figuring out how to get the head off and on again without a crane... ...must have Weetabix for breakfast |
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16th Jul 2021 2:56pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10568
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3 or more Weetabix will be a big help with the head removal
1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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16th Jul 2021 8:48pm |
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| donmacn Member Since: 07 Nov 2017 Location: Nth Scotland Posts: 1833 
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Then when the time comes you'll have two sets of grumpy head bolts to deal with!
Having four rocker bolts shear is hard to believe, isn't it? Someone had obviously never heard of a torque wrench! I did the heads on my V8 (RR P38) last month. Not something I'm used to tbh so I was a little beyond my comfort zone. As luck would have it, the first, and most awkward to access head bolt was a pain. The head just rounded away  .
I ended up getting some cobalt drills and using progressively wider bits, taking the head off the bolt. For the rest, I have a pretty meaty impact driver. Before tackling each head bolt with a 600mm breaker bar, and a hollow tube extension, I rattled away at it with the gun. I don't think it did a lot, but maybe generated some heat which might have helped. Even with what must have been about a 1 metre lever, they took a fair bit of grunt to shift - as you say, at the scary stage when you think something's going to break. On the rebuild, I really didn't fancy stretchy head bolts, so I went for ARP studs and nuts. Probably not available for a TD5 though? A breeze to use. You also wondered if a head could be skimmed a secnd time. Again, I don't specifically know about a TD5, but the RR heads were skimmed - they only took off 3 thou' and I think that could be done 2 or 3 times. There's some sort of maximum but that's beyond my techy knowledge. Good luck when the time comes. Donald 1994 Defender 300Tdi 110 SW - owned since 2002 - 230k miles and going strong (The 'rolling restoration' or tinkering thread: http://www.defender2.net/forum/topic58538.html ) 2000 Range Rover P38 4.0L V8 in the past.. RR classic - fitted with 200Tdi 1984 RR classic - V8 with ZF auto box 1993 Discovery 300Tdi not to mention the minis and the Type 2 VW camper... |
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16th Jul 2021 8:57pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Well it is scorchio out there today. Great day to do this engine work. All went exceptionally well today. The most important thing is that the head bolts came out with a creak and some fingers crossed. The head is loose that’s the important thing. Just waiting on my neighbour for a little grunt work to get the head off then it’s all go tomorrow for the rebuild.
Have to say I miss having a garage to work in, but thanks to the Aluminet I was able to work most of the day without getting crispy fried
Some interesting things, wear on the timing tensioner, gasket sealer debris in the hydraulic lifters and most annoyingly the glow plug connectors have perished to destruction… I know Nakatenenga do a kit to replace them but at £100 that’s just a step too far for a piece of wire and a plug
So hear are some images of the operating theatre: Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge |
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17th Jul 2021 7:37pm |
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