engine overhaul

[AdrianNPMajor]

Perfect!
This is a special engine because of your work.
Best, Adrian.

[Pavel]

Yes, Mathias; the head does look terrific -- but wasn't point 2 of a mm [8 thou of an inch] a bit excessive; unless it needed it, of course? We always reckoned that 5 thou or under was enough to true up a deck.
I mention it because this amount removed will have an effect on the ultimate injector timing because of the increased compression. I suggest that an advance of 1, or maybe 2, degrees should be considered as advantageous.
Pavel

[SvendH]

Not trying to be a wise guy but i think the effect of 0.2 mm would matter only if you took it off the Block (deck) and so bring the piston crowns closer to the head.

[oehrick]

It will slightly reduce the head volume and bring the injector tips closer to the piston crowns by the skimmed amount, probably diabolically major surgery on a Formula 1 engine but the volume is a drop in the ocean compared to the carbon Mathius has probably carved out of the head before skimming

When we see how well these D series manage to run even when horribly worn and coked, while aiming for perfection is fine (and I'm sure Pavel has good reason for suggesting this bit of best practice), there are probably other unseen factors which have more influence - like temperature on diesel viscosity or the yield in the quiet coupling material

[mathias1]

[mathias1]

4, 5 and 7 puzzels me where they go

[mathias1]

Due to other projects this one was a bit on hold. Looking forward to finish this soon. I' gonna install the new tappets and new camshaft. I also ordered some new core plugs.

[mathias1]

some more pictures:






Next is putting on the timing gears.
Any suggestion how to measure the end play on the camshaft?

[mathias1]

Timing gears all in place




I put some scotch on the bolt, as I still need to torque it down. Wanted to put some loctite on it, but have to order.




I also put new core plugs in the water compartiment of the head and the block. I reused the plug at the back of the camshaft.

[mathias1]

o-seal fitted

new gasket

ready to torque down the head bolts. Will do this in a few steps

[henk]

All nice and shiny on the inside.

[mathias1]

A little more progress:




The rocker shaft in pieces, so I could clean the inside. Needed to drill out one of the locking pins.


Found out I forgot a plug for the oil gallery behind the engine plate. So I had to do that part again.
So now I will check all the bits I've still laying around to see I've got everything. I hope I can find the bolts to fix the waterpump too :s
But all in all I'm happy with this progress.

[mathias1]

up next is the sump.
do the crankseals still need to be in oil?

[mathias1]

small update:
The loctite arrived, so I could torque down the crankshaft bolt and the auxilary shaft nut.
A new seals on the timing cover for the crankshaft.
I found the bolts for the waterpump, so got the waterpump installed. I've got the sump also bolted on.
The lower crankshaft seal is in, the upper not. I hope to do this when the engine leaves the engine stand.