jgra1 blog

[jgra1]

well well... thanks to my new fangled load of diagrams I downloaded recently, it seems to me that the 2.0 hdi and this 2.2 share the same head, even the same gasket kit !
(based on comparisons between this van and a generic 406 hdi)

so.. a stroked 2.0

[CitroJim]

That will make spares easier John so a big advantage there!

[jgra1]

Deffo jim.. hope i am right.. we know the 2.0 was always a good engine. they add a bit to con rods for some torx and maybe lower gear ratios and see if it this application can haul 3500kg reasonably ok

[jgra1]

a better night despite the hideously long day starting at 0330... not a good sleeper anymore !

The cam seal is causing the oil in the side of the engine, I would say.. its really nice to find faults oil in 2 places on engine and simple things like a cam seal and a holed intercooler, and being able to inspect with time and space ..

The head if off!

part of tonight's 4 hours .. the gunge in the valve area is loose really. with that and the cam seal and a clean and valve lap it's good enough to split the motor...

I think I am nearing the end of dismantling .. without a doubt the biggest job I have ever tried, and so far only a week and a half in, a lot has been removed....
hopefully, all back together, all clean and a new turbo cartridge, a new belt, and all the silly things fixed like the inlet pipework being in many pieces, vac pipes split, 2 dodgy injectors, and I think this engine will be - well - as it should ..

I can still see the cross hatch in the bores, which surprised me.. I cant tell if the gasket is original.. the coolant passages are mostly 50% blocked but I think that isn't unexpected at 114K .. otherwise not much to report

the injectors are still causing a small headache.. the £25 per injector ebay companies don't seem interested in Hdi's... one has just quoted £20 to test each one to tell me 2 have issues.. I will make a plan

[CitroJim]

Excellent progress John, well done!

Your day started at about the same time as mine yesterday then. No way i could have done what you did in the evening though. I was in bed at 8...

The engine internals don't look bad at all... A quick clean-up skim and a clean-up and all will be good.

I reckon you'll have it all done well before camping season begins next year!

[jgra1]

not too much to report.. late last week saw the valves out..the inlets are pretty horrid.. the sump came off on the weekend and half the oil pump. these are mostly ready for refit now and the valves to be lapped in .. sump didn't look terrible really ..

the engine is just a small thing on the bench

I grabbed a used shock that looks good ..a used caliper (old one very seized sliders) a good front cross member, a good intercooler, and a near side driveshaft.. the ds has slight play annoyingly.. will come back to that

the turbo and injectors remain untouched for now

bits of welding continue ..

and two more mechanical fails found.. a rear lower arm bush (a £10 bolt on part) and one of the two fans.. I did suspect the latter as the planet session wouldn't activate the fan..
the only part of the front of this vehicle that hasn't been touched is behind the dash and the gearbox!

interesting to note the torque of this 2.2 is 250 nm ..same as the 2.0 ..bit it has 10 less horses!

I was offered a van tonight I had had my eye on..a 3.0 that I have been in..remapped and quite impressive .. think it was 2011 and a good size. .he wanted 5000

[lexi]

hi Lexi
yes and no

reading betwixt the lines are you saying 'if you cant weld bin this' ? its on my mind a lot..

ask me in 24 hours

Well.....I was thinking you must have one if it needed the welding. Too far from me here John, as you could have borrowed my 210amp Portamig for that job. It eats that work! Had a few vans John, and they are such excellent things all round.
The worst van I had was a JU250. It was so high for loading up man. You had to throw the gear up and into it.

[jgra1]

thanks lexi that is very kind. unfortunately I am a bit new to welding.. have done a few hours worth with new metal, indoors and was quite happy with result. but I and my welder aren't really good enough for vehicle structure so I am having to pay to have this done , which is a shame..

[Hell Razor5543]

While it is good to learn new skills, it is also good that you know what your limitations are, and get somebody else to do the critical work.

[jgra1]

thanks James. . there are bits that aren't so critical that I can do bits of.. I am.using gasless wire which i guess is a major limitation ...

[Hell Razor5543]

One thing back in the depths of time that a teacher said was something like "Know your limits, but work to expand them. Never be afraid of admitting when you cannot do something, but take the opportunity to learn how to, if you can." I have taken that to heart, and I try to learn something new each day.

My Great Uncle Jim also had a nice saying, "Take time to see something beautiful each day. It does not have to be big, but enough to make you pause for a moment".

[myglaren]

And Robert The Bruce said: "If at first you don't succeed - to hell with it"

[CitroJim]

And Robert The Bruce said: "If at first you don't succeed - to hell with it"

Defeatist...

Practice makes perfect John

[jgra1]

thanks all

had a bit more time today due to leaving work quite early, about 12pm ! *
bought the 3 injectors I had an eye on, they have been tested as working and come with the report.. 68£ for four with one duff... so that makes 5 good altogether as it stands..2 of my existing are ok

sump cleaned, lower engine cleaned as I could, oil pump all back together and sump on..
gave the block a light wet and dry 600 and lapped the valves.. gave the head face a first going over, to help decide to skim.. cash was an issue and its just got a bit more so..


* after 20 years and 3 months since leaving uni, I got hauled upstairs this am to say I am one of 3 on a redundancy list.. a month of consulting before a final decision ...

shocked a fair bit....

[CitroJim]

* after 20 years and 3 months since leaving uni, I got hauled upstairs this am to say I am one of 3 on a redundancy list.. a month of consulting before a final decision ...

shocked a fair bit....

Fingers crossed on that one John...

Hope you're not one of the three