Re: 86 5ktqw Head gasket going?

[quk@isham-research.demon.co.uk (Phil Payne)]

In message <002101be5eec$02fd4c80$020101c8@penta.valadas.com> "Lino M. Valadas" writes:

> Now for the questions.  How big a job for the home mechanic is a re and re
> of the head on the 5ktqw.  Any special tools needed.  I see the
> intake/exhaust manifold and turbo being a big pain to pull apart.  Any
> BTDT's would be appreciated.    I'm trying to decide whether I should tackle
> it myself or just go to my friendly but expensive  dealer.

Dumb question.  INCOMING:

MB/1B engine - cylinder head removal (follow 1B for MC engine)

Drain coolant

Remove oil filter to empty head galleries

[MB] Remove headlight trims, radiator grill, bonnet release cable,
transom & auxiliary radiator

[1B] Remove radiator grill & intercooler

Loosen steering pump pivot bolt, slacken and remove belt, remove
adjuster, remove pivot bolt & tie pump out of way

Remove injector cooling fan deflector, plug wires, plug wire shroud &
distributor cap

Unplug Hall sensor

Remove spark plugs

Remove upper cambelt cover & upper securing stud

Turn engine to TDC (cam/distributor) using spanner on cam wheel bolt

Lock crankshaft with tool #2084

Loosen water pump & rotate to loosen cambelt

Apply cable tie to cambelt below cam gear

Break cam gear bolt loose (80Nm)

Undo cable tie and pull cambelt off cam gear

Remove cam gear & Woodruff key

[MB] Unplug & unscrew injector cooling fan & turbo after-run water pump
from side of block

Unplug control pressure regulator, unbolt from side of block & place on
metering head - fuel lines stay attached

Unplug cold start injector, unscrew from manifold & place on metering
head

Pull out injectors & place on metering head

Unplug fuel consumption potentiometer & fuel frequency valve, switch on
throttle body & cut cable ties to metering head

[MB] Loosely tie detached fuel pipes to metering head, undo fuel feed &
return, pull off breather hose, disconnect accordion hose, unclip air
filter housing, llift out entire fuel injection system & remove air
filter housing

[1B] Remove air filter cover

Tie loose loom back to filter housing bracket

Remove crankcase & cam cover breathers

Disconnect injector cooling fan thermoswitch & remove heatshield  & coil
grounding strap from cam cover

Remove right CV joint heat shield

Disconnect downpipe from centre exhaust section & detach downpipe from
gearbox mounting

Using a 3/8ths drive 13mm six-point socket & a taped UJ, undo wastegate
to downpipe nuts - assistant required

Detach both vacuum pipes from wastegate

Unbolt wastegate from exhaust manifold & remove

Undo turbo oil & water connections & remove upper oil line

Detach bracket holding upper turbo water feed from side of block

Detach downpipe from turbo & push  aside

Detach turbo to intercooler hose

Detach turbo from manifold & remove from car

Detach accelerator cable

Detach temperature sender wire, wastegate main feed, wastegate control
valve feed, ECU feed & differential lock feed from rear ofhead &
manifold

Remove injector air supply hose

Using a mirror and "removal grade" Allen drivers, unscrew and remove
inlet manifold

Unbolt  top water hose from side of  head

Detach wire from temperature sender below steering pump

Remove cam cover

Slacken head bolts from outside inwards, half turn at a time

--
 Phil Payne
 Phone: 0385 302803   Fax: 01536 723021
 (The contents of this post will _NOT_ appear in the UK Newsletter.)