Club 80-90 Forums

Hello all, it looks like i have a cracked cylinder head on my hands, 1.6 TD 1988 caravelle.

I'm gonna remove the head myself get it repaired(if poss) and re fit myself, i've never done anything like this before so was wondering if folk could give any advice pointers etc re. the job in hand. I will work slowly and methodically and take fotos and make notes as i go to help putiing everything back together.

If the head is completely knackered beyond all imaginable belief could any one advise on a company to supply a new/recond head, i looked at AW engineering if i remember rightly they were based in Darwin Lancs. Does anyone know this company?

Regards,

Rob.

Hi why do you think the head is cracked? Amc Spain make new heads.
You'll need a dial gauge to set the pump up.
what tools do you have?

Before committing to any repair work make sure you get the head pressure tested.

I didn't pressure test mine, and after a hefty recon bill found that there was actually a crack in it and the head should have been scrapped. I wasn't expecting it, but i'm new to this too so it's all part of the learning curve

Thanks for your response folks, the reason i think its cracked is that i had a smoky injector so i took them all out to be checked and serviced when it came to putting them back in again i removed the old flame traps to replace them and saw what appeared to be a 2mm square piece of the head missing from the surface where the flame trap sits this was what i thought was the dodgy injector. I'm no mechanic by any means what so ever but from what i can see it looks like the flame trap isn't sealing due to this 'hole' right under where it sits. I torqued the injectors up to the required 70nm, all the others are fine, i even nipped the problem injector up a little over the required 70nm just to see what happened and it still smoked.

I know heads can be repaired by welding etc but to get at this you would need hands like a church mouse! Thats why i'm thinking of buying another head be it a recon or new.

@dave friday i only have the basics tool wise a decent set of sockets etc but no specialist tools, what i dont have i can probably borrow. What does setting the pump up involve?

If i come unstuck i have friend who is a qualified mechanic but to be honest i'd like to do it myself to learn a little more about my van.

@Roscoe thanks for the advice, did you fit yours yourself?

I just got a quote today for a new assembled head with new head bolts and gasket-£498.00 inc VAT does this sound about right? Or is it possible to get one cheaper? I just emailed amc spain so will hopefully hear from them soon to make a comparison.

Thanks again!

Is the smoke coming from around the injector or from the exhaust?
oops just re read your post[smoke from injector!]
I'd loosen as many bolts as i could so as to know what route to take[i've had the head off mine 3 times]

The smoke is definatley coming from the base of the injector as far as i can see, when you'v removed your cylinder head have you done with the engine still in the van?

Cheers,

Rob.

Yes.
air cylinder out/off
4 bolts exhaust manifold to turbo off or if they dont want to come out...
8 nuts on exhaust manifold to cylinder head off then nuts/bolts turbo to sump off.
Post if you get stuck!

Thanks Dave much appreciated watch this space there will be no doubt more questions

I've been building a rock and roll bed today, the list is endless!

Cheers.

Hi Rob, yeah i fitted the head myself (but that's off now!). I've managed to get a second hand JX engine off of ebay which had a recent head recon, picked it up today and will be fitting it this week sometime. I definitely agree with what other people have said in the past about stripping and putting engines back together, that once you've done it you'll wonder what all the fuss was about. Just go slowly and follow a manual and you should have no issues. It's a lot more rewarding doing it yourself!

Hi Roscoe i agree its a just a case of working methodically and with confidence, i remember one of the first jobs on the van was to remove the broken rear heater and changing the coolant, i was well nervous about doing it as i'd never done any work on vehicles before but for no reason, definatley the head change is a bigger job but i reckon i can sort it and save a lot of cash doing it myself, and its a great way to learn a bit about the van.

Do you know if the JX engine is covered in the bentley manual?
I have the haynes but its only for the petrol engine.
Also what special tools will i need? I know theres a tool to remove the cam sprocket, is there special tools needed to remove the pump?

Good luck with the engine change.

Good stuff, that's the spirit!

I'm not familiar with the Bentley manual myself, the one i use is from just kampers (originally a 'pocket mechanic' book published by Peter Russek, which JK seem to have just photocopied and taken as their own!) which covers the JX: http://www.justkampers.com/shop/t25/acc ... 10839.html" onclick="window.open(this.href);return false;

Here's a list of the extra tools i've had to buy to do the head:
- Gear puller, just a standard one will do (for the camshaft gear/sprocket)
- VW timing tools (this consists of one metal bracket type thing which locks the camshaft, and a metal plug which locks the injector pump, usually sold together)
- Spline socket set (for the cylinder head bolts)
- breaker bar (again for the cylinder head bolts)
- Injector pump timing adaptor, the IDI version
- A dial gauge (to use with the above)
- Cambelt tensioner (i actually made my own from a length of wood, steel brackets and a sawn up screwdriver shaft)

Seems like a lot of extra stuff now that i've listed it all, but it'll get the job done. The money spent on the tools seems well worth it now that i have to replace the head again...

Cheers Roscoe, i'll start tracking the tools down that you mentioned. I'm also gonna order the book from JK, i'm sure it will help a lot, its a pricy hobby is T25 ownership, but worth it.

Thanks again, i'll keep you posted on how it goes.