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Topic: Head Gasket Replacement (Read 2520 times) |
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Mike_Floutier
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'97 2.3 Ultima saloon lpg
 
Posts: 296
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Head Gasket Replacement
« on: Aug 9th, 2008, 10:52am » |
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Ok, this is definitely my last thread as a Scorpio owner so many thanks to all for all your help over the years!
As you may be aware I now need to replace my head gasket - I can pick up a replacement gasket kit in the next hour BUT I don't think I can do it without online help.
I'm looking for someone who can help me. THe instructions I'lll be following are at http://www.fordscorpio.co.uk/manual/engines/dohc2_3/2300CylHead.pdf and I'm a bit puzzled by points 26. How do you set it to TDC,
28. Do you need this special tool or can I use something else?
30. Where do I get an M6 x 60 bolt, do I really need it? 32. It says; "In order", what order is that?
40. Do I just turn the crankshaft until the top of the piston is 25mm from the top of the bore? How accurate does this have to be?
Any volunteers??
Thanks
Mike
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Tompion
Administrator
1997 2.3 Ultima estate.
Posts: 2918
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Re: Head Gasket Replacement
« Reply #1 on: Aug 9th, 2008, 12:25pm » |
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Hi Mike
Not done the job on this engine but would say:
26 The mark on the pulley (attached to crankshaft) uppermost with both valves shut (compression stroke) on cylinder 1.
28 You shouldn’t need a special tool – just something to stop the sprocket turning.
30 I don’t know what this means but probably no great problem – it’s just a 6mm dia bolt 60mm long
32 Zoom in on the picture you’ll see they’re marked – make sure they go back to the same place/same way round.
40 Move the crankshaft to and fro slightly – just to make sure you’re at TDC then go back 25mm, a ruler is good enough
Dave
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Mike_Floutier
Full Member
'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #2 on: Aug 9th, 2008, 1:48pm » |
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Thanks Dave,
I've done a bit of dismantling (took a while cos all the autogas pipes etc get in the way).
I've decided to have a go so I'm going out to get the kit now and something to hold the sprockets.
Another thing I'm not sure about is the "wrench for cylinder head bolts" mentioned on page 1. Dose anyone know what size that would be and does it have to be a long one?
Mike
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Tompion
Administrator
1997 2.3 Ultima estate.
Posts: 2918
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Re: Head Gasket Replacement
« Reply #3 on: Aug 9th, 2008, 2:07pm » |
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Can't help with size or length, but looks like a torx bit.
I'd of thought your head kit should have new bolts, so you should be able to get the size from them.
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scorpio_man
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Ford Kuga awd
Posts: 5654
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Re: Head Gasket Replacement
« Reply #4 on: Aug 9th, 2008, 3:13pm » |
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hi mik,e
remember you need a new tensioner every time you take the head/chain off (about £50 a go).
good luck
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Mike_Floutier
Full Member
'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #5 on: Aug 9th, 2008, 3:25pm » |
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Man, it gets more complicated, the kit doesn't have bolts (I'm surprised too) so I'll have to wait and see - lol.
As for the tensioner, I think I read that. That too isn't in the "kit!". Why do I need a new tensioner, the old one was ok before; does something happen to them when you remove them?
And I couldn't get anything to hold the sprockets with, what would you advise using?
Thanks again.
Mike
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Mike_Floutier
Full Member
'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #6 on: Aug 9th, 2008, 3:28pm » |
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Oh and I knew there was something else. Why do I have to remove the camshafts and the little cylinder thingies etc? Can't I just take the head off after I've removed the sprockets and chain and bolts?
Mike
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Simmo
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I'm an OAP !
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Re: Head Gasket Replacement
« Reply #7 on: Aug 9th, 2008, 3:40pm » |
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Mike, Grandadman has just done a job on his Cosworth and THIS might help.
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Now I'm an OAP
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Mike_Floutier
Full Member
'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #8 on: Aug 9th, 2008, 3:50pm » |
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Ok, I guess you have to remove the camshafts to get at the head bolts.
Another question. How do you know that the sprockets are in the same position relative to the camshafts? Do the only fit in one position or do I need to mark them?
Thanks for the link Simmo, I'll look at that now.
Mike
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Mike_Floutier
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'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #9 on: Aug 9th, 2008, 3:59pm » |
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And another thing, where can I get the "chain tensioner hydaulic plunger" and do I REALLY need it?? Is it only from Fords? And, to recap, I need to know whether I have to mark the position of the sprockets relative to the camshafts.
Thanks
Mike
Ok back out into the rain - hehe
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Mike_Floutier
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'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #10 on: Aug 9th, 2008, 10:41pm » |
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And finally, when it talks about tightening/loosening of bolts, what do references such as "21–167" mean?
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Tompion
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1997 2.3 Ultima estate.
Posts: 2918
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Re: Head Gasket Replacement
« Reply #11 on: Aug 10th, 2008, 12:58am » |
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It means your brains fried from looking at the manual too long  (it's the part number of the tool on page 1)
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Mike_Floutier
Full Member
'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #12 on: Aug 10th, 2008, 6:58am » |
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Hahaha! Thanks Dave, I can't believe I've been wondering about that so long.
Ok, I'll have the head off this morning and we'll see how flat it is, and it's not raining!!!
Mike
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Mike_Floutier
Full Member
'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #13 on: Aug 10th, 2008, 9:12am » |
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So, torx socket broke after 3rd cyl head bolt so off to Halfords; I'll get two I think.
A few other things.
1. The upper chain guide (plastic) broke getting it out; I guess I can only get that from Ford.
2. That square joint in the vacuum pipe from the brake servo snapped when I was trying to remove it. HOW should I repair that do you think?
3. Also, because of the gas conversion, I had to dismantle the throttle/cruise control assembly (springs evrywhere!) are there any instructions for assembly that you know of?
4. Finally, one of the spark plugs snapped in two as I was removing it - hehe.
Thanks for all this help, man I've never seen the inside of an engine before, it's really beautiful, I'm so glad I've been using flush and regular oil changes; it looks like new and I only changed the oil 600 miles ago so you can imagine how lovely it looks - wife thinks I'm crazy!
Mike
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Mike_Floutier
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'97 2.3 Ultima saloon lpg
Posts: 296
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Help! - Head gasket
« Reply #14 on: Aug 10th, 2008, 11:03am » |
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This may seem a silly question BUT:
How do I lift off the head (including the in & out manifolds etc)? Working by myself, can I expect to do it by hand or do I need a hoist of some description?
Also, should I remove the bonnet?
Thanks
Mike
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Tompion
Administrator
1997 2.3 Ultima estate.
Posts: 2918
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Re: Head Gasket Replacement
« Reply #15 on: Aug 10th, 2008, 11:40am » |
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Hopefully someone will be along who’s actually done the job.
I would think the guide is a ford only item.
I don’t think it’s worth the risk repairing the servo joint, see how much a new one is – not everything costs an arm & a leg.
Something about the cruise control here, but probably not enough:
http://www.fordscorpio.co.uk/ccmanl.htm
(Not sure if you meant you were leaving the manifolds on) I would have thought you need the manifolds off - I think the inlet one is too vulnerable, I’d sooner have it out of the way.
You may need to give the head a tap sideways with a mallet to break the joint, but should be able to lift it off on your own – with a bit of cursing.
Wouldn’t have thought you’d need the bonnet off.
Dave
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Mike_Floutier
Full Member
'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #16 on: Aug 10th, 2008, 11:49am » |
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Ok, I've got both manifolds ON, that's what was recommended.
The head lifts about half an inch ok all round but that's as far as it will go, can you think what's stopping it - should I try to get hold of a lift?
THanks
Mike
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Tompion
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1997 2.3 Ultima estate.
Posts: 2918
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Re: Head Gasket Replacement
« Reply #17 on: Aug 10th, 2008, 11:57am » |
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I wouldn't use a lift in case what's stopping it is vulnerable - like the manofold.
I think there's a bolt under the inlet manifold, not sure what it's attached to, check that - assume you have the petrol pipes off.
Dave
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Mike_Floutier
Full Member
'97 2.3 Ultima saloon lpg
Posts: 296
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Re: Head Gasket Replacement
« Reply #19 on: Aug 10th, 2008, 12:35pm » |
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Yes, petrol pipes, I don't remember them being mentioned, that makes sense.
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