24v Engine Overhaul

After 140,000 miles and various signs during the last few months my Senator decided to blow it's head gasket.
With steam coming out of the exhaust I decided to lay it up for a while as much needed other work was looming anyway.

 

1. Leaking heater matrix, this would leak anyway with the mileage that it's done but was possibly accelerated by a pressurised cooling system.

2. Blown top hose, the hose appeared in good condition at the point that it had split.

3. Occasional mis-fire on start up, ie 1 in 10 start ups resulted in about 30 secs of mis-fire which had worsened during the last 6 months or so to a point that it was missing on every start until the gasket blew completely..

4. Increased fuel consumption.

5. Gradual loss of power.

6. Finally lots of steam from exhaust, constant mis-fire, noisy tappets(not neccessarily connected).

I bought a cheap run-around for the time being because this project was not going to be over very quickly.
The first job was to make a double 'A' frame hoist. I managed to borrow a block and tackle.
The engine was removed complete with all ancileries and gearbox.
                           
A holding frame was made up whilst the engine was hanging on the hoist, and bolted to it using the engine mountings.

With the engine at chest height easy work was made of removing the ancilleries.
The front was de-greased and cleaned.
                                          


Water pump, cam cover, top front cover, main front cover were removed to expose the timing gear, note that the head and sump were left in position, don't forget the bolt that is hidden within the waterpump aperture. The left hand primary chain guide rail is trapped in position by the head and a pivot pin pressed into the block. Officially the head has to be removed in order to replace the guide. I removed the old with a crowbar lever, but would not reccomend refitting it this way. It is possible to remove the pin from the block (interference fit) to save taking off the head.

                                            



                                    Pictures of engine being fitted into car