Disco 1 Overheating Disco

Cheers for all the advice peeps.
I am finishing work early today, about half 12, so i can get home and get this thing stripped. The local engineer who is testing the head said he can have it done by Saturday but i need to get it to him in the morning.
I will let you know later how it went, might even do pics as i go so i know how it goes back together.

Ok then,so head is now off, nothing too taxing. A few discoveries along the way.
Exhaust manifold was shot, that's the oil leaking down the side of the block sorted.
The head gasket didn't appear to be in too much of a bad condition and no carbon deposits on the push rods.
The core plug under the turbo was about to go, good scrape with a screw driver and tiny holes started to appear. So knocked that out. Put my finger inside the block and could feel a fair bit of rust sitting in the bottom. It's now apparent that this motor has spent a fair bit of time running without coolant and just water. Should I be overly worried about this in the block?.
Also the intercooler has a bit of oil in it, cleaned it put about 6 months ago. Is this signs of the turbo on it's way out?.

hoopfish said:

Ok then,so head is now off, nothing too taxing. A few discoveries along the way.
Exhaust manifold was yet, that's the oil leaking down the side of the block sorted.
The head gasket didn't appear to be in too much of a bad condition and no carbon deposits on the push rods.
The core plug under the turbo was about to go, good scrape with a screw driver and tiny holes started to appear. So knocked that out. Put my finger inside the block and could feel a fair bit of rust sitting in the bottom. It's now apparent that this motor has spent a fair bit of time running without coolant and just water. Should I be overly worried about this in the block?.
Also the intercooler has a bit of oil in it, cleaned it put about 6 months ago. Is this signs of the turbo on it's way out?.

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any pics
swap core plugs ,block wont be damaged but flush out

got loads of pics, will up load in a bit.
So the rusty block is not a problem james?

generally not, once flushed, theres 5 of those erc4996 core plugs

I cant get to the one at the back of the block without having engine out?

And how the fuck to you upload pictures on here?

Had the head pressure tested today and thank god it wasn't cracked, so had them face it.
Back on tomorrow hopefully, with new head bolts as well.

Click "upload a file" and browse to your pics folder

One of the core plugs from under the turbo. I have changed all apart from the bugger at the back of the block.

Right then, head is back on and tightened down.
Next question is, I have put the push rods and rocker bar back in, should the push rods sit in the hole tight or do they flap around a bit untill I bolt the bar down?

hoopfish said:

should the push rods sit in the hole tight or do they flap around a bit untill I bolt the bar down?

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The push rods will be loose fit until the rocker shaft is fully tightened down, you need to seat all the pushrods into the cam followers carefully before lifting the rockers on then one by one seat the top end of each pushrod into its rocker arm socket and tilt the rockers so they stay engaged with the socket until the shaft is pulled down in even movements, do not just tighten all the way down from one end move along tightening the holding down bolts in stages, keep checking to ensure that the rods are still properly engaged both ends. To set the valve clearances turn the engine over with a spanner on the crankshaft bolt, turn clockwise when looking from in front of the vehicle, use the TDC timing mark to start with cylinder #1 TDC on compression, valves both closed, set clearance to .2mm, inlet and exhaust..
Work in progression from there to the next cylinder on TDC compression, (both valves closed), adjust, etc,etc., finish off where you started re-checking that setting has not altered, (better a little loose than too tight), do not over tighten the rocker holding down bolts you risk stripping threads.

hoopfish said:

One of the core plugs from under the turbo. I have changed all apart from the bugger at the back of the block.

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and the one on the front

Any ideas as to what this fits on? Back left hand side of the head!

hoopfish said:

View attachment 91359

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It's the little black plastic pipe that sits by the heater plugs!

I think that's the top of the axle breather pipe.

Which fits on top of the axle?

or a transmission breather more likely

jamesmartin said:

or a transmission breather more likely

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Which fits????
It looks like it is in a position to fit somewhere near the back of the head. Dose not reach the injectors but can push half way down the head if that helps!