Euro cruise disaster

Was hoping to get my cylinder head back today but I wasn't able to get there before they closed, so wont get it back now until next Friday as I'm away all next week. I've had the head skimmed, valves re-seated and new stem seals, and head pressure tested.

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Front end stripped ready for new water pump, new drive belts and tensioner pulleys.

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Vanos stripped ready for new seal's. I bought the repair kit and replacement rattle ring but now its stripped I've found I don't need to replace the rattle ring which is a bit of a bonus because I can't strip / split the piston, =)) The rattle ring prevents excessive to and fro movement of the gear that drives the vanos piston. The vanos seal's maintains the correct oil pressure either side of the piston while it advances and retards valve timing.

I've got the new head gasket set, cylinder head bolts, water pump, tensioners, thermostat and drive belts so when I get the head back it can all go back together again.
 
Lee said:
Make sure you get plenty of photos we love a good nosey. I'll soon be pulling sam's 2.2 apart to fit new piston rings and valve seals it's using far to much oil.
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Be interesting to see that, mine's got the same problem. Already done the valve seals, bit of a hassle doing it without taking the head off but got it done anyway, shame it didn't make much of a difference. So some day soon I'll be taking the top and bottom off and trying the rings, just got to knock down a wall to be able to get a car round the back and into the yard. Came across something a while back showing totally gummed-up oil control rings, hopefully that'll be it.
 
was not so bad so far...as damages...beside the discomfort of interrupting the holiday.
I always have the feeling that when you love the car, technical challenge it's not deadly!
Keep up the good work; it's important to do it well, because it's almost winter anyway!
Wish you a nice week end!
Dan
 
Hopefully all will be sorted soon Garry.
 
Coming along nicely mate, just in time for Spring :thumbsup: :thumbsup:
 
Grumps said:
Hopefully all will be sorted soon Garry.
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Hopefully by the end of this month. I'm going to Bahrain on 12th Nov for a weeks work and will have a couple of days off work when I get back. I've got some jobs to sort at home but want to get the car sorted too, now I've got all the bits together
 
Coming along very well Garry, you'll be on the road again in no time:thumbsup:
 
Lets hope this cures the problem Gary. Would definitely be a travesty if it did not work after all the hard work and parts
 
A brief update

Got the cylinder reconditioned and fitted it back on the block. Torqued down in sequence to 40NM as BMW instructions. Then a further 90 degrees in sequence, all good so far. One round to go.

Then had a bit of a mishap ......
Was doing the final round of torqueing, a further 90 degree sequential tightening and one of the threads gave way. Oh bo8888ks I thought to myself =)) Oh well, ones gone so I'll carry on and see if there are any other weak threads. After all, the last thing I need is to find some more once I've fixed this one. Low and behold, another three gave way.
Not to be deterred I just said to myself, "Oh bucket" and removed all the bolts and removed the head again.

I ordered a set of long helicoils, (3 x diameters) and once they arrived I carried on with the repair.

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4 holes redrilled. I inserted one of the head bolts to give me an idea of the drilling angle.

Cleaned all the swarf away with a vacuum cleaner.

Next job was to tap the 4 holes and then fit the helicoil inserts which only took half an hour.

No more photos I'm afraid, forgot to take any.

Anyway job done for today. I'll refit the cylinder head the next time I've got a spare couple of hours. Might be a couple of weeks before I can get back on it.
 
Great thread mate, keep up the good work. Can't wait to see you on back the road again. :racecar:
 
Jack Ratt said:
A brief update

Got the cylinder reconditioned and fitted it back on the block. Torqued down in sequence to 40NM as BMW instructions. Then a further 90 degrees in sequence, all good so far. One round to go.

Then had a bit of a mishap ......
Was doing the final round of torqueing, a further 90 degree sequential tightening and one of the threads gave way. Oh bo8888ks I thought to myself =)) Oh well, ones gone so I'll carry on and see if there are any other weak threads. After all, the last thing I need is to find some more once I've fixed this one. Low and behold, another three gave way.
Not to be deterred I just said to myself, "Oh bucket" and removed all the bolts and removed the head again.

I ordered a set of long helicoils, (3 x diameters) and once they arrived I carried on with the repair.

View attachment 71985

View attachment 71986

View attachment 71987

View attachment 71988

4 holes redrilled. I inserted one of the head bolts to give me an idea of the drilling angle.

Cleaned all the swarf away with a vacuum cleaner.

Next job was to tap the 4 holes and then fit the helicoil inserts which only took half an hour.

No more photos I'm afraid, forgot to take any.

Anyway job done for today. I'll refit the cylinder head the next time I've got a spare couple of hours. Might be a couple of weeks before I can get back on it.
Click to expand...
Your a brave man, this s*** would frighten the life out of me, well done
 
Jack Ratt said:
A brief update

Got the cylinder reconditioned and fitted it back on the block. Torqued down in sequence to 40NM as BMW instructions. Then a further 90 degrees in sequence, all good so far. One round to go.

Then had a bit of a mishap ......
Was doing the final round of torqueing, a further 90 degree sequential tightening and one of the threads gave way. Oh bo8888ks I thought to myself =)) Oh well, ones gone so I'll carry on and see if there are any other weak threads. After all, the last thing I need is to find some more once I've fixed this one. Low and behold, another three gave way.
Not to be deterred I just said to myself, "Oh bucket" and removed all the bolts and removed the head again.

I ordered a set of long helicoils, (3 x diameters) and once they arrived I carried on with the repair.

View attachment 71985

View attachment 71986

View attachment 71987

View attachment 71988

4 holes redrilled. I inserted one of the head bolts to give me an idea of the drilling angle.

Cleaned all the swarf away with a vacuum cleaner.

Next job was to tap the 4 holes and then fit the helicoil inserts which only took half an hour.

No more photos I'm afraid, forgot to take any.

Anyway job done for today. I'll refit the cylinder head the next time I've got a spare couple of hours. Might be a couple of weeks before I can get back on it.
Click to expand...
Impressive work :woot: Engineer by trade?
 
Thanks for the vote of confidence guys but I would reserve judgement until it's sorted =))

@Andy McDonnell I served an engineering apprenticeship and this is basic workshop stuff, but yes I'm an engineer of sorts.

@Sean d it's all relative mate, the stuff you do with a bit of sand paper and a tin of paint is alchemy.

@hard top I'll be there Mike, either in this one or I'll buy another one
 
Good going Gary, let's hope the Helicoills do the job. I hate tightening heads down especially with an alloy block. I have never had to do it on a Zed but I did on my E30. The only alloy block I have done it on was an Imp.
 
mwpe said:
Good going Gary, let's hope the Helicoills do the job. I hate tightening heads down especially with an alloy block. I have never had to do it on a Zed but I did on my E30. The only alloy block I have done it on was an Imp.
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I've never used helicoils on an engine block before so this is a first time for me. I've used then on other jobs and they've been ok.

To be honest I half expected to find a damaged thread, but I screwed all the bolts into the head before I started and they all went in pretty easily. Sods law I suppose. I'll make sure I use plenty of lube when I refit the head after this experience.

All the damaged threads were around pot 4 which is the area the most contamination was, so I suppose it was a bit of a clue. As I said, I checked each hole by screwing the head bolt in all the way, but you can't see into a 10mm dia hole, so I don't feel too bad about it.
 
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