'97 ASTRA 1.7 TD smokes badly...

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 12:06 am

As per title, Isuzu engine (I think)
starts like an 80 a day smoker trying to get up in a morning...
runs ok when its started but I think its lacking a bit of power, seems to kangaroo a little in 4th at 35mph..

supposed to have had a recon head less than 200 miles ago but theres gasket seal round the head gasket edge (havent had it off) and the timing covers missing... (this was supposed to be the origional problem) doesnt look like a pro job at all...

supposed to have had another turbo out the scrappy but the bolts havent the slightest mark on them although the crimped metal pipe thing is brand new...

Timing on the head change was done with nail varnish about 5mm thick..

Ive got the origional head...

its done 81,000, bodyworks in good nick, as is suspension and underbody.

Last time I did a diesel head was years ago on a 305 peugot and I could bolt the cam wheel to the head and the big end to the block to set it up.. there doesnt appear to be the facility to do this on this engine... bit wary..

Just after some advise before I get the spanners out and 'have a bash at the head'... really dont want to spend loads getting it in the garage, or ages off the road...

Thanks in advance people

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 12:44 am

http://i3.ebayimg.com/03/i/000/eb/86/2675_1.JPG

this is the engine btw (if thats any help?)

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 12:55 pm

just been looking at it again and i have another query...
shouldnt i be either able to see the edge of the head gasket or at least a thin gap the thickness of the head gasket? Because it looks to me like there is no gasket on it at all!! I scraped a little of the gasket seal off (it looks and feels like bloody white silicon to be honest) and there is no gap whatsoever??? If this is the case I cant believe it even starts let alone runs!!

Borderglazer · Post by **Borderglazer** » Wed Aug 19, 2009 1:26 pm

Hi Chris,
Wi th regards to the gasket,normally yes there should be a gasket ( a few very rare exceptions) and sealant isnt normally used unless recommended and it certainly wouldnt be white silicone anyway and you're timing etc needs to be set up with a dial test indicator on these engines if i recall (have'nt done one for a long time).

I would suspect whoever did the job has either chucked the gasket and used a sealant of somesort or they,ve reused the old gasket and some sealant.

I would suggest pulling the head off at the very least and renewing gasket with a head skim if its warped in any way and retiming the engien afterwards.

Price wise maybe £40-£50 for a head gasket set + labour

Hope this helps a little.

Joe

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 2:03 pm

thanks mate, looking like im gonna have to have it off..

got a quote for 16 quid for a head gasket only, maybe do without / reuse the exhaust gasket? and leave the other stuff on?

Ive havent used a dti since i was at BAe as an apprentoid many years ago...
whats the procedure for timing up with a dti?

normally i just get top dead centre by eye and line up the cam wheel on a petrol but it looks like all ive got to work off is a big sliver of nail varnish on the cam wheel and head? and deisels have to be bang on dont they?

ill have another lookster for some timing marks..

Borderglazer · Post by **Borderglazer** » Wed Aug 19, 2009 3:49 pm

Hi Chris,
If i was pulling the head off id do all the gaskets but im anal like that!

, erm i cant remember the sequence for the timing on these,im sure you can find it t'interweb as im certain ive seen it and yep they have to be spot on especially the fuel pump.

Ill do a bit more digging and see if i can find the sequence.

Joe

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 4:29 pm

thanks mate appreciated..
im doing the same thing but so far have managed to come up with virually zip..

what i have managed to ascertain though is that its NOT THE ISUZU...
its a vauxhall / gm engine...

that pic got pulled off another link where someone had stated its an isuzu engine... its definately NOT..

but thats as far as ive managed to get...

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 5:02 pm

getting there... slowly...
i have torque sequence...

Stage 1 25nm/18lbf ft
Stage 2 90 degrees
Stage 3 90 degrees
Stage 4 45 degrees

Warm-up engine then

Stage 5 30 degrees
Stage 6 15 degrees

still dont know if the head gasket should be visible or how to set the cam wheel... im guessing to borrow a dti to set top dead centre?
anyone know if i need new head bolts for this engine of this year?

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 5:19 pm

im finding i need special tools to set it up, a dial test indicator, the cambelts on these are prone to slipping off due to the plastic bits on the tensioners wearing out...

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 6:49 pm

um.. err...
found the head gasket...
but theres a chunk missing out of the head.. im wondering how far back it goes..
and theres bubbles round two of the injectors..

i give up..

village idiot · Post by **village idiot** » Wed Aug 19, 2009 8:14 pm

first head i ever did (on a mk2 escort) i stupidly put monkey snot on the head gasket & some ended up on the piston but i didn't know that at the time
within 100 miles the snot had melted the piston to such an extent i could put a feeler gauge down between the piston & the rings

village idiot · Post by **village idiot** » Wed Aug 19, 2009 8:16 pm

here might help also, worth bookmarking
http://www.ilexa.co.uk/forum/

spunky · Post by **spunky** » Wed Aug 19, 2009 8:19 pm

chuck it on ebay mate and keep schtum..............someone'll ave it

mikew1972 · Post by **mikew1972** » Wed Aug 19, 2009 8:54 pm

chrisw w wrote:getting there... slowly...
i have torque sequence...

Stage 1 25nm/18lbf ft
Stage 2 90 degrees
Stage 3 90 degrees
Stage 4 45 degrees

Warm-up engine then

Stage 5 30 degrees
Stage 6 15 degrees

still dont know if the head gasket should be visible or how to set the cam wheel... im guessing to borrow a dti to set top dead centre?

anyone know if i need new head bolts for this engine of this year?

Yes,
Where the 'torque' settings are given like this (in 90 deg then another 30 deg etc. rather than all in torque settings) the head bolts stretch during tightening. This stretch is permanent therefore you always need to replace the head bolts.
It may be possible to get away without replacing them but not if you follow the recommended method of tightening them.
If you are doing the rest of the job properly them do it properly and replace them.

Deleted-user-3 · Post by **Deleted-user-3** » Wed Aug 19, 2009 10:20 pm

village idiot wrote:first head i ever did (on a mk2 escort) i stupidly put monkey snot on the head gasket & some ended up on the piston but i didn't know that at the time
within 100 miles the snot had melted the piston to such an extent i could put a feeler gauge down between the piston & the rings

marvelous... possible cause then?
nice one.. didnt know gasket seal did that to pistons... well worth remembering..