Cylinder head replacement

Hi all,
I purchased a replacement cylinder head assembly a little while ago, either every intention to get in and get it swapped out, however could just never find the time. Now the Mrs is putting the wind up me to get it done before Bub comes in about 8 weeks. I had originally planned to get my mechanic mate to give me a hand, but now with the sudden rush he doesn’t have a spare weekend within the time frame so my question is; how difficult is it to do the job unassisted? Is there somewhere I can get instructions or something?
Cheers!

there is the service manual you can download and its all in that, tho a bit spread out.
i assume zd30 engine. its a sizeable job but possible on your own.
whats pita is you basically have to strip everything off the engine. don;t forget to lock the scissor gear ie injection pump gear.
but big problem is getting valves shimmed. most likely you will need to take it to someone to do that for you.

Yeah zd30, pretty sure I’ve got a service manual in the shed somewhere so I might have to have a look for that!
I’d expected it’d be a big job, but might’ve gotten a bit hopeful after being told with my mates assistance we would get it done in about 6 hours! I’m not overly mechanically minded but love to get in and have a crack. But thanks for the advice! I’ll keep the injection pump gear locking in mind so as not to forget and will sus out someone to do the valve shimming!

i don't think even a mechanic could do it in 6 hours. the engine really does get stripped down. for home, i would allow one day to pull it apart, one day to put it back together and one day spare just in case.

HumphreyBHuman said:

Hi all,
I purchased a replacement cylinder head assembly a little while ago, either every intention to get in and get it swapped out, however could just never find the time. Now the Mrs is putting the wind up me to get it done before Bub comes in about 8 weeks. I had originally planned to get my mechanic mate to give me a hand, but now with the sudden rush he doesn’t have a spare weekend within the time frame so my question is; how difficult is it to do the job unassisted? Is there somewhere I can get instructions o

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HumphreyBHuman said:

Hi all,
I purchased a replacement cylinder head assembly a little while ago, either every intention to get in and get it swapped out, however could just never find the time. Now the Mrs is putting the wind up me to get it done before Bub comes in about 8 weeks. I had originally planned to get my mechanic mate to give me a hand, but now with the sudden rush he doesn’t have a spare weekend within the time frame so my question is; how difficult is it to do the job unassisted? Is there somewhere I can get instructions or something?
Cheers!

Click to expand...

Take your time, put new head bolts with it, mark the injectors so you put them back in the same pots.try keep all the nuts bolts in marked bags they're is a lot of them, clean the manifolds inside and out.depends on your attitude and experiance take a week with the engine in. Getting it right.

Got new head bolts with head assembly Even came with an order to tighten them in! Bagging and tagging is standard procedure for me so will definitely be done.
Is there a best way to clean manifold?
Have decided I will just do it at home once Bub comes! That way I can just take my time!

Cheers

HumphreyBHuman said:

Got new head bolts with head assembly Even came with an order to tighten them in! Bagging and tagging is standard procedure for me so will definitely be done.
Is there a best way to clean manifold?
Have decided I will just do it at home once Bub comes! That way I can just take my time!

Cheers

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Degreaser ,scraper long screw driver, gernie.good luck.

HumphreyBHuman said:

Is there a best way to clean manifold?

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I'm about to do mine so let me know how you go.

I have heard a good spray then soak with oven cleaner works well.

Chapster said:

I'm about to do mine so let me know how you go.

I have heard a good spray then soak with oven cleaner works well.

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Can vouch for this, did the same on my TDI engine when I ripped the inlet manifold off. It was caked with oily soot.

Yeah I just did mine on the weekend. Oven cleaner did most of the heavy lifting then degreaser for the balance. Came up really well.

tweak'e said:

there is the service manual you can download and its all in that, tho a bit spread out.
i assume zd30 engine. its a sizeable job but possible on your own.
whats pita is you basically have to strip everything off the engine. don;t forget to lock the scissor gear ie injection pump gear.
but big problem is getting valves shimmed. most likely you will need to take it to someone to do that for you.

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Hi @tweak'e. I may need to replace my head and I'm looking at buying off the shelf if mine is cracked. Do you need to get the valves shimmed for off-the-shelf?

jonot said:

Hi @tweak'e. I may need to replace my head and I'm looking at buying off the shelf if mine is cracked. Do you need to get the valves shimmed for off-the-shelf?

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yes.
i think we actually send the old head to the supplier and they did it. or local mechanic can do it for you. need to have all the cams etc bolt in to the head.