2002 2.4 Head gasket repair journey

[Rojie]

5 minutes ago, crazymac680 said:

Day 19

1 hour. 

Cleaned up the sump and reinstalled. 

Then installed a new oil filter. 

If my new exhaust manifold comes tomorrow I might have her running. 

 

 

5 minutes ago, crazymac680 said:

Day 19

1 hour. 

Cleaned up the sump and reinstalled. 

Then installed a new oil filter. 

If my new exhaust manifold comes tomorrow I might have her running. 

 

 

Epic journey.

 

Here's wishing you every success on behalf of all Club members

 

[crazymac680]

Day 20

3 hours

I'd decided to order a new exhaust manifold as I'd damaged a bolt hole on mine. It arrived today and it was the wrong one. It seems the 2005 2.4 is a different manifold from my 2002 2.4. 

Mostly the same apart from a slightly different angle where it joins the exhaust and those two bolts are in a slightly different place. 

So I was forced to repair my own. 

I filled the hole with weld. Then drilled and tapped a new thread. Actually went quite smoothly. 

I then had to remove 3 cut off bolts from the heat shield. 2 removed and that will need to do🤣.

Installed the manifold

Filled with oil 

Filled with water. 

Installed battery. 

I'd planned on turning over with the fuel pump disconnected but I was too lazy to find the fuse. 

She started on 3 quick key turn. Hunted for about 5 seconds and then purred like a kitten. 

Let it get to temperature and fans kick in. Kept checking the water. 

Turned her off and checked all the levels half an hour later. 

Took her for a spin and she is driving like she hasn't been off the road.

I'll add up the hours and my final thoughts in a couple of days🤣

 

[BigNev]

Wooho, blooming fantastic!!

[Gamith]

Nice, well done and a great result.

[Michael Brown]

Well done for completing your mammoth project, now go and enjoy driving

[Rojie]

Yes Danial, VERY well done.

 

We are all so pleased that your mammoth journey has been completed successfully

[Catweazle]

Bravo indeed!