2003 Freelander KV6 2.5 blown head gasket repair

[dgHUN]

I had to fabricate exhaust manifold gaskets

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Cleaned the head

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Every bolt was rusty and a challenge to take apart

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And finally the rear head is back on

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Next step will be to torque the head bolts.
I´m reusing the bolts, did not want to spend $150 on new ones.
25Nm steps are done, only the 180 degree turns are waiting for me.
Hopefully it will work out.

[dgHUN]

Both heads are back and torqued down.
I did the 25Nm steps and 90 degree in one round and another 90 degree in the second.
I felt it went to easily and I did another 45 degree on all the bolts. I hope it will hold down the head for a while.

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Homemade J-something tool to lock the tensioner, basically a nail

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Transferring marks from old to new timing belt

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Tool to turn camshafts, homemade, aluminum plate with two bolts




Crankshaft and front head are on mark and locked.



Rear head on marks



Last step, water pump hooked up



Effort = 2 hours to figure out steps, tools.

[dgHUN]

I could turn the crankshaft around, looks like timing isn't messed up.

I'm fighting now with the front exhaust manifold. Somehow the engine moved up and down, back and forth, I just couldn't put on the manifold to the bolts.

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Today's progress...

While putting back the oil pan, I dropped the screw that hid in a black hole on the engine.

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The engine is so much off, I couldn't put it back on the mount. I will need a cherry picker here.

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Cherry Picker and bolted up exhaust manifold.

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I had one exhaust bolt fell down and hid on top of the oil sump.



Found it when I didn't need it anymore.