Clattery when cold
Join Date: Feb 2012
Location: United Kingdom
County: Greater London
I have the turbo in bits too, currently all the exhaust side bits are having an overnight bath in Mr Muscle. I've found no shrapnel at all, but a small 3mm pea of what I thought was metal fell out from behind the variable vanes. Perhaps that was what was causing them to stick halfway. However it turned out to be just a lump of carbon, not metal. Turbo seems utterly unscathed here and very clean and unworn. Nothing loose in the cat. Another large money pit dodged.
It'll be good to give the turbo oil feed pipe a good flush through with brake cleaner. As I mentioned, Ned said to discard the gauze filter at the block banjo fitting as it clogs up and restricts oil feed to the turbo, and that kills the turbo.
Cleaning the block surface. Well, it's an iron block so a steel scraper or Stanley blade is usable if you're careful. Don't try to get it stain free, just smooth/flat. Not pushing rubbish into the holes is far preferable to trying to get it out. Especially don't push crap into oil passages. You can plug the holes with twists of clean cloth provided they are big enough to not get pushed right in and disappear.
As mentioned earlier head bolt holes have to be cleared of oil, else you get a hydraulic lock. In the past I've used coat hanger wire bent back on itself an inch at the bottom with a strip of cloth pegged through the bent-over bit then wound round the wire to make a sort of giant pipe cleaner that you insert and twist. Old cotton shirt is good as it's thin and doesn't shed fibres. Tedious and uses quite a lot of strips if there's much oil, but works.
If you want to drain the remaining coolant you can unfasten the bottom hose. But if any debris does fall into coolant holes does it's easier to use a twist of cloth to soak up coolant+crap, where draining it right down makes that impossible. As long as it's below the gasket level a few mm I'd leave it as it is. Mine is the same, BTW, and I'm not draining it.
Another Ned tip: free off the lifters before putting them back, as they gum up. He said they put them in a vice, gently, to get them moving. I'll probably give mine a bit of a bath in carb cleaner, pump them a bit, let them dry off then pump them in clean oil. Oil their wells before they go back in, and both ends of the rockers.
I'm going to put the turbo/manifold back, and then get stuck. Before I can put the head back I need to figure out how to get the huge HP pump bracket off the back of the block so I can (hopefully) get to the alternator which is still the prime suspect for my rattle, despite the one-way pulley seeming to function correctly.