Setting Valves on 2.5Di

[PistonMeetValves]

Just wondering if anyone has a step-by-step guide for doing the valves, as I have the new rocker cover gasket for my Banana engine!

Know the settings thread, just new to diesels and this engine - so needing a hand as I only have this weekend to do it and the pickup is currently my daily


Thanks in advance guys, you're awesome

[Kedishen]

You will need a socket set and the rocker cover bolts may... be star keys can't remember. Also feeler guages... A torque wrench would be useful, but not essential.



Looking at this picture, you will just have remove the right banana and you can get at the rocker cover. You may also need to disconnect the EGR throttle rod, EGR pipe and support bracket. (in the picture, EGR ROD has alreayd been removed, normally goes from top of fuel pump across top of engine to EGR - EGR is that UFO shaped thing)

(to remove the other side it looks like the injector pipes get in the way..., can't see why it needs to come off anyway)

There is a metal gasket between the bananas so be careful when you split them. There is also a gasket between the manifold and cylinder head. If you are careful you should be able to reuse it. Some gasket paper or some RTV silicone may be good forward thinking.

With the rockers exposed, turn the engine on the crank pulley and follow these settings:

http://www.fordtransit.org/forum/viewtopic.php?t=9565

Heres a picture of where crank pulley is, its the one with socket on.

http://www.ok.eclipse.co.uk/pictures/tr ... AG0336.jpg

When you put the cover back on, follow this diagram for tightening the bolts.
Torque settings are: 6-8 NM or 4-6 lbf ft (hand tight)



When putting the bana inlet manafold back:
Torque settings are: 20-25 NM or 14-18 lbf ft (till it bites, then a TINY bit)

[PistonMeetValves]

That is ideal man, can't thank you enough! I've just finished doing all of the disassembly by myself, then came in and thought, I hope theres a way to turn it over/ a reply to the thread! I already assumed behind the plastic cover on crank pulley would be a crank nut anyhows, so i'll try that.

Looking at my rockers, it doesn't look like there is a locking nut...! Just bolty type things, which thread down to the push rod.. Hrrm, will have to see how I get on!

New oil filter (drained it anyways, might as well service it while its parked up!) and rocker gasket ready anyways! My old one looked a little bent, but I think I caught it on the back rocker taking it off. Just made the mating faces as clean as possible between rocker cover gasket and head face as well. I had a bit on a thread how I accidentally bought ZX-1 as well, so i'll chuck that in with the new oil. Was gonna use Castrol GTX 10W40 semi-synth, as that's all I have atm, but will change to lighter oil before winter just to be nice!

Will update with progress!


EDIT: Meant to ask, when the guide lists the valves as '1' and '6' etc, how do you tell which is which?

[Kedishen]

Mix ZX-1 at 15%-20% if its the first go. Should also consider putting some in your gearbox and rear axle + your lawn mower, wheel bearings... anything that produces heat and is metal.

That castrol oil is expensive stuff. Leave it in!

For winter, make sure all the connections are good at batteries, starter motor and grounds from starter motor and to behind the drivers headlight.

[Kedishen]

post a pic of your rockers.

[Jim Archer]

Valve No1 at front (ex) valve No8 at rear (in) as per diagram I thought was in the valve timing/setting thread(?)

From front it's ex - in -ex -in etc.

Jim

[All4n]

Nice guide above there set them on mine the other day and it started up like a dream compared to the bag of smokey spluttering spanners it was few days previously!

Be careful when tightening rocker cover bolts up tho if you don't have a torque wrench as they're very each to shear off if not careful!

[MinorMatt]

Rockers are "stiff bolts" - perfectly normal.

Valve 1 is radiator end, valve 8 is bulkhead end

[williejbell]

would the settings on the valves be the same on my 2.5Di which is not the bananna jobby. I think mine need doing cos its quite tappity.

[AndyG]

The settings are the same across the range

[williejbell]

Thanks for that AndyG I'll get mine done at the first available opportunity. Fitting power steering to the old beastly sweetheart on tues or wednesday might just do it then. Thanks again. williej

[AndyG]

Re tap the threads in the engine block (3 from memory) as the build up of rust will make it very difficult trying to get the bolts in for the pump bracket

[PistonMeetValves]

Wow

Thanks for all the replies, as I was still uncertain and was needing the pickup for Monday, I just cleaned up the rocker surface really good, noted that the inlet bananers would need cleaned (bout 5mm death dust in em ), so I left the valve clearances. Until next time, of course!


Engine fired up really well on the Castrol GTX 10W40, and purred like a kitten once the ZX-1 took effect (although it may be placebo! )

Driving really well, no leaks.

Will do valves once the missuses car gets back so I don't have to flog the poor pickup as a daily


Your help and support has been bloody invaluable!

[tibsy]

if/when you do the clearances, make sure you use a tight fitting socket or ring spanner on the adjuster.an open ended spanner can shear the adjuster head off!
how do i know that!

[vanfox]

Do tell....What's ZX-1.