Evening all,

 

where did we leave off oh yes....the liners... (my previous blog is working, but due to the unfortunate issues on RMweb a lot of my photos have been lost on my previous blogs before that....hopefully over time i can upload the photos again).

 

After you install the liners....its best to get some confidence they have sealed...this typically involves filling the block up and leaving it for a period of time....hoping none of it escapes into the sump.....which is of cause the reason we are doing this heavy repairs...

 

 

Pistons 6 and 5 fully cleaned and ready to be installed into the engine.

 

 

the components of pistons 5 and 6 being transported to the lifting gantry ready to be installed in the loco, you can see the end caps and the end cap bolts....as well as the bearings. The end caps and bolts are unique to each piston and are together for life. You can also see the lifting eye in the top of the crown which enables the whole piston to be lifted into the air.

 

 

piston no6 mid-flight waiting to be dragged over to the centre of the loco.

 

 

Piston no6 sat on blocks having the rings thoroughly oiled by myself you can see just below it the ring compressor which compresses the rings into the bore as the piston is lowered, this is the last piston to go into the loco, absolute cleanliness is essential at this point to avoid debris scoring the bores.

 

 

After the pistons come the heads...this is no6 head with the air inlet facing you, to give you an idea of the amount of air the loco gulps in, you could easily get your fist into the opening.

 

 

Head 1 being installed with some "touch up in progress" the red rubbers are the transition seals which transfer water too and from the head from the block

 

 

 

Two views of heads 1 and 2 you can clearly see the push rods for the rocker gear and a fully populated fuel gallery, in the foreground right you can see the locomotives engine governor.

 

 

 

repeat....until all 6 heads have been installed in the bottom photo you are now looking at the exhaust outlet for each head, at the base of the heads you can see the transition cups and rubbers, which transfer cooling water to and from the heads.

 

 

after you put the heads on....they have to be torqued down...to 850NM This is where our resident strong man comes in (fireman sam) using a torque multiplier ( a reduction gearbox ratchet effectively) he can achieve the required torque for each head following a specific order on the nuts to avoid distorting the soft iron ring which seals the head to the liner.

 

 

After this is complete you can now install rocker gear which is used to operate the exhause and inlet valves, the pipework is to the bottom right and top right is the oil supply to the rocker gear and fuel leak off, to the right of the picture is the high-pressure fuel pipe.

 

Another view of the rocker gear, waiting for the tappets to be set to the correct clearances.

 

 

Two views of the completed fuel gallery, the engine is now nearing completion.

 

Anyone know the correct reason why 26s have opening windows ?? 

 

 

Bodywork continues with several views of progress so far

 

The engine is now complete and has had antifreeze in it for now 3 weeks, this is where we come full circle

 

 

we had to do this repair...after we found leaking cylinder liners after an oil change....we now come full circle and its time to put the oil back in, as before....2 barrells of engine oil. now 15w 40 instead of SAE 30.

 

 

 

After you put the oil in....you run the triple pump, this is to make sure...oil is getting to everywhere it should be before you start the engine....this is your last chance to find any blocked oilways...as can be seen, a very healthy flow of the (now) black stuff (its picked up dirt and soot from the crankshaft oil ways) The next step is to "motor" the engine...this is where you take the decompression plugs out and isolate all fuel pumps and attempt to "start" the engine...the engine will crank over and you listen for any noises demanding mechanical sympathy....if all is good you go to the next step!

 

26043 starts for the first time on 3 years after a major engine overhaul - YouTube (fist in the air from me)

 

 

A view of the rockers in action