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Bulletin 11 - 12th December 2005 - 29th January 2006

I described in Bulletin 3 how we removed the head from cylinders 1 to 3 to attend to a leaking injector sleeve. The head was sent away to Blane Engineering of Killearn to have this remedied, but they told us after a pressure check that in fact two of the three injector sleeves were not watertight. They asked us to provide new injector sleeves, but these could not be sourced either here or in Australia. However, we were fortunate that a spare cylinder head had come with the bus and this head was dropped off at Blane for testing and all three sleeves were found to be watertight. We would have preferred to use the original head, as the engine ran well, but the inability to source new sleeves left us with two options; either have new sleeves made or have the spare head prepared for use.

Blane Engineering took the spare head, skimmed the joint face, machined the valve seats, cleaned and ground the valves and changed over the inlet guides on the old head to exhaust spec on the new head. With work completed in early January we decided to get the overhauled head fitted which would allow us to finish the engine ready for installation back in the bus.

A new head gasket was fitted from our own stock of spares and the new cylinder head went on without any problem. However, as so often happens it is the apparently straightforward jobs that take all the time. The studs on the side of the head for locating the exhaust manifold and the top water manifold were found to be too short! Either this head had come from an Albion model with different manifolds (which seems unlikely) or someone had replaced the original studs with shorter studs. The latter seems more likely as so many Sydney Albions ended up with small independents or private owners who may have adopted a make-do-and-mend policy. Either way, we couldn't use these studs as there was hardly enough thread to allow the nuts to bite when the manifolds were fitted. So after much heating, coaxing and encouragement (vocal and otherwise!), the old studs were removed, new ones fitted and the manifolds replaced.

To finish off the job, the injectors were all checked in a nozzle test rig to ensure that both jets on each injector were clear and that they were opening at the correct pressure of 175 atmospheres. Only one injector was found to be incorrectly set and this was adjusted accordingly. The copper washers were annealed and the injectors refitted. All we have to do now is replace the hoses and we will have one Albion EN 242 9 litre oil engine ready for refitting.

John prepares the face of the block to accept the new head

The new gasket goes on

The overhauled head. A final wipe of the joint face.

Paul torques the heads nuts down to the required setting

Nearing completion or so we thought! The studs on the side of head for
locating the exhaust and water manifolds turn out to be about 12mm
too short and we have to wait a week to get the correct parts.

Longer studs have been fitted and the water manifold goes on.

The injectors go on to complete the rebuild of the Albion 9 litre engine.