Bongo Fury

Hello Everyone,
I have just started removing the cylinder head due to head gasket/head problem.
I am taking it quite slowly for the sake of my sanity.
I have all the relevant factsheets.

Can someone give me some tips on removing the exhaust manifold?
Do I need to remove the Turbo to get to the lower mounting bolts, or can it be left in situ? This is mentioned in the fact sheet, but I can't quite decide what is meant.

Any advise on this, or any other part of the process would be gratefully apreciated.
Thanks
Adam

Don't think the turbo can be left in place if you want the head tested, but some more knowledgeable person will doubtless be along soon

Can't help personally, but Maxheadroom is currently removing his in order to put a new one on. Simon Jones is another who's DIYed this job and may be able to advise (worth reading his advice on ensuring the block is flatted off before fitting new gasket / head as this is key to success I believe)

Sorry to hear of your troubles. I too had head gasket failure & had the head tested & skimmed, but when I reassembled it water was still being blown out the expansion tank. After speaking to a well-known Bongo garage, they gave me two invaluable tips:

Deck the block. This is where you use very fine abrasive on a granite slab to remove any high spots from the top of the cast iron block. There is no point in fitting a perfectly flat new/skimmed head to a block that is uneven.

Use Wellseal gasket sealant. Although sealant on gaskets is not generally the 'done thing' these days, it gives the best chance of a pressure-tight seal.

I've mentioned both these points on a few occasions, but its worth bearing them in mind as they really can make the difference between a quick fix & a long term solution. So far 10,000 miles later & it's still going strong (touch wood )

With regard to exhaust manifold, I was unable to undo one of the nuts that held the turbo to the manifold, so I took it off in one big lump. Getting to some of the nuts at the bottom of the manifold is a bit tricky. I seem to recall they were 13mm nuts & I wish I'd had one of those ratchet spanners with the swivel head as it would have made it much easier. Overall, if you've got the time, patience, tools & skills then its definitely a DIY job. While you've got it in bits, change the water pump, thermostat, cambelt & tensioner. You will also need new head bolts as they are of the stretch variety & should not really be removed. All the bits are available from the club shop at competitive prices, although I did buy the water pump elsewhere to save a few pounds.

Good luck - lots of folk here can provide you with technical (& moral) support.

Left my turbo attached but as Simon says fiddly to get to all the bolts on the manifold. Head bolts were very tight had to us a tommy bars about 800mm in total length on my ratchet to get them to crack.

Good luck and keep us posted, I haven't played with mine so far this weekend as I haven't finished decorating the nursery yet

Thanks for all your advise, I will keep you posted.

Just one more question though, when removing the Camshaft Pulley, is there a way to lock the pulley/shaft?

Thanks
Adam

maxheadroom wrote:I haven't finished decorating the nursery yet

Hmmm, does the signify anything significant? Or has young Ruby been exercising her artistic skills?

ADAMD wrote:Thanks for all your advise, I will keep you posted.

Just one more question though, when removing the Camshaft Pulley, is there a way to lock the pulley/shaft?

Thanks
Adam

Adam,
theres a nut shape cast on the shaft for a spanner don't know what size as I haven't done mine yet but it is less than 28mm

I have finally made a bit of progress with this job.
I have separated Turbo from Manifold
Removed injector pipes, glow plugs , lower inlet manifold fixing etc etc.


I have a few queries before I proceed at the weekend.

1) Does the exhaust manifold need to be removed – can remain attatched to the head, and then remove when head is off vehicle?
2) Can the Air inlet manifold thing be removed in one part, ie complete with elbow, ERG pipe etc?
3) Do the injectors need to removed in order to have the head pressure checked? If so how do you ensure they do not come apart as they are removed?
4) Why does the Crankshaft pulley have to be removed, does it stop the camshaft from being removed?
5) When is the best time to undo the pulley, with belt still attatched? I guess you need to be very carefull not to turn the pulley while applying the huge force needed to undo it.

I am very grateful to everyone for their help.

Thanks
Adam

1.no it doesnt,in general a head is stripped as much as poss just to make task of getting it out as easy as poss,can only say i've always stripped manifold off still attatched to the turbo.
2.Yes
3.not sure about pressure testing, pulled set of injectors earlier this week, use a deep socket and shouldnt have any problems
4.Yes
5.only have to worry about turning cam independantly from crank if the head is still bolted in place
Julian