Bongo Fury

Driver+Passengers wrote:Rocker cover gasket finally arrived today, after ordering on 14th. One question: the new gasket is significantly 'taller' than the old one, and means that once I've tightened all the cover bolts to where I'm happy, the cover and head are not fully mated, as in the first photo below. Is this ok? Feels ok, but I don't want to over-do the bolts, or damage the gasket.



Made two EGR blanking plates from thin aluminium plate I had in the garage (2mm for the inlet manifold, 3mm for the exhaust pipe) and applied instant gasket and threadlock when fitting them both. One of the connections on the EGR valve is threaded, the other has studs - that gives you a pair of nuts and a pair of bolts for the plate that goes on the pipe coming from the exhaust. For the blanking plate to go on the intake manifold, I had to cut down the bolts to account for the loss of thickness having left the EGR pipe off. I wasn't sure about making my own but now I see them on, it's a piece of cake. Went a little heavy on the instant gasket, though.



Removed the elbow and large rubber hose that goes down to the metal pipe coming from the intercooler. Note: there's a 12mm bolt holding the metal vacuum pipe to the elbow. Cleaned out the inlet manifold, elbow and hose with boiling water and washing powder twice, scrubbing with a toothbrush on the end of a stick. Rinsed and dried with a hairdryer. Lost one of the hose clips for half an hour, and then called it a night.



Put another half litre of ATF in, to take me to 5 in total. I'll probably add another half to whole litre before running and warming it all and then stopping to check the level.

teenmal wrote:It looks like there is a Step on the rocker cover/head(1st Pic)or is it just the camera angle?

Driver+Passengers wrote: Put another half litre of ATF in, to take me to 5 in total. I'll probably add another half to whole litre before running and warming it all and then stopping to check the level.

Driver+Passengers wrote:

teenmal wrote:It looks like there is a Step on the rocker cover/head(1st Pic)or is it just the camera angle?

No, it's a vertical gap. Which is going to get larger when I remove, clean and replace the rocker cover in the next hour or two. I'll post a pic later. The torque setting is about 8Nm, which is nothing, so the gasket is hardly going to compress at all.

Assuming I haven't already damaged the one I've got...