First service, and other jobs (DIY)

[Driver+Passengers]

OK. I saw the lines connected to the rad. I'm assuming I'll find flexi hoses attached to the box and disconnect from there? I suspect the oil will have drained back to the box already - I've got the front wheels up.

I'll take a look, though. Cheers for that. If you were gunged up, what did your fluid look like?

[dave_aber]

Yup, there are 2 robber hoses connected to the box on the offside, just next to the dipstick.

My fluid looked OK actually, pretty clean, red, no smell of burnt toast. Maybe it was cooling OK - who knows?

Also check the breather pipe for the box. Mine had become detached, and was hanging down underneath. It's got a 180° bend on the end, and it's open at the end, so quite obviously a breather. Should be attached to the body close to the dipstick support on the box. Mine's now tywrapped to the dipstick tube.

Cheers
Dave

[Driver+Passengers]

Mine had become detached, and was hanging down underneath.

Snap!

[Driver+Passengers]

Dave's thread on AT breather and cooler: viewtopic.php?f=3&t=48915

[dave_aber]

Wow, 5 months ago already!

[Driver+Passengers]

I easily got 7 litres out (cold). 4l straight into the pela, 1.5l from the pan, 1l more from the pan after letting it drip for 2 days and another 0.5 when I removed the strainer.

I've reattached the pan, but I'm going to remove it again after I've got some gasket seal and thread lock.

I've only got 4.55l on hand and another 4.55l on order, so will have to wait until next week to finish this.

Tonight, I'll get in about the rocker cover.

[Driver+Passengers]

Sorry I don't have Photoshop and GIMP's not working so I'll just describe stuff on the photos...


To the right of the rightmost top intake manifold stud is a sensor, to the right of it is a bolt that I found to be loose. Any ideas?

The second rightmost bottom intake manifold bolt secures a small bracket to which a perished vacuum hose was found dangling.


To the rear of the two valves on the right is a double-tee connector. The right hand side of this was unconnected. I'm guessing the previous dangling hose goes here.

The lower left hand valve had two dangling hoses. One on top, one on the left side. Two connections hose stubs were found with nothing attached - one on the EGR valve and a plastic one on the air hose that runs from filter to turbo, which is still intact. Bear in mind that I'm blanking the EGR (and may remove it since it's off anyway).

I haven't scoured the forum/diagrams yet, so if anyone knows the appropriate plumbing layout or posts a link before I do...

The intake manifold wasn't that bad...

Very oily and some gunky buildup but didn't look restricted in any way. I'll clean it out, and the elbow and perhaps the hose feeding it all (stuff will have run down the way, I'm sure). Can I clean the air intakes on the head in anyway? I wouldn't want spirit/fuel to run down the intakes into the chamber, would I? Wipe them out with a damp but not soaking rag, or just leave them be?

[Driver+Passengers]

Re: vacuum tubes...
http://lushprojects.com/bongopartsmk2/c ... 1of02.html
This confirms that the open end of my double tee should be connected to the metal pipe supported by the bracket secured under the inlet manifold bolt.

1300/20-300 is the EGR valve. 1312/13-341 is the "air funnel", though I appear to be down a check valve.

So the top connector on the front left valve goes to the EGR valve, and the one on the end of the front left valve goes to the EGR.

Can anyone say anything about the check valve in the tube that goes to the air funnel nipple? Again, I'm removing EGR so it doesn't really matter.

So I'm guessing that I've had no fast idle or EGR operation if the feed from the vacuum pump to the double-tee has been disconnected all this time. Presumably I leave double-tee disconnected, start engine and switch on AC - revs should go down - connect tube and revs go up. I'll try this out when it's all back together.

[Driver+Passengers]

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.

[Driver+Passengers]

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?

Apparently not - did 10 miles last night, and another 10 this morning. I'm somewhat spattered over the inlet manifold, the tubes above it, and that general area. I've wiped it all down, tightened the bolts down (starting to see the gasket squeezing through the remaining gap - still not quite flush, and the rubber's not poking out). Wiped down the back of the timing belt cover. Will see what happens next time I take it out. Hopefully nothing.

Finding it difficult to read those dipsticks. I think I'm bang on with the ATF I think. Oil is reading high but I've only put in 6l (after filter change), not 6.7l.

Exhaust blow needs done ASAP - the front pipe is cracked about 1/2 way round.

Still haven't worked out what that loose bolt is at the front/driverside of the cylinder head, so it's in the cab cubby hole at the moment.

On running (stationary), I'm hearing what sounds like an air rush. Can't quite locate it (probably easier with the van lifted at the garage to minimise the reflections). It's somewhere near-ish the front of the engine. Perhaps just coolant flow? I really can't tell. I think there's also a slight whoosh/rush after I switch it off, lasts for 20-30 seconds. Again - don't know. I'm listening harder than I have before due to the work that I've been doing, so perhaps it's nothing new. Good to understand though.

Anyway, on the road for now.

[Simon Jones]

I'm somewhat spattered over the inlet manifold

Always wise to remove yourself from the engine before driving long distances .

I don't have the torque settings for the rocker cover to hand, but you need to be careful not to over tighten it otherwise it may distort the gasket. Personally, I would remove it, give it a good clean & add a smear of gasket compound on the mating surfaces before re-assembly. Did you get new rubber seals for the mounting bolts? They will harden over time & may not perform so well once they have been disturbed.

[Driver+Passengers]

I'm somewhat spattered over the inlet manifold

Always wise to remove yourself from the engine before driving long distances .

I don't have the torque settings for the rocker cover to hand, but you need to be careful not to over tighten it otherwise it may distort the gasket. Personally, I would remove it, give it a good clean & add a smear of gasket compound on the mating surfaces before re-assembly. Did you get new rubber seals for the mounting bolts? They will harden over time & may not perform so well once they have been disturbed.

Yes, I have new mounting bolt seals. I was thinking about removing it to clean the gasket. It's a bit of faff - shouldn't be much more than an hour, though.

Torque settings will be in the service manual (I have it) - my biggest problem is the (new) torque wrench appears to be 'stuck'. Bought it in March, may no longer have receipt. I know that's no excuse to be 'cowboy' about things...

Edit: I've just worked out how my torque wrench works. There's no way that 8Nm would seal that! I will loosen them though, clean the surfaces, use a little instant gasket and try again. I think I have tightened the bolts beyond specification, but certainly not beyond reasonable for the materials involved. Perhaps the oil has come from somewhere else... can't think where.

In the meantime, here's the crack in the exhaust...

[rhino-wayne]

Hi Driver+Passengers,

just a quick thank you for doing this thread & all the photos....gives me a bit more confidence to keep my bongo healthy with some DIY

[Driver+Passengers]

Hi Driver+Passengers,

just a quick thank you for doing this thread & all the photos....gives me a bit more confidence to keep my bongo healthy with some DIY

I'm really pleased - I hoped it would do just that for someone.

Just bear in mind - six months ago, I knew nothing about cars! I expect to learn a whole lot more when it all goes wrong sometime soon...

I just figure that by getting my hand in, the van is going to see more work than I'd ever voluntarily pay a garage to do. Like "would you mind taking a look at the intercooler, just in case it's a bit dirty...?"

Matt.

[Driver+Passengers]

viewtopic.php?f=3&t=29958

definitely going to remove the rocker cover gasket again, inspect it for damage, clean it off, smear sealant and replace with torque to spec.

Then look for more splatter originating from elsewhere, perhaps...