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have I worked on such a nightmare vehicle as my Surf. I have spent all day stripping my engine, and seemed to have stood still.
Most of the work is removing all these little hoses from every sensor known to man. Then you have all the electrical connectors that on some you push at the front and others you push in from the back, but all are facing the wrong way so you can't see where to push.
Then there is the exhaust and intake manifolds. The turbo/exhaust flange has three nuts holding it on. The two outer ones are easy to undo. But the third next to the head, what a fuc*ing bas*ard. I had to remove the metal heater pipe from the top of the thermostat so that I could push it (the slight movement undoing it gives you) out the way just enough to get a long socket onto it. I'm using an 18" power bar to crack the nuts.
The intake manifold is no better. This has all this BACS (some altitude compensation system thingy) system fitted to the bulkhead side of it with all these sensor type things, little rubber hoses and electrical connectors attached. I've marked the hoses, but by the time I have to refit, god only knows where they are all going to go. Then there is the injector pipes running over the intake manifold. What a $$$$ design this is. Oh and don't forget the aircon pump that has to be removed and it's bracket after.
I have still got to remove the injector pipes, injectors, camshaft pulley, timing belt and tensioner, head, manifolds etc,etc.
If you want my advice, if yours goes, book yours in with TonyN and let him do all the work. Believe me, it's worth paying someone to do this job...
Oh, and just to add. I would have had my Defender stripped and rebuilt in the time it took me to get that poxy exhaust nut off.
Most of the work is removing all these little hoses from every sensor known to man. Then you have all the electrical connectors that on some you push at the front and others you push in from the back, but all are facing the wrong way so you can't see where to push.
Then there is the exhaust and intake manifolds. The turbo/exhaust flange has three nuts holding it on. The two outer ones are easy to undo. But the third next to the head, what a fuc*ing bas*ard. I had to remove the metal heater pipe from the top of the thermostat so that I could push it (the slight movement undoing it gives you) out the way just enough to get a long socket onto it. I'm using an 18" power bar to crack the nuts.
The intake manifold is no better. This has all this BACS (some altitude compensation system thingy) system fitted to the bulkhead side of it with all these sensor type things, little rubber hoses and electrical connectors attached. I've marked the hoses, but by the time I have to refit, god only knows where they are all going to go. Then there is the injector pipes running over the intake manifold. What a $$$$ design this is. Oh and don't forget the aircon pump that has to be removed and it's bracket after.
I have still got to remove the injector pipes, injectors, camshaft pulley, timing belt and tensioner, head, manifolds etc,etc.
If you want my advice, if yours goes, book yours in with TonyN and let him do all the work. Believe me, it's worth paying someone to do this job...
Oh, and just to add. I would have had my Defender stripped and rebuilt in the time it took me to get that poxy exhaust nut off.
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