how can I remove the inlet manifold?

[JimSuperSix]

Getting there with this head removal, but now I'm stumped as to how to actually reach the inlet manifold bolts - this is the current state of the engine bay (http://www.jameskett.dsl.pipex.com/engcur.JPG) so how on earth can I reach most of these bolts?

HOWEVER, before I remove all these complicated parts, I noticed that the rubber bottom of the pressure cap has a few small chips out of the edges - seeing as the only symptoms my Surf had were pumping out a little coolant from the reservoir after an uphill run (doesn't overheat at idle, no mayo, no steam etc...) is it possible that the presure cap could just be letting hot water into the expansion bottle too soon and therefore overflowing it? The thermostat tests just fine (opening around 80 to 90 degrees). I'd like to be sure before I finally remove the head.

As a final question, can I get hold of a manual from somewhere that actually relates to the imported 2.4TD Surf?

thanks
James

[marky]

When the head goes on the 2.4 you dont seam to get symptons that you would get on a petrol engine, mayonnaise, oil in water etc.

[JimSuperSix]

drat. Ah well - do you know how I can get at the inlet manifold bolts? Looks like all the pipework for the injectors is in the way - can I remove it all from the pump thing just under the manifold?

[da SLUG man]

sounds like you're jumping in and changing the head before you actually know for sure it's the head that's the problem?

if you can't get the manifold off in situ, could you take it off with the head removed form the block?

[JimSuperSix]

I was really hoping it was not head but I've asked here before and the general opinion seemed to be that it was either the head or headgasket. Also a local 4x4 specialist checked it over and said the headgasket was blown (or leaking) but he thought the head was still OK and uncracked.

If I could just get at these manifold bolts/nuts, the head is almost off - it's just the fuel pipes to the injectors are in the way - has anyone else here changed the head on a 2.4 turbo Surf? If so, I'd like to know how you got the inlet manifold off.

I'd not considered removing the head with the manifold still attached, but the does sound like it would be easier. The fuel pipes still have to come off though, and I'm just a little unsure of how to do that - any advice?

[stevo]

head off

Easiest way is to leave the manifold on when removing the head, undo the injection pipes from the injectors, then undo the clamps holding the pipes to the manifold, then pull the pipes out of the way, you will have to remove the glow plug electrical feed wire ( note the order the insulators come off ) also another terminal attatched to the underneath of the manifold, there is a bracket which holds the dipstick tube to the inlet manifold fixed with a 12mm bolt on the bottom row 3rd one along, remove this bolt then you can lift the head and manifold up over the dipstick tube.
Cheers Steve.

[JimSuperSix]

excellent, thank you very much for that description, it will be a big help!

thanks again
James

[Guest]

I think Stevo has the besy suggestion however you can get at all the bolts and unbolt the manifold and leave it in situ, you need a 1/4 drive socket set, 12mm socket and preferably a 1/4 drive UJ plus 2 short extensions. By removing the water pipes you can reach under and get onto the bolts. It's harder putting it back together as you need to get two of the bolts through brackets (one for a wiring support and one for the dipstick support. The rear one is the most difficult and you really need to remove the short piece of 1 inch pipe that bolts onto the egr and onto the inlet trumpet. Once this is out of the way it is easier but also unbolting the fuel filter from the bracket and pulling it out of the way also helps.

Cheers