Inlet manifold

Mrsuperheterodyne · 2021-01-12 18:38:18

Hello, I am hoping that one of you experts may be able to help me here. (pardon the pun)

I am going to change my glow plugs because my van Dispatch DW8 1.9 is a pain to start when it's cold.

I have removed the EGR and undone all the bolts and fittings to the inlet manifold and it is now loose and ready to come out.

My problem is that no matter which way I tilt it, there doesn't seem to be enough room there for it to come out.
I would like to remove it fully to get proper access to the plugs and injectors.

Anybody have any experience or advice?

Me and my now bloody knuckles will forever be in your debt.

smile smile

kenbw2 · 2021-01-12 18:48:05

I got mine out eventually. Can't remember if I had to take the coolant header tank out, but I just wiggled it and fought it till it came out.

Looking at that picture, looks like I did take the header tank out

Last edited by kenbw2 (2021-01-12 18:48:52)

Mrsuperheterodyne · 2021-01-12 19:08:25

Thanks Kenbw2,

I was starting to get a horrible feeling that the engine may need to be dropped or something daft.

I haven't taken the coolant bottle out just shoved it to one side, so I'll do that in the morning and see how we get on.

Big relief to know that it is possible without too much dismantling.

It got dark and my frustration levels reached the point where it's safer to stop and ask than continue.

Glad I found this forum.

Thanks for taking the time to help me.

Casper · 2021-01-12 19:45:31

You know there is 4 bolts aye? And yes you can tuck expansion tank aside. I had a stuck bolt in mine so ordered another on ebay and smashed the bugger out big_smile

Mrsuperheterodyne · 2021-01-12 19:50:26

Yes Casper, I have got the thing loose and free, just can't seem to get it out.
Everything seems in the way and there does not seem to be enough clearance to get the ports to pass over the rocker cover.

I will remove the water bottle tomorrow morning and see if that gives enough room to wiggle it out.

Even smashing it out - that's a pretty tidy job you did LOL.

Thanks for the reply. smile smile

Last edited by Mrsuperheterodyne (2021-01-12 19:51:31)

Mrsuperheterodyne · 2021-01-13 12:03:13

Oh the joys..... 2 out of 4 of my glow plugs are proper seized.
Managed to get one out - the next two were easy to undo but stuck on the shafts, got them out though.
This last one is the mother of all nightmares.
It's barely turning a thousandth of a turn each time - then back a bit - then more... using a 1/4 ratchet to try to limit my strength.
Tempted at this stage to say "what will be, will be" and go for a bigger ratchet just to speed up the torture. big_smile

Honestly have no idea how garages quote for this kind of work... this is going to take all day and even then might end up in disaster. lol roll mad

kenbw2 · 2021-01-13 14:57:23

It's always the way, just had the same nightmare with my brake calipers

One tip I was given for stuck bolts is to turn it anticlockwise as far as you can, then clockwise again, go back and forth to try to loosen it up. WD40 etc too.

Maybe run the engine as well, heat will loosen things up? Dunno if that would work but at least it means you don't get cold hands

Mrsuperheterodyne · 2021-01-13 16:29:03

Thanks for the reply. Managed all 4 anyway.
Nipped the plugs up, but not too tightly with a light coat of silicone grease on the threads.
Noticed slight (only slight) bubbling around two of them (residual WD40). Took the whole manifold apart again and gave one of them a good nip up. Still dong it - so I expect it's something that seals itself up with time and carbon?

Appreciate the help.

Casper · 2021-01-13 19:52:09

I changed my glow plugs also due to being a crap starter when cold. Was just the same after swapped so looked at relay also. Swapped that over twice with scrapper ones and still the same. Started to ignore the glow plug light and just listen for the relay click as 25 - 35 seconds and its been firing up fine since.

On the Convoy facebook page i help run a lot of the guys have the old Ford Di engines. 2.5 with no glow plugs. When cold they just do a 2nd cycle of the glow plugs and it fires into life no problem on the cold mornings.

Mrsuperheterodyne · 2021-01-13 23:27:02

Thanks Casper, I will let them heat up till the relay clicks to see if that helps.
Turns out my throttle cable is about to snap - lucky I saw it during this job - it's got a single thread left hanging on!!

I was thinking along the lines of a non return valve in the fuel line if, after waiting for the relay to click doesn't do it for me.
I'm suspicious that there is draining back happening overnight.

kenbw2 · 2021-01-13 23:45:11

Yikes, that was a lucky spot!

For the fuel lines, you should have a clear pipe somewhere near the fuel pump, see if there's bubbles in it?

Mrsuperheterodyne · 2021-01-14 23:03:08

kenbw2 wrote:

Yikes, that was a lucky spot!

Absolutely Kenbw2! It was only held on by one hair!

For anyone interested - I repaired it in under half an hour using a kit from eurocarparts.
https://www.eurocarparts.com/p/aa-throt … -545776443

Only cost £3. Came with the wire rope, and three retainer things.
At that price thinking it may be wise to have one in the glovebox.

Only slight issue I had was that the bulb / knob / nub whatever you call it at the end of the wire was a little smaller than the original and the wire itself is of a smaller diameter (only slightly) so it was a little looser in the holder at the pedal than I would have liked. I sorted this out by putting heat shrink over the end and shrinking it with a lighter to make it a bit fatter which allowed me to wedge it in with a little more confidence. I don't think it's going anywhere.

Am happy to report that for the first time in a long time, the van started on the first turn of the key!
So, although it still needs to crank for a couple of seconds - it's a massive improvement over the 5 or 10 minutes of work it used to be.

I have noticed slight bubbling in the fuel line, so there must be sucking in going on somewhere.
Still - am very pleased with the starting this morning.

Interestingly though I tested all the glowplugs that I removed and found them all to glow from the tip correctly.
One was a little slower than the rest.

I don't know - I have never applied power to a brand new one so I can't really say whether what looked OK to me, would look OK to someone who has seen a new plug glow.

wink wink wink wink

kenbw2 · 2021-01-14 23:11:12

For your fuel draining back issue, you can prime it using the push button next to the fuel filter, that should help it start a bit faster

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#1 2021-01-12 18:38:18

Inlet manifold

#2 2021-01-12 18:48:05

Re: Inlet manifold

#3 2021-01-12 19:08:25

Re: Inlet manifold

#4 2021-01-12 19:45:31

Re: Inlet manifold

#5 2021-01-12 19:50:26

Re: Inlet manifold

#6 2021-01-13 12:03:13

Re: Inlet manifold

#7 2021-01-13 14:57:23

Re: Inlet manifold

#8 2021-01-13 16:29:03

Re: Inlet manifold

#9 2021-01-13 19:52:09

Re: Inlet manifold

#10 2021-01-13 23:27:02

Re: Inlet manifold

#11 2021-01-13 23:45:11

Re: Inlet manifold

#12 2021-01-14 23:03:08

Re: Inlet manifold

#13 2021-01-14 23:11:12

Re: Inlet manifold

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