 | Home > Maintenance & Modifications > Help please .. airbox again.. |
 
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| JOW240725 Member Since: 04 May 2015 Location: Suffolk Posts: 7904   
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I watched Pete Bell fit my Hi-Flow intercooler and hoses, all I can say is it isn't easy, quite a fiddle.
I'm sure if you call Pete he'll help all he can. Have tried YouTube for a video? Good luck  worth it in the end. James
MY2012 110 2.2TDCi XS SW Orkney Grey - http://www.defender2.net/forum/topic43410.html MY1990 110 200TDi SW beautifully faded Portofino Red - https://www.defender2.net/forum/post743641.html#743641 MY1984 90 V8 Slate Grey - https://www.defender2.net/forum/post744557.html#744557 Instagram @suffolk_rovers |
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31st Jul 2017 7:53pm |
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| derbywill Member Since: 25 Mar 2010 Location: Derbyshire Posts: 556  
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There seems to be a lot of dust on the clean side of the filter, make sure the filter is sealing correctly and all hoses and any seals are intact.
Cheers Will 2005 90 XS 1954 86'' Series 1 tilt 1968 88” 2A 200tdi 2002 110 Hardtop |
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31st Jul 2017 8:25pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20294
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Yes, drill the rivets out all of them and the whole airbox will come up vertically with fettling.
The grommets can be tight but will come out if wiggled about. A good bit of force needed but with in reason as the plastic can be prone to breaking if not careful. I can't see any need to remove the headlight but extra access can sometimes be helpful. ⭐️⭐️God Bless the USA 🇬🇧🇺🇸 ⭐️⭐️ |
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31st Jul 2017 10:39pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17337 
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I found that shortening the plastic pegs on the airbox before refitting it made it much easier to remove and refit subsequently.
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31st Jul 2017 10:46pm |
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| Sadi Member Since: 23 Jul 2015 Location: Windhoek Posts: 334  
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Thank you all !!
Time always a bit tight - but will report back on progress - may not be today though. Will also email BAS for some tips. |
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1st Aug 2017 5:22am |
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| Sadi Member Since: 23 Jul 2015 Location: Windhoek Posts: 334
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Emailed Pete at BAS: he warned me that there is still a clamp at the alternator that needs to be released. This clamp totally obscured by the 'platypus beaked' dirty air intake. Pete didn't think airbox removal was necessary - but I decided to go for it. Removed the OS headlamp - and there I could actually see the 2 vertical feet and 2 horizontal feet. Lubricated with aerosol oil. Continued with removing the lugs on the water radiator. Then tried the airbox again - by inserting some levers between the underside of the airbox and the black steel footplate connected to it. The gap is fairly big - eventually had to use a pry bar - as it filled the gap sufficiently and gave such tremendous leverage that it lifted the airbox with grommets and feet intact. To remove the airbox completely - had to manouvre the aircon hose though - this necessitated detaching the side plate that holds the stay that keeps the bonnet open. Put a camping mattress in front of the windscreen and used a ski rope to roof rack "hoist" to secure bonnet in +/- 80 degrees upright position. Gave more play and movement of the aircon hose - but still was difficult to remove the airbox - but eventually succeeded. Now have a good view and access to the turbo to IC hose. But now late & dark - and decided to leave it for a another better daylight opportunity. Progress and photos of this to follow.
2 Horizontal feet of airbox:  Click image to enlarge 2 Vertical feet: Click image to enlarge |
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3rd Aug 2017 4:51am |
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