Member Since: 02 Aug 2009
Location: bude , cornwall
Posts: 206
Glow plugs and manifold gasket
Suspected the glow plugs on my 07 Hard top 90 were past there best as starting on colder mornings was taking longer and I had white/ blue smoke from the exhaust,
Also had oil mist blowing out of the manifold gasket in a couple of places so it was time to do both jobs at once,
This is how I did this, not sure if its the workshop manual way but it worked for me,
After undoing the 9 captive bolts holding it in place and the 2 bolts holding it to the pipe holding the MAF sensor,
I managed to remove the manifold by moving pipes and wiring out of the way and wriggling it carefully towards the radiator it was a tight squeeze but by taking it slowly wasn't a drama,
Once it was out I could see where the oil was blowing and the amount of sticky residue in the manifold and inside the cylinder head,
The 4 glow plugs came out relatively easily as I had warmed the engine first and used plenty of spray releasing oil on them first, once it got past the threaded section the technique I used was holding the threaded section with a small pair of mole grips twist it and pull up at the same time,
The new glow plugs were fitted after applying copper slip to the threads and torquing to 12nm,
I then spent the next hour cleaning the manifold and the ports in the head of the black gunk the were caked in,
After fitting the new seals refitting was the opposite of removing and was managed in the same way torquing the 9 bolts evenly to 15nm,
Then re fixing the various clips and brackets that hold everything in place.
The first start was a bit smoky, but to be expected as there was some residue of the brake cleaner in the remaining carbon in the manifold but once it had ran for a minute the engine settled down and on the next start it fired up straight away with no smoke.
Here are some pictures of the job,
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12th May 2020 6:25pm
williamthedog
Member Since: 29 Dec 2012
Location: south wales
Posts: 3441
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12th May 2020 8:05pm
