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BDR Inlet Manifold removal - and now to refit


anthonym

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I agonised over whether to remove this inlet manifold applying "if it's not broke, don't fix it". However, I found an exception to this idea. Which is when I cannot discern whether it is broken or not. I found this when fixing the cooling system overflow system. Everything looked "not broken" but the overflow system was not working. Air was ingressing somehow, somewhere. In the end I replaced every single component and suddenly it worked for the first time for me in 23 years. So I fixed something though to this day I am not sure what.

In that same vein the carburettors tuning has been very erratic and every time I fix/replace something it gets easier. Given that the carbs are off and access is easy I chose to remove the inlet manifold for inspection and cleaning. The old gasket is brittle and left many marks on the interface, which I have cleaned with acetone and fine grade Scotchbrite.

Here are some pics:

after cleaning with acetone and fine Scotchbrite

IMG_2723.webp

 

after cleaning with acetone and fine grade ScotchbriteIMG_2724.webp

 

after cleaning with acetone and fine grade ScotchbriteIMG_2725.webp

after cleaning with acetone and fine grade Scotchbrite

IMG_2726.webp

 

after cleaning with acetone and fine grade ScotchbriteIMG_2727.webp

 

this shows a code I found on both inlet manifolds, Z2 or 22 

IMG_2729.webp

shows the new Cometic INLET MANIFOLD GASKETS  test mounted. Nice and flexible unlike the brittle old ones (which did well enough after nearly 40 years "applause").

IMG_2730.webp

 

the bundle of gaskets from Burton Power, purchased for just one gasket andI bought the bundle thinking over time I will need many if not all of these. No Head gasket. (inlet manifold gaskets removed). We can play "spot the gasket".

IMG_2731.webp

Showing the Motorsil D gasket sealant I hope to use if it has not gone solid all the way through.

IMG_2732.webp

From the Cosworth doc issue 2.     Torque settings for bolts of 
1/4" bolts 5-7 lb.ft.               5/16" bolts 10-15 lb.ft                3/8" bolts 20-24 lb.ft
Conversions - to convert lb.ft to Nm, you multiply by 1.35582
1/4" bolts = 6.35mm is 6.78nm to 9.49nm        5/16" bolts = 7.9375mm is 13.56nm to 20.34nm           3/8" bolts = 9.525mm is 27.12nm to 32.54 nm
So my inlet manifold 11mm nuts will be say 35nm.

So I figured out which order to re-install these with an old photo zoomed in: thant blanking screw is only on one side, so the same spot on the other side of each is not drilled, just the spot is marked in the moulding.

IMG_8197-WHICHWAYAROUND.webp

To my amazement getting 1/4"UNF Nylocs has proven practically impossible in my locations so I am very grateful to Threadfast of Congleton supplying all I need for £8.50 all included and posted to Europe. I used them years ago to rebuild this same car as it happens and they are real engineers for fasteners.  Threadfast of Congleton, Ask for Anthony Heeley Anthony@threadfast.co.uk +441260278236 , see if he remembers me. Vast stock of everything last I was there. I used to work in Congleton in the 80s. They are hidden down the back streets.

Edited by anthonym

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Yup, I have a couple of those gasket sets for just a couple of them too! 
It is nice just calming down and going through something properly rather than patching all the time….

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