BDR Inlet Manifold removal - and now to refit
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
after cleaning with acetone and fine grade Scotchbrite
after cleaning with acetone and fine grade Scotchbrite
after cleaning with acetone and fine grade Scotchbrite
after cleaning with acetone and fine grade Scotchbrite
this shows a code I found on both inlet manifolds, Z2 or 22
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").
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".
Showing the Motorsil D gasket sealant I hope to use if it has not gone solid all the way through.
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.
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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