Mansfield
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| posted on 6/9/07 at 02:40 PM |
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1.6 97 Tigra head gasket jobs woes.
I really hope someone on here can help me, SWIMBO's Tigra needs a new head gasket.
I have done a few head gaskets so I have taken two days off work to do the job. I am near the end of day one as well as my wits end.
The only thing that is seperating me from getting the head off is the inlet manifold. The haynes book of lies is telling me to take the head off with
the manifold attached, but a big bundle of wires goes through the manifold between 2 & 3. Due to the ridiculously large connector I cant pass
this through from the top so I have to disconnect everything below the manifold and bring the wiring up through the manifold.
I cant find everything I need to disconnect, I cant feel it or see it from any angle around the car.
Normally I would expect to leave the manifold with the car but I cant get the access I need to the manifold nuts due to the wiring, plumbing and air
intake duct.
Any ideas, sensible suggestions, or helpful websites would be very much appreciated.
Unless I have a flash of inspiration or some decent advice I am going to put it all back together and get the job done at the garage. That will
hurt.
Thanks, David.
Picture coming.
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Mansfield
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| posted on 6/9/07 at 02:41 PM |
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More problems. 
Where is the attach picture button gone?
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locoboy
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| posted on 6/9/07 at 02:41 PM |
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Cut the wires above the manifold and re solder / heat shrik them together ?
ATB
Locoboy
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SyKaTurbo
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| posted on 6/9/07 at 02:42 PM |
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can you not just remove the upper part of the manifold and get access to the between the lower inlet?
Also, if you take the head off you can shift the whole lot forward and dismantle from behind.
The large inlet pipe behind the engine can just be undone from the throttle body and left hanging there.
[Edited on 6/9/07 by SyKaTurbo]
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Mansfield
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| posted on 6/9/07 at 02:43 PM |
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Picture in archive of progress.
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SyKaTurbo
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| posted on 6/9/07 at 02:45 PM |
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The loom should be able to be completly removed from around the inlet with a bit of fiddling too.
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RickRick
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| posted on 6/9/07 at 02:48 PM |
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can you whip the pins out of the large conenctor? bit of labeling and the like for re assembly
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Mansfield
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| posted on 6/9/07 at 02:48 PM |
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SyKaTurbo - you sound like you have done this job before.
Will disconnecting the throttle body end of the inlet pipe give me much more access? I cant get to the manifold nuts form the top - at least not all
of them.
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MikeR
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| posted on 6/9/07 at 02:50 PM |
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i think someone sort of said this ........
can you not move the head forward with everthing else removed - thereby getting more access to the back and hopefully removing some of hte wires. -
otherwise cut and crimp / solder back is an option, how many wires?
Can you not go 'in' from under the car to unplug? i'm guessing you'll have to remove a shield of some sort but it may help.
looks too many to cut and re-solder / crimp.
Actually, whats stopping you lifting the head 6" and putting some wood to hold it in place, then gaining 6" of access to the back of hte
engine and the wires?
[Edited on 6/9/07 by MikeR]
[Edited on 6/9/07 by MikeR]
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SyKaTurbo
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| posted on 6/9/07 at 02:52 PM |
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Yes, if you undo the jubilee clip from the back off the throttle body that plastic pipe will drop down alot.
Also, if you work from under the car there is loads of access room to get to wiring, manifold bolts etc. That engine uses a stupid long inlet system
designed to lower power but keep a high torque. Downside is miles of pipe work with odd shaped inlet.
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MikeR
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| posted on 6/9/07 at 02:58 PM |
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also, undo the alternator and let it swing down on its mount bolts. That should give you more access (from haynes on how to remove inlet manifold).
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Mansfield
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| posted on 6/9/07 at 02:59 PM |
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I am struggling to see much at all from the underside of the car, everything seems to be in the way.
I had considered moving the head forward but I am bit worried that if I still cant get it apart I will have to tow it to the garage - how embarrassing
would that be.
You are giving me hope though, I haven't felt this calm for hours.
So which way should I go - leave manifold in car or disconnect the wiring?
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Mansfield
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| posted on 6/9/07 at 03:02 PM |
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I am not convinced that Mr Haynes has done this job with the engine in. I have moved the alternator but it only pivots a couple of inches then hits
the bulkhead.
I would like to remove it altogether but I think I would have to remove the inlet duct but I have yet to find the bolts to undo that.
Edit - bad English
[Edited on 6/9/07 by Mansfield]
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Mansfield
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| posted on 6/9/07 at 03:08 PM |
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Ironically I think the wiring will stop me lifting the head much at all. If I could lift it up that far I might be able to work through the gap.
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locoboy
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| posted on 6/9/07 at 03:09 PM |
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Rip it out and stick a bike engine in.
Sorry not helping you much
ATB
Locoboy
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Mansfield
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| posted on 6/9/07 at 03:11 PM |
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If I could rip it out I would have done so by now.
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Mansfield
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| posted on 6/9/07 at 03:32 PM |
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Expect more questions soon.
Thank you all so far.
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graememk
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| posted on 6/9/07 at 10:37 PM |
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did you get it done ?
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Mansfield
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| posted on 7/9/07 at 12:46 PM |
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To my great shame I cannot do it. I am now going to put it back together so it can go to the garage.
Apart from exhausts I have never paid to have a car fixed, I have always done it myself (20 years riding/driving).
I have also never given up before so I feel a bit low right now. It is hard to get motivated to put it back together after getting so far.
Never mind, there is always beer and fags to cheer me up.
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