Top 10 preventive maintenance tasks when buying a D2a

rebuild the auto

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Originally Posted by slug_burner

rebuild the auto

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Pull the aircon drain nipples and insert a length of vacuum hose which you cable tie to the chassis - this will help to prevent DC joint failure and also XYZ switch issues..

Check injector harness (under the rocker cover) for oil and if you don't have one, keep a spare in case you have issues - 10 minutes replaced and you're mobile again - without the engine trying to escape from the engine bay! Also check ECU end and clean if required.

On my 2003 D2a TD5 I've had to replace the ABS modulator (3 Amigos), replace fuel pump, clean and service injectors, replace injector harness, replace both plastic seat recliner knobs on the front seats, replace air-cond compressor clutch assembly, replace casings on the keys... she's running beautifully now *touch wood*

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Originally Posted by alpick

This action i was expressly advised against by the Experts at Greame Coopers in sydney.

"The Exhaust studs break because they are too weak for the Job (8mm i think) not because of the design of the exhaust manifold. If you drill the webbing out you chance getting manifold cracking as well as stud failure"

Their advice?

If you want to do some preventative maintenance to stop the exhaust stud problem better to replace them with 10mm studs and even better use stainless steel 10mm studs.

:)

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I am no EXPERT but:

Firstly the reason why the studs break is because of differing expansion rates between the aluminium head and the cast iron manifold. Increasing the bolt size will worsen the problem, giving less room for movement. Increasing the hole size allows the exhaust manifold lateral movement before putting stress on the bolts. The gasket has been designed out of several thin layers of metal to facilitate this movement.

Cutting the webbing will reduce the likelihood of cracking, not increase it IMHO

Stainless would not be the first choice due to its work hardening properties.


Erich

I am no expert either, that is why i follow the experts advice!

Dont things generally break because they are not strong enough?


cheers

we took dads manifold off when the studs broke and the manifold itself was like a banana thats what broke the studs we just rang M.R auto and got a machined flat one(exchanged about $90) drilled the holes etc and all sweet. We could have got ours machined but had no time so got the exchange one.

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Originally Posted by alpick

Dont things generally break because they are not strong enough?

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Cheers

so far in my 2004d2a i have done 2 airbags in the sls , had a leak on the air hose around the fuel tank [ had to replace about 300mm of hose ] ,replaced a diff centre , had the aircon drains moved , thought i had a delaminated hose or stud failure the hose clamp on the turbo hose had come loose
:angel:

Happy days bit of preventative maintenance! Road trip to Adelaide coming up so time to check the oil pump bolt...157k and solid as a rock....its all peace of mind:p

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Originally Posted by Bundalene

I am no EXPERT but:

Firstly the reason why the studs break is because of differing expansion rates between the aluminium head and the cast iron manifold. Increasing the bolt size will worsen the problem, giving less room for movement. Increasing the hole size allows the exhaust manifold lateral movement before putting stress on the bolts. The gasket has been designed out of several thin layers of metal to facilitate this movement.

Cutting the webbing will reduce the likelihood of cracking, not increase it IMHO

Stainless would not be the first choice due to its work hardening properties.


Erich

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Ceramic coating the manifold as well.