Thread: Replaced the exhaust gasket on TD5

There was a lot of black soot along the side of the head, on the turbo side.
It was blowing out there ,ordered a new gasket and other bits. Started the job and it soon became trouble with tight bolts and hard to get to studs under the manafold..
It took 2 hours to undo the under neath studs, I had to cut the pop riverts from the cover over the turbo at the back near the fire wall,( this is what came to be a half a day looking for a problem) When I got all the nuts off, its still didnt come off ,had to undo the 4 bolts that hold the air con, compressor down, drop the belt off..The manafold was bent like a banana, had it serfaced and it looked so much better. I went and got some 8.8 bolts to replace the studs so next time I wont have to undo the air con. compressor. It went back much easier than it came off. All smiles stood back and was happy with the job.
Ok went to start and noway, it just did zip ,cranked over ok but nothing. and the emergency lights went off and I couldnt turn them off, had to pull the fuse. I spent half a day tring to find out what the problem is.
Had a look on here and saw where some one had rolled their Defer. over and couldnt start the motor. Yep when I cut the pop riverts off I hit the cut out,rollover switch with the hammer,not hard but it must have been enough to open it or close what ever. Thats the little black rubber covered thing on the fire wall just near the turbo... funny thing is after reading about it I went and pushed it but didnt try to start it thinking that couldnt be the problem..
Had the Hawk Eye conected and it gave all sorts of things that didnt make sence. 2 hours later rang some very helpful people and started to explain, turned the key and it went..Mate!!! carnt write what I said.....Hope this helps some one...
Bob

Hi skuilnaam,Yer did all the things and used a low loktite on them as well. Im not putting the cover back just yet so as to keep a eye on the thing..

Im trying to get away for the winter up north or over the west is even a better choise. better fishing. Thanks for the remarks..
Bob......