Oil problems solved 1.6 tdci

[Focusoap]

Still sorting the 2005 1.6 tdci and having a go at the engine oil leak which fills the injector wells and cascades down the front of the engine. Had the injectors out (more fun and games with last one always the way) and replaced all the seals in the injector tube and the copper ones as well. Still getting oil in the injector wells so thought I'd sort the cam cover useless gasket. Bonkers design and relies on sealing via the rubber skirt on the aluminium cover face and not over tightening.

Threw the original one away and made one from a length of O ring rubber material about 5 mm diameter and stuck it in the gasket groove with super glue (see pic). Works a treat and seals properly without it squeezing out when tightened down. oil leak sorted and no more messy injector wells and oily engine.

While I was at it I took the sump off and took it to local blacksmith who pressed the sump plug indent out from the inside so that when you drain the oil it doesn't leave 30 ml of old oil in the sump. He got it red hot then stuck it on his press and pushed it out. Magic! oil stays cleaner much longer in conjunction with the blanked EGR. Only charged me a tenner as well!

[biff55]

some first class diy fettling there , well done that man !

 

:-)

[Focusoap]

Meant to mention that a friendly proper mechanic (not a part swopper until the problem goes away) told me about the two studs at each end of the sump which, after you have removed the nuts, can be unscrewed and the flange on the stud separates the sump flange from the crankcase casting without having to struggle getting a blade in to break the silicone seal. Saves the agro of flattening the sump flange later. 

A bit of thought at the design stage saves hours for the grease monkey who has to take it apart!