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TD5 engine cover removal


bear
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Hi Everyone,

I've just changed my faithfull 200tdi for an 04 TD5 and whilst giving it the once over this weekend I was unable to remove the single o/s bolt securing the plastic engine cover. The 2 n/s ones were ok as they fix into the head but the o/s one is turning as if there is a captive nut behind that's come loose. I tried putting some tension on the bolt head with a screwdriver to no avail. Can anyone please tell me exactly what it bolts into (manual no help)and a possible solution to remove it.

I suspect this will be the first of several questions to the "knowledge bank" until I get used to the new beast :D

Many thanks,

Bear

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Hi,

I had this problem recently.

The bolt screws in to an insert in a small bracket on the o/s of the engine. The insert is only held with friction (serrated edge) and can come loose if the bolt is over tightened.

I managed to get a small pair of mole grips under the cover to hold the insert and unscrew the bolt. I then welded the insert in to the bracket so it won't happen again.

Scrumps

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Hi Scrumps,

When you say "..from underneath" do you mean having first removed the 2 other bolts and lifted the cover up to give acess from in between the cover and rocker cover or from underneath the outside of the cover under the actual bolt?

Regards,

Bear

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Hi Scrumps,

When you say "..from underneath" do you mean having first removed the 2 other bolts and lifted the cover up to give acess from in between the cover and rocker cover or from underneath the outside of the cover under the actual bolt?

Regards,

Bear

Hi Bear,

Both !!

I removed the other two fixings and got enough movement to see the problem then I used long nose Mole grips from the lower RHS to come up under the cover and grip the insert.

Once the bolt loosened about 1/2 a turn it spun out with my fingers.

Scrumps

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