6 Blokes, 3 Pandas and 8,000miles - The 2005 London to Mongolia Rally - -1209 days to go
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Sunday, March 27, 2005

Putting it all back together again

Rich and I have spent the last two days dismantling and re-assembling the Panda. The two main jobs we did were to replace the fuel tank and the cylinder head. The toughest part about the cylinder head was replacing the cam belt. We just couldn't work out how to keep the crank wheel still so we could slacken the nuts off it. In the end John came to our rescue by shoving a screw driver through the clutch inspection panel. We had to get a few replacement bolts for the cylinder head as a couple of them had corroded badly. We also managed to shear a few nuts and bolts on the inlet manifold and rocker head but it wasn't two much of a problem sorting that out.

At the same time we were wrestling the old tank off. This was nightmare job as every time you touched clouds of dirt and rust fell off the tank straight into your eyes. Disconnecting and reconnecting pipes was also a bit of a struggle.
After putting 5 litres of fuel back into the car and replacing the coolant, John timed it up for us and we started the engine. It ran perfectly, for five minutes, and then concked out. We'd run out of petrol in the tank as we had it up on stands. So I nipped out to get some more fuel and put that in. But by this point the battery had gone flat and even with jump starting we had massive problems getting it started. We worked out that fuel lines were probably restricted, so I dropped the new tank down a bit and wiggled them round a bit before re-tightening. This seems to have sorted it, but we still have few nagging doubts about the fuel pump pushrod. Anyway, next weekend John is going replace the pushrod and tune the engine for us, so this should sort out and remining problems.


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