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Question: Can you replace the head gasket without removing the engine?

Discussion in 'Problems, Fixes, Tips...' started by welz, Nov 29, 2018.

  1. welz

    welz Copenworld Regular

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    Jun 8, 2015
    Location:
    Leverkusen, Germany
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    copen 2003
    Hello, after cost estimate for the replacement of a head gasket incl plan over 2500 euros, I would like to know if the engine must be removed.
     
  2. BarnsleyRob

    BarnsleyRob Copenworld Veteran

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    2009/59 silver Copen 1298 cc (now gone to a new home)
    @welz

    I’m not an expert, but it’s overhead camshafts so I would guess that it would need to come out to get proper access to the all the associated gubbins on the left side (as you face the engine). Getting the fuel injection rails and stuff off will also be a PITA with the engine in.
     
  3. Salieri

    Salieri Copenworld Veteran

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    Ich schätze es wird einfacher wenn du den Motor rausnimmst, aber wenn du genug Platz im Motorraum hast, warum nicht?

    I guess it will be easier if you take the engine out, but if you have enough space in the engine compartment, why not?
     
  4. BarnsleyRob

    BarnsleyRob Copenworld Veteran

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    Further thoughts may be to undo the engine mounts and jack up the left hand side to get better access to the ancillary pulleys and timing chain/belt assembly. It would save hassle with the gearbox.

    It goes without saying that the bonnet will need to be removed but that’s only a few bolts.
     
  5. Ewoud van Munster

    Ewoud van Munster Copenworld Newbie

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    Daihatsu copen 0.7
    It is NOT nessesairy (i've done a replacement with the engine in the car).
    However you need some small hands for some of the components like timing chaine tensioner/ intake manifold, and some electronic plugs etc.

    So if you would pay for the labour, i would advice to take it out, since it is most likely faster with the correct tools,
    if you do it yourself and have plenty of time avaiable, you can do it yourself.

    Keep an real eye out for the timing chaine, since you do not want to drop it! (if you do, you cannot see the mark on the bottom timing gear, and than the engine might has to come out).
     
  6. welz

    welz Copenworld Regular

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    copen 2003
    Hi Ewoud,

    Does you have more photos from the engine, you can send me?

    what do I have to unscrew.everything?

    How can I secure the timing chain. Special tools needed?
     
    Last edited: Dec 5, 2018
  7. Ewoud van Munster

    Ewoud van Munster Copenworld Newbie

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    Hi Welz,

    You have too unscrew everything that is attached to the upper parts of the motor block,
    But also Airco/headlights/pumps/ intake and outlet mannifould/radiator/turbo etc.
    You need roughly 5-6 different gaskets, and also some 1 time use parts like the white couplet in the exhaust.
    This also means unplugging some hard to reach sensors/bolts. So small hands would be nice;)

    For the timing chaine i took a piece of string and rubber band, and attched it to the open bonnet.

    you don't really need special tools (I did it without) but this do meand sometimes carefuly asses which is the best way to do things.
    I did need to unscrew my cam shafts since i needed to change a valve, if you only do the main gasket, probably you don't have to do this, this was the most tricky part where i could have used some special tools.

    It will take you most likely 2-3 full days if you (just like me) have some experience with tooling around, but never replaced something from an car engine.
    And use the Manual from the resources! this is very usefull!

    I also had a small bridge with which i could raise the car, very usefull, but if you simply jack it up a bit, it would also work, but sometimes a bit hard for your back;)
     

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  8. welz

    welz Copenworld Regular

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    Hi Ewoud, thank you very much. So, I think , I will do it by my own.
     
  9. Ewoud van Munster

    Ewoud van Munster Copenworld Newbie

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    Good luck!

    let me know if you run into something and need to talk to someone,
    I also have some spare parts from a 0.7 copen, including motor parts;)
    In case you break something :p
     
  10. BarnsleyRob

    BarnsleyRob Copenworld Veteran

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    @Ewoud van Munster

    A great addition to the forum as you’re someone that has actually done the work. Sadly, I sold my Copen in the summer but I suspect you may be invited to a lot of Copen meetings so others can use your experience.

    Leverkusen anybody ?
     
  11. Ewoud van Munster

    Ewoud van Munster Copenworld Newbie

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    Hi Rob,

    A pity you sold your Copen,
    you bought something bigger?
    Or you didn't liked all the positive attention it got :p?

    Yes i will try to join the germany meeting somewhere in june it was, (is on my calander;) )
    I have spoken with my Daihatsu dealer, who has bought most of the parts i needed for revision of the valves/turbo etc,

    The fun part was that he said he had never taken such a motor apart.
    He explained that Daihatsu makes those engine quite reliable, and maintenance free, so they never has be taken apart.
    Unfortunattely that also means that in a small crash or problem like a cilinder gasket leak, the car is most likely not worth the large expeses of labour costs...
     
  12. welz

    welz Copenworld Regular

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    hi ewoud, thats my problem too, how to get the parts. Will search in internet...

    Had ask for repair in lot of dealers, nobody was eable to try or costs over 2500 Euros.

    If I get problems I will ask you for help, thanks again.

    edit: the headscrews must be new ones too?
     
    Last edited: Dec 6, 2018
  13. Ewoud van Munster

    Ewoud van Munster Copenworld Newbie

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    Hi,

    Yes it is officially advised, but the first time i didn't do it.

    But don't try to cut too many corners with gaskets etc or you end up doing it all over again!
     
  14. welz

    welz Copenworld Regular

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  15. Ewoud van Munster

    Ewoud van Munster Copenworld Newbie

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    I honestly wouldn t know, bought all my parts at dealer
     
  16. welz

    welz Copenworld Regular

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  17. BarnsleyRob

    BarnsleyRob Copenworld Veteran

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    Ewoud,

    It was a great car and I spent more than I should have done bringing up to the best condition. Unfortunately, the availability of spares and some minor issues that I couldn’t live with meant I bought an MX5 folding hard top. Other than parts availability, it has a useable boot even when the roof is down.

    I’m still very happy that the Copen was my introduction to open top driving even if it took me until almost 60 to get there !
     
  18. welz

    welz Copenworld Regular

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  19. welz

    welz Copenworld Regular

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    copen 2003
    found the bolts 60Euro.Thanks
     

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