TD5 Head Gasket failure almost certain

[eckolsim]

:(

Just happened to be going to Graeme Coopers for a new expansion tank cap and thought it safe to put the car on the dyno and rule out the head gasket being blown as a result of all the water issues I have had.

I knew deep down that it was gone but had always been in denial.

The dyno confirmed that the cooling system was being over pressurised from the cyclinders.:eek:

Reached 20psi in 90s from cold start under load.

I am going to do this myself with some help from a mate who rebuilds engines.

I shall try to get some photos.
Wish me luck :eek:

[spudboy]

Good luck!!!!

[WildOne]

Best of luck mate, i find that the only time i stuff up doing an unfamiliar job is when i try to rush it, if you've got access to the correct tools and info and take your time you'll be fine;)

Cheers, Phill

[awabbit6]

I am going to do this myself with some help from a mate who rebuilds engines.

I shall try to get some photos.
Wish me luck :eek:

You'll be right. I did mine (300Tdi) a couple of weeks ago for similar symptoms. If you have done one before (on any other engine) you'll have no problems.

[Blknight.aus]

best of luck mate, take your time, be pedantic buy a RAVE CD from inc for your vehicle and FFS ask questions if your in any doubt....

check then double check the block and head for flatness.

dont forget to oil the threads and the underside of the new head bolts...

Auke should be a good POC for any questions especially RE injector seating.

again, best of luck.

[eckolsim]

A trip to Rovacraft today and I have just about all the bits I need for just on $400 (including a new expansion tank cap). I did manage to get double billed for the head bolts but I am sure that will be easily rectified tomorrow.

I shall post full parts list later for record (plus photos) as used.

https://www.aulro.com/afvb/images/imported/2008/08/206.jpg (http://www.aulro.com/app/showphoto.php/photo/11386) https://www.aulro.com/afvb/images/imported/2008/08/207.jpg (http://www.aulro.com/app/showphoto.php/photo/11385) https://www.aulro.com/afvb/images/imported/2008/08/208.jpg (http://www.aulro.com/app/showphoto.php/photo/11384)

[eckolsim]

I am now in the middle of the rebuild. The tally so far:

1. #2 pot confirmed as leaking to cooling system - required machining and rebuild
2. Radiator leak confirmed - requires replacement.
3. Replacing all major cooling hoses.
4. Replacing all of those fuc#ing spring clips with stainless hose clamps.
5. Spare parts cost has hit the $1k mark.
6. The head rebuild (labour only) is at the $650 mark.
7. Having a great time doing the job (except for that burning feeling in the wallet)

photos have been taken.
will advise as refit starts tomorrow.

[2 rocks]

Good luck for tomorrow!
You have my admiration (sincerely)!! I can't stand changing the oil filter on the !@#%$ thing (who thought up the placement for that?)
Let us know how it goes...
Cheers
Mike

[justinc]

Well done! A warm feeling will come over you when it is up and running again! (And no, I'm not talking coolant leaking all over your shoes...)
One thing, have you got steel dowels to fit in place of the plastic rubbish ones???

JC

[Piddler]

Well done! A warm feeling will come over you when it is up and running again! (And no, I'm not talking coolant leaking all over your shoes...)
One thing, have you got steel dowels to fit in place of the plastic rubbish ones???

JC

whats the go with the dowels JC
most say replace the plastic some say with early ones you must use them.

Being an engineer knowing what dowels normally do I can't see why you cannot go to steel.

Cheers

[spudboy]

There have been a few threads on replacing plastic dowels with metal. 2 streams of thought:
- some say don't because the metal dowels are longer (?) and will mess up the head
- some say they are only locating pins and it don't matter.

A search should turn up the threads.

[Psimpson7]

I am pretty sure they aren't interchangeable as such, but if you make some steel ones, the same size as the plastic ones you are replacing you will be able to use them.

At least this is my understanding.

Rgds
Peter

[eckolsim]

When I put the kit together the plastic dowels were not even offered. I have installed the metal dowels. They fit just fine and are there for as locators only. For info, one of the plastic dowels was broken on removal.

Finally, the re-assembly has halted for the weekend due to a trip away. Still to finish the plumbing on the car.

Regards

[Redback]

I was told NOT too put the metal dowels in if you have the early D2, the metal are only to be fitted to the late model D2a update.

It is in a LR bulliten somewhere.

Baz.

[eckolsim]

Redback - bugger. It is done now. I had heard about this issue but really, after completing the job I can't see any valid reason not to.

BTW - It started :D:D:D
and even ran :D:D:D
unti I took it for a run up the street. It was surging... I had left off the sense line from the outlet of the rubo to the solenoid thingy. All better now.

No leftover's either. Just the next week of constant fluid level checks and leak checks and I'll be happy.

[justinc]

Redback - bugger. It is done now. I had heard about this issue but really, after completing the job I can't see any valid reason not to.

BTW - It started :D:D:D
and even ran :D:D:D
unti I took it for a run up the street. It was surging... I had left off the sense line from the outlet of the rubo to the solenoid thingy. All better now.

No leftover's either. Just the next week of constant fluid level checks and leak checks and I'll be happy.

Good job! Excellent result. It's great to see someone having a go. Feels good doesn't it?:D:D:D


JC