Thread: 300tdi Head Gasket

Originally Posted by trumpycam

.... Has anyone fitted one and where did you connect sensors?
Joe

Never fitted one, but they look like they work with the commonly used loop/ring/washer type sensors.
For the engine temp sensor, front of head, just below the thermostat housing is an unused threaded hole.
You can see it from the front closer to the LHS of the head.
I'm pretty sure it's M8 .. dunno how deep tho, but a 10-12mm M8 bolt looks as tho it'd be perfect.
You can test fit one of your pulley bolts to confirm it yourself.
That is, remove fan and one bolt from the belt pulley. Fan/waterpump/power steering pulley all use the same bolt size(thankfully!) and it's about 10/12mm thread depth.

Trans sensor? .. auto or manual?
If Auto, and you're 100% sure that the ring would provide a perfect seal, remove the trans temp sensor and fit it between the pipe to the trans cooler and the sensor.

All done and running well,bought a 90mm oversize intercooler to finish off, however did not just slip in as hoped, spent a lot of time modifying everything associated with it rad surround hoses as well as intercooler itself, but eventually got it to fit. Last job was valves, not sure what is common way to do but trying to turn crank from underneath was a PITA doing it alone, so decided to remove fan again and glow plugs and job can be done from top and engine turned easily. Old RRC seems to have appreciated the effort hopefully for another 300K.
Thanks again
Joe

Originally Posted by trumpycam

All done and running well,bought a 90mm oversize intercooler to finish off, however did not just slip in as hoped, spent a lot of time modifying everything associated with it rad surround hoses as well as intercooler itself, but eventually got it to fit. Last job was valves, not sure what is common way to do but trying to turn crank from underneath was a PITA doing it alone, so decided to remove fan again and glow plugs and job can be done from top and engine turned easily. Old RRC seems to have appreciated the effort hopefully for another 300K.
Thanks again
Joe

I usually just lift one front wheel off ground, put it in fourth gear and pull the IP solenoid wire off, then you just turn the wheel to turn over engine.

24" ratcheting breaker bar!
Remove fan, 27mm or 1-1/16th socket on breaker bar, handle protrudes just high enough for good access, and the ratchet action means you don't have to continually remove it from the crank nut and find an appropriate location .. you just ratchet it.

24" cost me about $50 or so from a discount tool store in Melbourne's west. Handy for when the wheel nuts have over tightened themselves a bit too much too.
Best tool for a tdi when doing tappets