Off it comes...D2 TD5 headgasket swap

**Hendrik** · 31st October 2009, 12:33 AM

Hi all
I never thought the day would come where I'd have to do this, as my D2 has been a very reliable car. But lately some clear signs have shown that the headgasket is on its way out, and having been overheated before, I decided it was time to do the job. I see it as a preventative measure, as my D2 is an early one with the plastic dowels and 260kms on the clock. The thing was gargling excessively and after having bled the thing about 50million times, as well as losing water, it just has to come off. Hopefully the head can be reused, I will get it machined, cleaned and pressure tested and maybe a valve grind as well depending on the condition of the valves. Then hopefully it will be good for another 260 000kms

Here are some pics of the head removal, all that needs doing is the loosening of the headbolts. Using Petes' (psimpson7) excellent write up, as well as the RAVE manual on the laptop, it took me a little over 2hrs to get to this point. Using air tools and having small hands (LOL) really does make the job easier. Keeping everything really organise helps a lot too, at the moment I am putting back all the bolts in the holes they come from, after undoing them. As well as keeping the tools organised, it just makes the job so much more enjoyable and easier when you don't have to look for things all the time, coz you've misplaced them.
I will remove the bonnet tomorow as I will have an assistant, and hopefully the head is still in good condition.
So far, really enjoying working on it, like Pete mentions in his write up, it is a really good engine to work on....What else would you be doing on your Friday night???

Will update the thead with more pics when the head is off.

**Cannon** · 31st October 2009, 06:21 AM

good luck with it mate.

fingers crossed it all goes well

have fun

**strangy** · 31st October 2009, 12:52 PM

All the best with it mate. My head came back yesterday as planned and they took 6 thou off. All looks good and I m about to go out and bolt it all back together. Have fun! I am!!

Cheers.

**Mully** · 31st October 2009, 04:21 PM

Sweet. Enjoy your time alone with your beast!

**Hendrik** · 31st October 2009, 06:56 PM

Well I spent about 2 more hours on it today, got the head off pretty easy. I did it without an engine crane, was just me and my brother and we lifted it off pretty easy, it was not as heavy as I thought and we did it with the manifolds in place.
Thankfully the head is still good, as well as the valves which surprised me seeing as this car has done so much work. I guess the fact that it has had an easy life helps its case.
The head strip is pretty much done too, just need to lift out the injectors and it'll be ready for skimming.

Head removed from engine:

Sleeves still look really good, which means the rings are good too.

The head strip, again it really pays to keep things organised

To my surprise, the exhuast manifold had two gaskets, this isn't normal is it?
It must have had some warping issues in the past.

The valves

This is what 10years of egr gunk looks like, its amazing how thick it is, about 3-4mm in some places, I couldn't believe it.

Inlet port with a lot of gunk as well

Will send the head away for skimming, cleaning and pressure testing next week. Still considering doing valve grind too, again considering the kms the car has done.
Your right Strangie, it is a lot of fun to do this...I'm having a great time

**justinc** · 31st October 2009, 07:43 PM

Good work Hendrik and associates

Manifold gasket is actually 2 tin sheets pressed together, common for them to delaminate when removed. It might well be a good idea to send the inlet manifold in for acid bathing too to get rid of the EGR muck, you have an EGR bypass already don't you?

Enjoy!

JC

**Hendrik** · 31st October 2009, 08:11 PM

Hi Justin
Yes I do have an egr bypass, but only fitted that about 10 000kms ago, so theres a lot of gunk in there. I guess the oil combined with the exhuast gas makes a deadly mixture.
Would u recommend a valve grind, I know Pete didn't when he did his, but mine does had a lot more kms on the clock?

**justinc** · 31st October 2009, 08:15 PM

Hi Hendrik, Yes at 260K I would do a valve job, there is no doubt that at 300K or thereabouts they will be receeded/pitted and require reseating, so now is a good time to do it, considering the $$ in parts etc to remove the head AGAIN to do it in a short period of time. Plus, no more EGR gunk means longer lasting valve seats and better efficiency from now on

JC

**Hendrik** · 31st October 2009, 10:37 PM

Thats a good idea.
I'm kinda kicking myself for not doing a compression test before i took it off, to get some idea about the condition of the rings. How long do they normally last? Like you say concidering the effort involved, sorta have to do everything while I'm there...within reason.

**justinc** · 1st November 2009, 08:52 PM

Hendrik,

Don't worry about rings etc, at 260K it is still a baby

, if anything, poor valve sealing will be the only issue effecting compression at those K's. These engines are very tough and long lasting, the head gasket issue that you are now experiencing is its ONLY achilles heel. (Apart from oil pump drive bolt but that isn't all THAT common)

Steel dowels and some careful reassembly and you're ready for 250,000+km yet

, infact the gearbox and diffs etc will wear out first

Even chipped to 450+Nm it'll go and go and go....

JC

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