Thread: Off it comes...D2 TD5 headgasket swap

One intersting thing I found when I removed the fan shroud, was when i removed one of the factory self tapping screws that holds the shroud in place. Coolant started coming out of the hole where the screw goes in. Now does this mean, I need a new radiator, or do I just have to make sure it seals properly on refitting? It just seams odd, that coolant would escape from a screw hole that is just meant to hold a piece of plastic in place.

Doesnt sound good, I suppose you could put it back that way with some sealant but its very bodgey. Maybe a plastic welder could help before replacing the radiator.

Good to hear its back on the road.
When you took the head off, did you remove the injectors as well?
I am having a bit of trouble removing mine, as they have been in there for a while. LR uses a special tool to remove them, so I might have to quickly fabricate something simlar. I just don't want to damage the head while trying to remove them.

I used the leg off my bearing puller to gently prise out the injectors.They dont require any force. Just make sure you remove the pedestals and use something with smooth or rounded edges so you dont gouge the head. One of the pics in here shows an allen key being used.

Mine went back together just as easy as it came apart and it is sooo much smoother and my other surging issue since the upgrade chip has almost dissappeared as well.

2nd the socket choice. These suckers will work you into sweat and a cheapy socket wont cut it for the reassembly.

Cheers.

Well after a very busy two weeks I was finally able to keep working on my D2. Got the injectors
and valves out and will go in for machining tomorow.

After a bit of a trail and error I got the injectors out using an old screw driver bent to 90 degrees:



Here are a few pics on removing the valves:
Firstly, I made this little pedastal job and used a G-clamp to gently compress the springs and remove the "retainers" on the stems:



Then placed the g-clamp in place, with the other end pressed against the valve head (I did place a little cloth in between, to avoid metal to metal contact, I am paranoid about damaging the head)


Here is the spring compressed:



Now using a pen magnet, I gently removed the retainers, made the job very easy I have to say.


Removing spring


The valve can then be removed from underside of the head. Then by using my trusty bent screwdriver, the valve stem seals were removed.


This is the cylinder 5 inlet valve, it had the most carbon/egr gunk on it.


The valves and seats still looks really good, but will get a valve grind done, and with new seals it should be good as new





Will do the other "while I'm here jobs" tomorow, like intercooler clean etc.

Hi Hendrik, I was wondering how it was all going.

Nice work on the valve spring jig!

Good to see it's all happening for you.
I left my valves in and the shop receced them after surface grinding to original hight from face.

What did you decide to do with the radiator?

Cheers, Kyle.

Well the head is at the machinging place now, and picking it up again tomorow, then reassembly can begin.
Did a bit more work today, removed the radiator and intercooler. And also pulled out the CV and axle as the oil seal was leaking and I also discovered that the CV gaitor is stuffed.

Dan (The_Fish) came to give me a hand today and we decided to pull the intercooler out of his tdi too and give them both a clean at the same time. We just filled them with diesel so hopefully that will do the job. Mine was pretty clean, which was a bit of a suprise.





Bit of a contrast between the tdi and Td5 intercoolers.





I will probably just flush the radiator for now and see how badly it leaks from that screw hole, then look at maybe replacing it or getting it plastic welded.

Well seeing as the radiator/intercooler job only took about an hour, we decided to pull the CV and axle out as the o-ring was leaking badly. I did find a lot of gunk in there, which is a worry coz the cv gaitor is split, which means it could easily have got into the CV. The gaitor will have to be replaced obviously, but the lower balljoints are also stuffed so a fair bit of work to do on the front axle.







Reassembly will happen soon, will update then.
I really do hate the way it looks now, can't wait to get it back together.

Originally Posted by Hendrik

Well after a very busy two weeks I was finally able to keep working on my D2. Got the injectors
and valves out and will go in for machining tomorow.

After a bit of a trail and error I got the injectors out using an old screw driver bent to 90 degrees:

Here are a few pics on removing the valves:
Firstly, I made this little pedastal job and used a G-clamp to gently compress the springs and remove the "retainers" on the stems:

Then placed the g-clamp in place, with the other end pressed against the valve head (I did place a little cloth in between, to avoid metal to metal contact, I am paranoid about damaging the head)

Here is the spring compressed:

Now using a pen magnet, I gently removed the retainers, made the job very easy I have to say.

Removing spring

The valve can then be removed from underside of the head. Then by using my trusty bent screwdriver, the valve stem seals were removed.

This is the cylinder 5 inlet valve, it had the most carbon/egr gunk on it.

The valves and seats still looks really good, but will get a valve grind done, and with new seals it should be good as new

Will do the other "while I'm here jobs" tomorow, like intercooler clean etc.

Good that you show us how to get the injectors and valves out.

But is there a tool to do the job?
I dont think I can make the tool like you did.

Coming on well Hendrik. Nice work.

Rgds
Pete

The machining of the head is taking a little longer than expected, will get it back monday and ordered the steel dowels in too. In the mean time I have removed the worn steering knuckle balljoints on the front axle, I have not heard of anyone who has done this themselves before...so I will be putting up a little how to thread up on it soon.

Strangy and Pete, did you get the injectors professionally cleaned before you put them back, or did you just refit them as is?