Help, trying to remove head 2.0 hdi

Discuss, ask, or get help with engine and mechanical queries in here.

Moderator: Moderators

Post Reply
dirtydirtydiesel
3.0 24v
Posts: 1308
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Help, trying to remove head 2.0 hdi

Post by dirtydirtydiesel » Sun May 27, 2018 4:26 pm

Hi all,
Anyone out there with service box account please advise me how to remove the plastic thermostat housing
that goes into the end of the head, the whole assembly.
I've unbolted it all but there's a metal coolant pipe
that comes out of the back & runs under the manifolds.
I don't want to break it :frown:
There are some pictures of it removed in a post by jamelxdt (The head is off......almost)
Which Welly kindly linked to my post about head gasket replacement,
You can clearly see it removed & the pipe still in place across the back of the block.
But I can't workout for the life of me how.

ps it's been a pig of a job up to now :(
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

dirtydirtydiesel
3.0 24v
Posts: 1308
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Help, trying to remove head 2.0 hdi

Post by dirtydirtydiesel » Sun May 27, 2018 7:14 pm

No problem guys it's off :)
20180527_182542.jpg
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

dirtydirtydiesel
3.0 24v
Posts: 1308
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Help, trying to remove head 2.0 hdi

Post by dirtydirtydiesel » Mon May 28, 2018 9:30 am

Sorry for the out of focus picture :oops:
Probably due to arm shake due to lifting off the head assembly complete with manifolds turbo ect.
Not ideal but it work's :?

I am convinced that the plastic thermostat housing that I referred to,
was broken off by jameslxdt in his post.

I decided to leave it in place & remove the studs from the end of the head, allowing me to remove it.
You can just about make it out in the photo.
As with the head off I still can't see how you can separate them.
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

dirtydirtydiesel
3.0 24v
Posts: 1308
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Help, trying to remove head 2.0 hdi

Post by dirtydirtydiesel » Fri Jan 11, 2019 2:04 am

Sorry for the late update but better late than never :wink:
So to catch you all up, I believe now that my 150bhp re-mapped tow car blew the head gasket back in 2014 on a very steep part of the A30 coming home fully laden with the caravan in tow :roll:
I had high oil temp , like triggered engine stop light bur not high water temp :?

So when we got home I fitted a 13 row Mocal oil cooler kit 8)
That sorted that I thought & ran it for a coupe more years like this.

Well summer hols 2017 & water temp started to play up ie: low level warning light
Checked & yes low so topped up & carried on.
Well this became a habit :(
By the November it was pushing it out the header tank cap :roll:
I nursed it through the winter until the warmer weather & undertook this job in the May,
You might remember that last March / April was horrible :frown:
20180527_182542.jpg
So first pic engine bay minus the head
20180527_182542.jpg
Head assembly complete on the bench, fresh off the car.
20180527_182610.jpg
Head back from work all skimmed, nice & flat now to clean & polish the valves then lap them in :roll:
20180626_184929.jpg
Valves done 8)
20180626_184950.jpg
Decided to fully clean up the ports & give it a flow job whilst it was off ( be rude not to, free power & economy :cheesy:
20180626_185035.jpg
Another pic of the ports from a different angle
20180626_185115.jpg
Top veiw of head / cam carrier
20180626_185136.jpg
New parts & boxed & tagged parts, hope I can put it all back together :supafrisk:
20180626_185157.jpg
20180626_185429.jpg
Next job, clean out the sludge from the inlet manifold & you guy's wonder why we get rid of E.G.R valves :roll:
Your engines eat their own sxxt & slowly die :(
20180626_185438.jpg
20180626_185528.jpg
Gasket matched for optimum flow :cheesy:
20180626_185615.jpg
Next up strip / inspect & rebuild turbo, done mainly due to location ( it's a pig to get at in the car) & due to the low cost
& amount of time & money I was investing in the car it seemed daft not to :wink:
20180626_190024.jpg
New turbo core from Direct turbo uk for £95.00 posted 8)
20180628_214514.jpg
Turbo fully rebuilt
20180628_214535.jpg
Also ported / flowed exhuast, turbo manifold........ why not :cheesy:
20180628_214450.jpg
Head being reassembled
20180705_191723.jpg
Knew this rust was there but not this bad :roll:
Thought I'd better sort it while access was good.
20180705_195452.jpg
Close up.
20180705_212544.jpg
Part way through clean up!
20180707_164357.jpg
Rust treatment on,
20180711_190955.jpg

All painted & good for years to come 8)

20180712_191109.jpg
Head back on :)
20180718_203916.jpg
Nearly done, lots of plumbing & stuff to remember :roll:

Lot's & lot's of other stuff done but no more photo's at the moment

But all's good now running great with no issue's, good for many more years happy motoring

More to come ........... :lol:
Attachments
20180705_205547.jpg
20180711_190955.jpg
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

dirtydirtydiesel
3.0 24v
Posts: 1308
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Help, trying to remove head 2.0 hdi

Post by dirtydirtydiesel » Fri Jan 11, 2019 2:09 am

Sorry for the three random picture, was getting tired doing this post :wink:
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

User avatar
steve_earwig
Moderator
Posts: 18992
Joined: Thu Oct 04, 2007 6:09 pm
Location: Jastrebarsko, Croatia http://www.jastrebarsko.hr/lokacija/

Re: Help, trying to remove head 2.0 hdi

Post by steve_earwig » Fri Jan 11, 2019 9:23 am

I wouldn't worry about it :wink: Just look at all them lovely pictures, that's the sort of mechanicking I used to enjoy. You don't see a lot of it these days, sadly gone are the days of buying a complete gasket set from a factors for little money, I think these days it would be cheaper to buy a complete car and swap the best bits over.
dirtydirtydiesel wrote:
Fri Jan 11, 2019 2:04 am
Head back from work all skimmed, nice & flat now to clean & polish the valves then lap them in :roll:
So, just the 8 valves? It could be worse...
Image
:shock:
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
1953 Matchless G3LS - It's alive!!

User avatar
Welly
The moderator formally known as Welton
Posts: 14647
Joined: Tue Jan 10, 2006 1:52 pm
Location: East Midlandfordshire

Re: Help, trying to remove head 2.0 hdi

Post by Welly » Fri Jan 11, 2019 9:40 am

Hat's off to you DDD that is brilliant work! thanks for sharing I'd love to be able to do that sort of thing without making a royal hash of it :frown:

Your improved gas flow should mean faster spooling and a crisp throttle response, I hope it made a difference and was worth while, have you fitted a new standard head gasket?
Cars in my care:

2005 Volvo S40 T5 a bit pampered
2010 Citroen C4 1.6 HDi turbo de' explosions
2010 Renner Twingo refreshingly simple

trufflehunt
3.0 24v
Posts: 508
Joined: Sat Aug 25, 2012 9:15 pm
Location: Axbridge, Somerset

Re: Help, trying to remove head 2.0 hdi

Post by trufflehunt » Fri Jan 11, 2019 10:36 am

Very nice work indeed.
2002 VW Golf 1.9 TDI (100 bhp)
1993 Mazda MX5 Mk1 1.6
2000 "W" HDI 110 Executive Saloon (Recycled).

User avatar
Doggy
Mod with a 2.2 HDi, De-Fapped!
Posts: 10069
Joined: Mon Oct 13, 2008 11:49 pm
Location: Northants

Re: Help, trying to remove head 2.0 hdi

Post by Doggy » Fri Jan 11, 2019 10:48 am

Brilliant post DDD and clearly a job well done, Hopefully a good investment for the future too.

C30SE head looks even longer than it really is in that pic Steve (according to my tee shirt) [/fond rose-tinted memories]
2003 HDi 2.2 6-speed Exec Estate

User avatar
Welly
The moderator formally known as Welton
Posts: 14647
Joined: Tue Jan 10, 2006 1:52 pm
Location: East Midlandfordshire

Re: Help, trying to remove head 2.0 hdi

Post by Welly » Fri Jan 11, 2019 12:14 pm

Doggy wrote:
Fri Jan 11, 2019 10:48 am
C30SE head looks even longer than it really is in that pic Steve (according to my tee shirt) [/fond rose-tinted memories]
Ohhh, that, right, I was looking at that wallpaper :shock: :lol: :lol:
Cars in my care:

2005 Volvo S40 T5 a bit pampered
2010 Citroen C4 1.6 HDi turbo de' explosions
2010 Renner Twingo refreshingly simple

PeterN
3.0 24v
Posts: 1442
Joined: Sun Mar 04, 2012 7:04 pm
Location: Charmouth, Dorset

Re: Help, trying to remove head 2.0 hdi

Post by PeterN » Fri Jan 11, 2019 1:12 pm

Haven't done that job for many years, last one was a 2.1 XM head must be over 10 years ago. I have just fitted a thermostat to a Merc 220 diesel, pig of a job, all the fuel lines had gone hard and I broke a connection and had to make up a new pipe.

Proper job that (as they say down here) I don't think I would be allowed to do mine indoors but its a lot warmer.

Peter

dirtydirtydiesel
3.0 24v
Posts: 1308
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Help, trying to remove head 2.0 hdi

Post by dirtydirtydiesel » Fri Jan 11, 2019 7:05 pm

steve_earwig wrote:
Fri Jan 11, 2019 9:23 am
I wouldn't worry about it :wink: Just look at all them lovely pictures, that's the sort of mechanicking I used to enjoy. You don't see a lot of it these days, sadly gone are the days of buying a complete gasket set from a factors for little money, I think these days it would be cheaper to buy a complete car and swap the best bits over.
dirtydirtydiesel wrote:
Fri Jan 11, 2019 2:04 am
Head back from work all skimmed, nice & flat now to clean & polish the valves then lap them in :roll:
So, just the 8 valves? It could be worse...
Image
:shock:
Thanks for the kind comments Steve,
It really was just down to economics, I've already done so much to the old girl & spent a fair bit too :roll:
I'd have been lucky to get £250.00 for her with the head gasket gone :(
& when she's running well she does all we ask of her :)
Cost me less than £400.00 to do it including doing the turbo & a new intercooler.

I bought her as a one owner car with 75k on the clock & I've looked after her & improved her quite a bit.

I must say I've been very impressed with the shed :cheesy:

Oh & as for the valves, I've got 48 more to do :shock:
See my Other post :lol:

Keep up the great work mate :)
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

dirtydirtydiesel
3.0 24v
Posts: 1308
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Help, trying to remove head 2.0 hdi

Post by dirtydirtydiesel » Fri Jan 11, 2019 7:10 pm

Welly wrote:
Fri Jan 11, 2019 9:40 am
Hat's off to you DDD that is brilliant work! thanks for sharing I'd love to be able to do that sort of thing without making a royal hash of it :frown:

Your improved gas flow should mean faster spooling and a crisp throttle response, I hope it made a difference and was worth while, have you fitted a new standard head gasket?

Thanks Welly,
Yeah it's a bit better all round, does go well for a Pug 2.0 hdi :wink:
Not sure it was worth the extra effort but only cost me about sixteen hours of my time,
When the total job was spread over about four weeks but I did do ALOT of things / jobs whilst in there :supafrisk:
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

dirtydirtydiesel
3.0 24v
Posts: 1308
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Help, trying to remove head 2.0 hdi

Post by dirtydirtydiesel » Fri Jan 11, 2019 7:11 pm

Thanks for all the kind comments :)
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

Post Reply