406oc.co.uk

2002 406, DW10, HDi 90.

ok so the head went a few days ago, something I have been expecting for a while as the header has been pressurised for a long time now.

I have removed just about everything necessary to isolate the head, but I am really struggling with the turbo and / or the bits attached to the exhaust / inlet manifolds. The Haynes is a little sparse here, I suspect due to the fact they used a DW12 which has subtle differences? For instance it shows them removing the air inlet pipe to the turbo, no chance with the DW10 that I can see!

Anyway they also suggest removing the turbo mounts via approximately 4 screws. Looking from below I can see only one, and then a bracket. Hard to see anything tbh!!!

I have undone a few pipes, the flexible section of the exhaust and other bits that are going to be nearly impossible to put back on reassenbly, so there cannot be much more to remove. The lack of room makes the head on my Zetec Escort seem like childs play!

I am so close to getting the head off now, I have rocked it and where there is a small gap between head and engine block, I can prize the head very gently (I know this should not be done but I really was gentle and it is not actually between mating surfaces, it is outside the gasket on a corner as said with a gap...

Oh yes the two mount bolts are out...

Was so hoping to get it to a machine shop today!

So damn close yet so far :-(

Anyone give me some tips please?

Alright so I think I have found the bolts that attach turbo to manifold, however they are rusted solid and hard enough to get too!

So I am wondering has anyone else managed to remove the head with the turbo still attached? It would make like a whole lot easier however the Heynes Manual would suggest this is not possible, even though it does not state that!

removed the head with everything attached in the end. I think I will remove the turbo to exhaust elbow as this proved to be rather awekward!