CRD Head Gasket - What's the Prognosis?

kafingerlos · **Posted:** Sat Jul 04, 2015 10:25 pm

Well, it's day two of the long weekend, and day two of the re-assembly project. New glow plugs, ARP studs, new head, Weeks Stage 1 and Stage two kits are installed. Also took the chance to replace lower and upper radiator hoses - after seeing where the lower is routed I figured I'd rather not be trying to that one later. At this point I think I've got it to what would effectively be the reassembly portion of a timing belt change. There is hope for tomorrow.

Head on the block -

ARP studs in the head -

Exhaust manifold back on, and Weeks Stage 2 Plug -

Turbo back and heat shield on the manifold -

Lower radiator hose was replaced, and then connected.

Thermostat reinstalled, and upper radiator hose connected (I do have a feeling I'm going to regret connecting this "early").

Put the rockers and lifters back together. The makeshift pin at the rear didn't work (conflict with the trans dipstick). The pin at the front had to move as well because it was too short to remove after the valve cover was in place.

Valve cover reinstalled - that one's a bugger. Thanks Geordi for the tip about making some alignment pins at home depot. Also used a couple pieces of 1" PVC pipe to keep it from dropping down on the rockers until I was ready.

Cleaned up the injectors and removed the o-rings and copper seals

Fuel rail back where it belongs

Fuel rail and injectors reinstalled -

Intake side of the Weeks Stage 1 and 2 kits installed -

CAC hoses and all of the heater hoses put back in place

So now its just inner timing cover, timing belt, pullies, tensioner, outer cover, serpentine, harmonic balancer, fan clutch, fan shroud, and coolant tank to go. Starting to feel like there is an end to the tunnel. The pile of "left-over" parts is also growing. All stuff that I know why it belongs there so far though.

kafingerlos · **Posted:** Sun Jul 05, 2015 11:16 pm

Well, day 3 of the reassembly project comes to a close. And it's good news - at least it starts, it runs, and it doesn't sound obviously broken.

Added the coolant tank

Attached the rear timing cover

Installed the cam pullies, idlers

Installed the timing belt

Clocked it forward two, and then two more rotations checking intake and exhaust pin alignment (if two is good, two more is better right?)

Installed the front timing cover

Then Installed the serpentine components, Installed the air box and battery tray, Filled up the radiator,

...and then I started it up. https://www.youtube.com/watch?v=FprkI1RQApU

One minor issue, I tore the airbox to turbo intake hose and forgot to order a replacement. That should be here next week.

racertracer · **Posted:** Mon Jul 06, 2015 6:38 am

Wow, great job.

olypopper · **Posted:** Mon Jul 06, 2015 8:45 pm

Well.........at least you didn't do what I did.........I forgot the two alignment dowels on my work bench and didn't notice until I had the timing belt cover mounted on the front of the engine last night!! Doh!!!!!! :furious:

Thanks for posting the pics though! It jogged my memory and at least the engine isn't in the vehicle yet.

kafingerlos · **Posted:** Thu Jul 30, 2015 10:34 am

1,000 miles in and running good - except that it blew a CAC hose last week; so it got new silicone hoses (thank you idparts.com). Also failed the boost control solenoid at the same time.

Hoping I can see another 4,000 miles without another CEL.

CRD Head Gasket - What's the Prognosis?

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