Help, trying to remove head 2.0 hdi

[dirtydirtydiesel]

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
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

[dirtydirtydiesel]

No problem guys it's off

[dirtydirtydiesel]

Sorry for the out of focus picture
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.

[dirtydirtydiesel]

Sorry for the late update but better late than never
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
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
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
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

So first pic engine bay minus the head

Head assembly complete on the bench, fresh off the car.

Head back from work all skimmed, nice & flat now to clean & polish the valves then lap them in

Valves done

Decided to fully clean up the ports & give it a flow job whilst it was off ( be rude not to, free power & economy

Another pic of the ports from a different angle

Top veiw of head / cam carrier

New parts & boxed & tagged parts, hope I can put it all back together

Next job, clean out the sludge from the inlet manifold & you guy's wonder why we get rid of E.G.R valves
Your engines eat their own sxxt & slowly die

Gasket matched for optimum flow

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

New turbo core from Direct turbo uk for £95.00 posted

Turbo fully rebuilt

Also ported / flowed exhuast, turbo manifold........ why not

Head being reassembled

Knew this rust was there but not this bad
Thought I'd better sort it while access was good.

Close up.

Part way through clean up!

Rust treatment on,

All painted & good for years to come

Head back on

Nearly done, lots of plumbing & stuff to remember

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 ...........

[dirtydirtydiesel]

Sorry for the three random picture, was getting tired doing this post

[steve_earwig]

I wouldn't worry about it 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.

Head back from work all skimmed, nice & flat now to clean & polish the valves then lap them in

So, just the 8 valves? It could be worse...

[Welly]

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

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?

[trufflehunt]

Very nice work indeed.

[Doggy]

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]

[Welly]

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

[PeterN]

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]

I wouldn't worry about it 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.

Head back from work all skimmed, nice & flat now to clean & polish the valves then lap them in

So, just the 8 valves? It could be worse...

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
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

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

Keep up the great work mate

[dirtydirtydiesel]

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

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
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

[dirtydirtydiesel]

Thanks for all the kind comments