Changing The Headgasket On A 205 Turbo

[Tandoh 17]

Right well Im looking at doing this for a friend but just want to get some more research from you guys over here!

Its pretty much just has the 2.0 turbo lump fitted and the head gasket has now gone.

I believe that you have to drop the engine out a bit to get the exhaust manifold off the head. Is this correct and is there any way of doing it without dropping the engine out?

Also does anyone know the torque settings for the head, or a link to an online Haynes manual lol

 

Cheers guys

[m_attt 31 1 Cars]

i just done this job about 2 weeks ago, and what a PITA it is.

 

there didnt seam anyway to get the turbo out with the engine it situe, we undid the mounts and used a pry bar to pull the engine forward still not enough room.

 

so best way is to remove the turbo/mani and just let it drop and leave it there.

 

head settings will more than likely come with the head gasket on a piece of paper with the pattern of bolts there aswell.

 

i did an new turbo at same time, and rested it down the back then refitted the head, then lifted the turbo back. its not easy or plesant but doable.

[Tandoh 17]

So did you leave the engine in the mounts, and just unbolt the manifold at the turbo or do that with the engine dropped out abit? Did you use a standard head gasket? Cheers

[m_attt 31 1 Cars]

undid the rear mount, and took the square rubbers out of the top mount on drivers wing, this alowed the engine to be moved forward by putting a bar in the gap were the rubber mounts sit and pulling against the mount, that allowed enough room to unbolt the exhaust mani with turbo complete and drop it down.

 

i had my head skimmed and used a slighty thicker standard head gasket, did have a metal cometic one but it looked far to thick so never bothered with it.

 

EDIT: undid exhaust mani bolts with engine sat normal, with a ratchet spanner from the top.

Edited May 11, 2010 by m_attt

[m_attt 31 1 Cars]

[jonnyturbo 3]

one problem that hits most people is when you come to time it back up, look at the crank pulley to see if it has slipped.

[m_attt 31 1 Cars]

one problem that hits most people is when you come to time it back up, look at the crank pulley to see if it has slipped.

 

 

best way is to put a mark at 12 and 2 on the cambelt and top pulley, and two marks at the bottom on belt and block, then when you get new cambelt hold them together and mark the new one, that way you dont need locking pins and if bottom pully slips its dead easy just have to line the marks up.

[jonnyturbo 3]

can also use the 1.9 gti crank pulley iirc? to time the engine.

[Daviewonder 533 3 Cars]

can also use the 1.9 gti crank pulley iirc? to time the engine.

 

Yeah you can, I did this on my engine

[crackass999 0]

hi there,ive just replaced the headgasket and wasnt too bad. i managed to get the head off with exhaust manifold and turbo intakt but it was tight against the servo.

I got the engine back together last night,it fired up more or less straight away but it runs like a bag of spanners,no power , very lumpy and very slow to rev,it sounds alot like a scooby. I have done the usual checks,spark plugs,ht leads etc. I have done an extensive search when i came across this thread and i am wondering now if i have the cambelt fitted wrong?? I didnt personally do this part but i know he used two bolts,one to lock the the cam pulley and the other for the crank. is it possible the cam is out by a couple of teeth?

Thanks,matt.

[Daviewonder 533 3 Cars]

These engine suffer with the outer section of the crank pulley coming unbonded from the inner section and slipping round so the timing hole is no longer in the correct place. I would either buy a new pulley or use a 205 gti one to time up the engine.

[jonnyturbo 3]

one problem that hits most people is when you come to time it back up, look at the crank pulley to see if it has slipped.

 

 

check ^^

[crackass999 0]

one problem that hits most people is when you come to time it back up, look at the crank pulley to see if it has slipped.

 

had a look at the crank pulley to see if it has slipped but didnt really know what to look for. Are there any marks to look for or is it a case of fitting a 1.9gti pulley?Thanks.

 

http://i744.photobucket.com/albums/xx85/cr...ld/IMG_0420.jpg

[crackass999 0]

is this what i'm looking for?A solid pulley?

 

http://i744.photobucket.com/albums/xx85/cr...uild/pulley.jpg

 

or have i got it all wrong?