Disco 200 25td Head Removel

The Haynes manual worked pretty well for me. Also Turner engineering have a very nice resource off their site too.

Steve

On or around Wed, 8 Dec 2004 23:28:36 -0000, "Office" enlightened us thusly:

Haynes isn't bad. I do actually have a real genuine workshop manual, but it's a sod to use.

HBOL *is* of no use when swapping/repairing an autobox however - after taking you through dismantling most of the interior and vehicle,draining the coolant etc, they then say "take it to a specialist!" - we read it before we did it properly and had a good laugh :-)

Fools :-)

Do a google on " 300tdi overhaul manual pdf "

YES! I know its the manual for the 300 and you're working on a 200 BUT in general terms the 300 is a refined version of the 200 so most of the info there should be fairly relevant together with the HBOL.

IIRC when I did my head (300) the combination of the two did prove useful - the LR manual mostly assumes you've done it before and have already stripped everything away from the head you need to and haynes give you all the info on stripping the stuff away! ;-)

Another handy hint is to print out a circle with degrees marked on it for when you are torquing the head back down - 1st do all the bolts up to xNm then tighten by x degrees (twice) Bottle of tippex to mark the head bolts that you've tightened so you dont lose your place. Take the bonnet off to make getting into it easier. Have a piece of card ready and a marker pen to hold the push rods and number them so you know where to put them back. Have a roll of pvc tape to tape the valve caps in order to the cardboard as well. In fact, label/mark everything as it comes off so you know exactly where to put it back! The rocker cover bolt at the back of the engine is a bugger to get out but it will eventually ;-)

Also... get a new set of head bolts - the existing ones can be re-used upto 5 times (so I believe) however after this the threads can be stretched too much. For the sake of 15-20 quid it's worth doing. Especially if you don't know the full history of the car and whether or not the head's been off before.

I know on the 300 there are different thicknesses of head gasket denoted by up to three small holes punched into the gasket between the last and last but one injector (at the back of the engine bay) - this should be visible with everything intact.

You'll also want a new rocker cover gasket.

Be careful when refitting the bolts that clamp the injectors in too - you'll know why when you look at the refitting pics ;-)

Some pictures of the removal here

Try ebay for cd-rom technical manuals - less than aud$20