TD5 Discovery II HGF (Head Gasket Failure)

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dirtylillandy

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Salisbury
After the last limp mode break down, it was time to face up to the truth, the inevitable H.G. failure. Well what else would you expect from an engine that has plastic locating dowels :confused:.

Diagnosing the HGF fault on my TD5 was not so obvious as the usual creaming in the oil as a tell tale sign is apparently quite rare on the TD5's.

I even got a chemical test done to make sure it was the HG which returned a negative result! :confused:

So I did what any sane person should do and search Landyzone for the various advices for checking a HGF and sure enough a popular check is to fill up the coolant bottle to the top, run the engine for a little while and wait for the tiny little bubbles to appear. Sure enough they did on mine.

Other indications can be loss of coolant, stiffness of the cooling pipes and a loss of interior heat from the heating matrix.

If you dont want a large garage bill, sell it for spares now! or if you are up for the challenge, DIY! I'm by no means a mechanic but I do like to tinker, so I decided to do the work myself (I like a good challenge).

I'm lucky enough to have a friend whom has an envious large man shed with extras like a ramp and storage for long term tinkering :rolleyes:.

The TD5 Haynes Manual was a Christmas present (she can obviously read me like a book, no pun intended :D), a sure sign that the misuses didn’t want the bill either. However it proved to be an invaluable resource for a few things that I needed to reference.

Festivities now firmly out of the way, a week ago I decided (between shifts) to just get on with it :eek:.

First I searched the Landyzone forums for tips and short cuts but did not find a decent post on Landyzone however I did on the LRO forum which some Australian has done for a TD5 defender.

Eventually I got the head off and found one of the plastic locating dowels had completely shared in two. Suprisingly there was only a tiny movement but enough to cause problems.

I had the head pressure tested (and would recommend anyone DIYing to do the same) as well as getting it checked to see if it was warped. Luckily mine wasn't cracked but it was slightly warped.

After being machined I sort advice from the specialist regarding HG replacement and opted to increase the thickness from a two hole .500mm to a three hole .650mm which is easily identified on a tab on the HG.

As soon as I've done putting mine back together I might add my two cents in a sort of helpful guide.

I'll keep you posted
 
If they recut the valve seats after skimming you can use the same size gasket as the one that came off. If not then fit the thicker gasket but make sure you know how much they skimmed off the face. So long as its not more than 0.150mm (calculated from your gasket thicknesses above) you should be OK. Using a gasket that is too thin can lead to interference problems between valve and piston.

As always turn the engine over by hand before cranking it on the starter. That way if something is wrong you wont cause any damage.

I still cant get used to this metric nonsense - whats wrong with Imperial thousandths of an inch ? ;)
 
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Thanks for the advice Shifty and Sorry Tony, no I didn't find it, so thanks for the link. Incidently it was 007 thou of an inch that was removed and the valves were not re-seated.
 
Ok. 7 thou = 0.177 millimeter so I would definitely go for the thicker gasket as the valve heads will protrude the extra 0.177mm than what they did before skimming. The difference in compression is minimal with the thicker gasket and not worth worrying about. You wont notice any difference in performance.
 
Ok. 7 thou = 0.177 millimeter so I would definitely go for the thicker gasket as the valve heads will protrude the extra 0.177mm than what they did before skimming. The difference in compression is minimal with the thicker gasket and not worth worrying about. You wont notice any difference in performance.
Just a thought,
The haynes workshop manual recommends you do not have the head skimmed/machined in any way.:confused:
 
HG just been diagnosed on my TD5, losing water when hot from the back near the manifold (app a common fault)? I cannot sort this myself so its a trip to Adventure 4x4 and £700 less in my back pocket. booked in for the 29th so steady driving until then.
 
I got all my parts off Lee at Adventure 4x4 when I did my HG apart from the HG kit itself which I got from Turner Engineering.

It's a good set up that place and I always use him to do the jobs I can't easily do on my drive

T
 
I got all my parts off Lee at Adventure 4x4 when I did my HG apart from the HG kit itself which I got from Turner Engineering.

It's a good set up that place and I always use him to do the jobs I can't easily do on my drive

T

I am thinking of attempting this myself soon...just wondering where you guys send your heads to be pressure tested?? I am based in northampton and my need a bit of advice as I go about this.:eek:
 
Noticed for a while that there was exhaust gas leaking from the back of the engine, assumed it was manifold. Head gasket / cylinder failed ( still waiting to find which)
When I was visiting the garage to see if they had started, was able to get look at monifold and it's looks fine, certainly no reason for the exhaust gas to be coming from the back of the engine. Could this exhaust exhaust gas been sign that the head gasket had / was going?
 
On the current theme, I have just suffered the same HGF, also caused over pressure in cooling and punched a hole through the radiator, (not in the best of nic anyway!) Have been recovered to where I am temporarily working, but 100 miles from home. Fortunately have a fairly comprehensive tool kit with me but no haynes manual. So far this pm I have stripped out the radiator and hoses and stripped all gubbins off round the head. Tomorrows job is to lift the head but need some guidance before I do that. Have rocker cover, injector harness and injector rocker shaft off. Next thing is to take off the valve cam timing chain pulley. Any advice on do's and dont do's before I take this next step? Have done this many years ago on a td5 disco but a bit rusty! :confused:
PS checked the head gasket and it is a three hole one. Does this tell me anything significant or do I just change like for like?
 
On the current theme, I have just suffered the same HGF, also caused over pressure in cooling and punched a hole through the radiator, (not in the best of nic anyway!) Have been recovered to where I am temporarily working, but 100 miles from home. Fortunately have a fairly comprehensive tool kit with me but no haynes manual. So far this pm I have stripped out the radiator and hoses and stripped all gubbins off round the head. Tomorrows job is to lift the head but need some guidance before I do that. Have rocker cover, injector harness and injector rocker shaft off. Next thing is to take off the valve cam timing chain pulley. Any advice on do's and dont do's before I take this next step? Have done this many years ago on a td5 disco but a bit rusty! :confused:
PS checked the head gasket and it is a three hole one. Does this tell me anything significant or do I just change like for like?

where abouts are you btw?
 
Presently located North Berwick!

your just over an hour away from me.

i'm away from fri morn until tuesday.

but if you get stuck tomorrow, give me a pm and i can make my way over at some point.. could bring some bits and bobs and make a cup of tea ;)
 
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