Disco 1 200TDi exhaust blowing from back of head

GrantPT · Feb 6, 2019

Hi all
I appear to have an exhaust blow from the back of the cylinder head. I have held my hand around the exhaust manifold and can't feel any leaks there, but if I put my hand between the back of the head and the bulkhead from the opposite side of the engine to the exhaust manifold I can feel it blowing.
I'm hoping it's just the exhaust manifold gasket (although if it is I would have thought I'd feel the blow when I held my hand around the manifold), but is there anything else it could be? Any common 200TDi problems that would give these symptoms?
Thanks in advance.
Grant

Kev12 · Feb 6, 2019

Common for HG to chuff there

GrantPT · Feb 6, 2019

Kev12 said:
Common for HG to chuff there

HG as in head gasket I assume? If so, b*****ks. Not what I need right now! Any advice on further checks to confirm if it is the head gasket?

Kev12 · Feb 6, 2019

Yes head gasket, not a big or expensive job on these. You should be able to pinpoint the leak by feel. Its not even a particularly urgent job, oil and water doesn't mix when it blows here just keep checking the levels til you get it done

GrantPT · Feb 6, 2019

Kev12 said:
Yes head gasket, not a big or expensive job on these. You should be able to pinpoint the leak by feel. Its not even a particularly urgent job, oil and water doesn't mix when it blows here just keep checking the levels til you get it done

Ok thanks - that's something at least. I'll have a search around here on the forum for any posts saying how to replace the head gasket on these engines. Or is it pretty much the same as on a 300TDi? I don't know what the differences are between the 200Tdi and 300 Tdi to be honest.

Sestina · Feb 6, 2019

My 200tdi blew her HG just the same way.

Flossie · Feb 6, 2019

Sestina said:
My 200tdi blew her HG just the same way.

And mine. I wouldn't leave it too long as the gas leak will start to scar the head like mine did.

lynall · Feb 6, 2019

And mine, quite common, luckily piece of **** to replace.
Head bolts will go again
Elring gasket

GrantPT · Feb 6, 2019

lynall said:
And mine, quite common, luckily piece of **** to replace.
Head bolts will go again
Elring gasket

Gasket-wise, am I right in thinking there are more than one type of gasket, and I won't know which one I need until I get the old one out?

jamesmartin · Feb 6, 2019

GrantPT said:
Gasket-wise, am I right in thinking there are more than one type of gasket, and I won't know which one I need until I get the old one out?

if you look at the gasket between 3 and 4 injector theres a tab protruding count the holes 1,2 or 3

GrantPT · Feb 6, 2019

jamesmartin said:
if you look at the gasket between 3 and 4 injector theres a tab protruding count the holes 1,2 or 3

Brilliant - great info! Thanks!

lynall · Feb 6, 2019

New inlet/exhaust manifold gasket is a good idea as well.
Rocker cover gasket includingt he little half moon bits.
Dont drop/lose the valve lash caps.

GrantPT · Feb 6, 2019

lynall said:
New inlet/exhaust manifold gasket is a good idea as well.
Rocker cover gasket includingt he little half moon bits.
Dont drop/lose the valve lash caps.

Thanks. Been doing a bit of research and it looks like it's an easy enough job so I'm gonna do it myself I think. Any other tips will be most welcome!

sparepart · Feb 6, 2019

GrantPT said:
Thanks. Been doing a bit of research and it looks like it's an easy enough job so I'm gonna do it myself I think. Any other tips will be most welcome!

done this recently on a 300tdi pretty straight forward. Just take your time. the rear head bolt doesn't lift out with the head in situ on the discovery. Hold or use a rubber band to hold out the way while lifting the head.
re-assembly again take your time and ensure you tighten in sequence and correct torque. I brought an angle meter to help but can be done without,

mr glee · Feb 7, 2019

I would advise getting the head checked for warpage while it's off or you will be wasting your time and money.as sparepart says you don't have to use an angle meter as each flat on the bolts are 30 degrees.

lynall · Feb 7, 2019

mr glee said:
I would advise getting the head checked for warpage while it's off or you will be wasting your time and money.as sparepart says you don't have to use an angle meter as each flat on the bolts are 30 degrees.

I know Im a grade A bodger, but have never had any heads checked for flatness on any head gaskets I have done on a variety of cars and a good few 200 and 300.

Rip it off, clean it up, not polish it just clean it and chuck it back on, start digging and you will be there forever.

It was the same at work on the trucks, off clean and back on, mind you we always fitted all new core plugs, sadly I got to do loads as I was the only one who could do them in a shift, still paperwork was easy, R+R cylinder heads!

Flossie · Feb 7, 2019

Undo the block water drain bolt or you end up with water down the bores. Drain bolt is below the exhaust manifold on the block towards the front.
It's brass and rounds off easily and might have been already butchered.
If it doesn't want to come out then leave it, mop out the water from the bores and dry it all off then change the oil when the jobs done for peace of mind.
Make sure all the head bolt threads in the block are cleaned out , you don't want water left in them, compressed air is useful for that sort of thing.

GrantPT · Feb 7, 2019

jamesmartin said:
if you look at the gasket between 3 and 4 injector theres a tab protruding count the holes 1,2 or 3

It's got three notches, as per the photo. So that means I need a 1.5mm gasket? For example - https://www.paddockspares.com/err5263g-head-gasket-1-50mm-3-notch-tdi-elring-oe.html

jamesmartin · Feb 7, 2019

GrantPT said:
It's got three notches, as per the photo. So that means I need a 1.5mm gasket? For example - https://www.paddockspares.com/err5263g-head-gasket-1-50mm-3-notch-tdi-elring-oe.html

View attachment 169286

yes

GrantPT · Feb 7, 2019

jamesmartin said:
yes

Thanks. And apologies for the daft question, but it is 3 holes you can see on the photo? I only ask as the one on the left is half covered by the cylinder head...

Disco 1 200TDi exhaust blowing from back of head

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