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Just a quick update on this. Test drive went okay, blew intercooler hose off but nothing catastrophic. Got a bit tappy when warmed up and wouldn't start when hot. Redid clearances and it was even worse, was missing and sounded like ****e. Inspected pushrods and, somehow, 4 were now bent. May...

It's been blowing out the head gasket by the bulkhead for about 3 years but still perfectly driveable so decided winter was a good time to undertake the work. Assumed the head might be scarred from the exhaust blow so go a replacement to "save time". I started the job late November so time...

After my catalogue of mistakes, I wouldn't have been surprised! 😀

Thanks for the advice, can't feel my fingers or toes after being out in the cold for an hour but it started up and sounds pretty sweet. Really appreciate it! Clearances were all far too tight so must have been holding valves open. We should have done the leak down test with the rocker shaft on...

I'll give that a try then, thank you very much for the advice. I didn't think it would make that much difference initially so didn't bother with that step :)

Didn't touch the timing so hopefully that's still okay, unless it jumped a tooth when I tried starting it with coolant in the cylinders but not sure how likely that is on these engines. We didn't do valve clearances yet, it is a different head so that is definitely worth a try. I assumed it...

Morning all. Replaced HG on my 200 TDI recently and put a 2nd hand head on (looks in decent nick, cleaned up valves and fitted new stem seals). I did balls it up and put gasket top-down initially (it was dark, that's my excuse..). Tried starting, sounded like low/no compression as turn over was...