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C900 HEAD GASKET Replacement

This DIY section was created because of a shortage of money and a need to get my SPG back on the road. After paying $1000 for my mechanic to put the head on the car 2 months ago, I wasn't ready to do it again.

Since, I had just replaced the intake manifold with the yellow one, I knew at least 50% of the job was doable. Last year I replaced the cams on the car, so that was another 10% I knew how to do. Last year I also replaced the turbo, so that was another 10% of experience.
Basically, the only part I had never done before was removing the head. I figured there was no better time than the present.

First things first. Get a couple of boxes that are about the size of a case of beer. If you're like me you'll have a couple of empty beer boxes ready to be put to work!

You will also need the Bentley repair book and 1 special tool.

The Bentley book should be right next to you so you can refer to it for anything I may have missed or wasn't clear about. The special tool you need is an E-16 torx socket. I got the set of torx sockets from Sears for about $20. I don't think they are the highest quality and they are only 3/8" drive, but they work. I would strongly recommend you find a 1/2" drive E-16 Torx socket before beginning this task.

Eeuroparts sells a nice headgasket kit that contains almost everything you need. I do not think it includes the turbo oil gaskets or the turbo oil return o-ring. These are good to replace as they tend to leak after being messed with.

NOTE: For those that have a 2.1 head and intake manifold on the car, you will need a 2.1 intake manifold gasket. You will still use a 2.0 head gasket.

There are a bunch of other things you can do as preventative maitenance. This includes, belts, waterpump, alternator bushings, timing chain tensioner, etc...

Another area to lookout for is rusted and broken exhaust and turbo studs. These get very brittle with age.

Snap-on carries some very handy tools for removing broken studs.
The first is cobolt reverse thread drill bits. These allow you to drill out the stud in reverse which sometimes pulls out the stud along the way.
They also carry a super fancy stud removal tool. It basically latches on to the stud and you unscrew the stud using the tool.
These tools are not cheap, but they work very well. I have both in my toolbox.

No matter what, I highly recommend you pull out all of the studs in the head and replace them with new ones. I bought some very expensive ones from www.summitracing. Basically, you need a M8 x 1.25 thread by 45mm (1.75") long. The ARP part # is ARP-400-8013 and retails for about $72.

End result

Let's Begin!

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