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Well you bought the car entering the mileage where the headgakets start to give out. Plus a turbocharged motor puts more stress and strain on the HG to begin with.
Your just going through the teething issues with your car so don't give up yet. I haven't done a HG job myself yet but the process is fairly straight foward.
1. Make sure no fuel pressure is left in the fuel lines
2. Jack up car
3. Remove belt
4. Unbolt power steering pump and set aside (don't have to disconnect the hoses)
5. Drain oil and coolant
6. Unbolt downpipe
7. Unbolt water and oil lines for turbo
8. Remove intake plumbing and intercooler hose off the compressor
9. Remove DI so as to gain access to screw on PCV pipe
10. Remove exhaust manifold and turbo as one unit (good time to switch to a td04 now, you'd have to pick up two M12x1.5 banjo's and 1/2 crush washers)
11. Remove delivery pipe to throttle body
12. Disconnect fuel lines from fuel rail
13. Disconnect throttle cable for both accelerator pedal and cruise control
14. Dissconnect and label all ecu harness plugs from injectors, sensors, IAC (some like IAT (from removing charge pipe) will have already been done)
15. Disconnect any vacuum lines from throttle body and label them.
16. Unbolt intake manifold and remove (It has a stay bar for support underneath running to the block
17. Unbolt valve cover
18. Remove chain tensioner
19. Remove chain from cam gears
20. Unbolt cam caps and remove cams with cam gears attached (don't forget which is intake and exhaust
21. Unbolt head bolts (special reverse socket can't remember)
22. Remove all coolant hoses still attached to head
23. With help of a friend remove the head and then remove old gasket and clean up the deck
24. Do everything you can to assure that the deck is flat and smooth, repair any pitting as necessary
25. Send head to machine shop for same detail as well as some cleaning up
Reinstall.
Is the same as all before in reverse. Make sure you have new head bolts and then rotate engine to TDC and make sure your timing marks on cam's all line up.
posted by 199.8.17...
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