How hard to replace blown head gasket in 1989 200 TQ? Is it DIY in home garage?
 

I have oportunity to buy one with blown gasket for ~ $500. Is it worth it to fix it or part it?

I just did mine about 2 weeks ago..
 

we did it in the garage to a cost of about $400

hardest part is breaking the crank bolt loose to change the timing belt. I have pics I can post or email.

Is there writeup for it - I couldn't find by searching...

I didnt do one but can..
 

this is written for people with general automotive repair knowledge.

Disconnect the battery, drain the coolant, and oil.

remove the grille, front bumper, intercooler, headlights, and core support.

disconnect the downpipe from the cat

remove the cruise unit, vacuum lines (3 on the back of the manifold)and throttle brackets from the intake.

disconnect the breather tubes to the crankcase and the airbox from the valve cover

remove the air shroud and hose, disconnect the upper radiator hose and temp sensor wires

remove the v belts from the ac, power steering and alt.

remove the timing cover and power steering pump (no need to disconnect the lines, just remove the mounts and lay it back)

disconnect the cold start injector wiring, the o2 sensor wiring, and the throttle switch wires

remove the fuel lines from the fuel distributor (mark them for ease of reinstallation) disconnect the warm up regulator lines from the regulator and lay them over the fender.

remove the distributor cap and wires (leave the wires on the cap so reinstall is easier) disconnect the hall sensor wires

remove the air pipes from the turbo (in and out)

remove the alternator from its mounts hang it from the frame with a coathanger or disconnect the wires (i prefer to hang it, less chance of wire damage)

remove the water and oil lines from the turbo (2 each) WARNING! the bolts holding these on are usually very rusty allen bolts and are very hard to get out!

remove the crank pully (the large bolt in the center -- Note this bolt is VERY hard to get off, an impact is usually required or a big breaker bar

remove the lower timing cover

loosen the water pump and remove the timing belt

remove the valve cover noting where the grounds and brackets are located

break the head bolts loose starting from the center and working out - ( this requires a special socket )

remove the headbolts and check for any other wires, hoses etc you may have missed

GET A FRIEND TO HELP YOU!!!

pick the head and manifild assembly up THIS IS VERY HEAVY DO NOT ATTEMP THIS ALONE. if you drop the unit you will damage the head and/or the block! tip the front of the unit up as you pick it up, the down pipe will clear the axle and the whole thing will pick right out.

remove the old gasket and clean up the surfaces checking for damage to the head and block, also take the time to inspect for cracks, burned valves etc

assembly is reverse be sure to align all the timing marks when you reinstall the timing belt.
<img src="http://pictureposter.audiworld.com/71349/p2260002.jpg">
<img src="http://pictureposter.audiworld.com/71349/p2250001.jpg">
<img src="http://pictureposter.audiworld.com/71349/p2260005.jpg">

that doesnt look like it was fun, why not paint the valve cover while it's off

Re: that doesnt look like it was fun, why not paint the valve cover while it's off
 

I'm going to build up the other motor i have, so I just wanted to get this together and running. I had to have it for work the next day so time was important. the other engine will look nice.

You can crack that crank bolt with a socket/breaker bar using the starter.
 

Yeah it sounds bad but it does work. Got a Bentley? It's all in there.

Thank you...

How long would it take for the person who never done it before?

took us about 8 hours.. so plan on a weekend