C900 Head Gasket Replacement
From here on out it's just a matter of bolting everything back up.
When installing the intake manifold gasket, I have found that it is good to put just a little bit of sealant around the coolant passages.
It helps prevent coolant from leaking into the intake!
The turbo oil return tube can be a challenge to install.
I found that if you attach the tube to the turbo first it really makes life much easier.
Do not tighten the bolts that connect the turbo to the exhaust manifold. This allow you wiggle room to get the O-ring into the block.
Then you can use move the turbo to force the tube into the hole. You can also put some soapy water on the O-ring to help it go in.
When you start the car up for the first time look just let it sit and idle for a good 10-15 minutes and look for the following:Lots of white smoke coming out of the exhaust.
There could be some coolant in the exhaust, but you really should not see smoke much past a couple of minutes. If you do, then you need to start looking at things.
Make sure the car is not leaking any fluids.
Make sure the cooling fans activate and cool the engine down.
In most cases this is why the head gasket blew in the first place. Be sure you have fixed the actual problem!
Check the timing of the engine. It should be 16 degrees before TDC (18-20 for us performance folks!)
Additionally, I have found that both the intake manifold bolts and newly installed exhaust studs seem to loosen up after the first real heat cycle.
Be sure to double check all of those bolts after the first warm-up.
Although everyone says a headgasket doesn't need any break in time, I always allow the engine about 200 miles of regular driving to make sure things were sealed correctly before really opening up the boost.
It's been about 2 years now it is still holding up under 20+ psi of boost!