by Replacing the 1.5 DV5 diesel head gasket is one of the biggest repairs you can carry out on the Vauxhall Vivaro, Citroën Dispatch, Peugeot Expert, and Toyota Proace. If your van is overheating, losing coolant, or producing white smoke, a failed head gasket may be the cause.
In this guide, I’ll walk you through the complete process shown in the YouTube video, explain the tools you’ll need, highlight common mistakes, and share professional tips to help you complete the repair successfully. The DV5 engine uses torque-to-yield head bolts and a strict tightening sequence, so accuracy matters as much as mechanical skill.
Watch the full tutorial
Video Title: How To Replace 1.5 DV5 Head Gasket (Vivaro, Dispatch, Expert, Proace)
This article expands on the video with written instructions, extra tips, and troubleshooting advice.
Vehicles covered
This tutorial applies to the PSA/Stellantis 1.5 BlueHDi DV5 diesel engine commonly found in:
- Vauxhall Vivaro
- Citroën Dispatch
- Peugeot Expert
- Toyota Proace
If your van has the 1.5 BlueHDi / DV5 engine, the overall procedure is very similar across all four models.
Signs of a blown head gasket
Before stripping the engine, make sure the head gasket is actually faulty. The most common symptoms include:
Engine overheating
Temperature rises quickly or the cooling system pressurizes.
White smoke from the exhaust
Coolant entering the combustion chamber often produces persistent white smoke.
Coolant loss with no visible leak
A disappearing coolant level is a classic warning sign.
Milky engine oil
Oil contaminated with coolant may look creamy under the filler cap.
Loss of power or poor compression
The van may struggle under load or become difficult to start.
If you’re experiencing two or more of these symptoms, it’s worth carrying out a pressure or compression test before dismantling the engine.
Tools & parts you’ll need
Having everything ready before you start saves hours of frustration.
| Tools | Parts |
|---|---|
| Torque wrench | Head gasket set |
| Angle torque gauge | New head bolts |
| Timing locking kit | Valve cover gasket |
| Socket & Torx set | Intake & exhaust gaskets |
| Breaker bar | Fresh coolant |
| Engine support (if needed) | Engine oil & filter |
| Straight edge | Brake cleaner |
Important: Always replace the cylinder head bolts. They are torque-to-yield bolts and should not be reused.
Step-by-step DV5 head gasket replacement
1. Drain fluids
Start with a completely cold engine.
- Disconnect the battery.
- Drain the coolant.
- Drain the engine oil.
- Remove the oil filter.
This prevents contamination during disassembly.
2. Remove the top-end components
You’ll need to remove everything blocking access to the cylinder head.
That includes:
- Air intake system
- Fuel pipes
- Wiring harness
- Injector connections
- Turbo pipework
- Rocker cover
Take photos as you go—they’re invaluable during reassembly.
3. Lock the engine timing
The DV5 engine must be locked at Top Dead Centre (TDC) before removing the timing components.
Use the correct locking pins for:
- Crankshaft
- Camshaft
- Timing system
Incorrect timing is one of the biggest causes of engine damage after repair.
4. Remove the cylinder head
Loosen the head bolts in the reverse tightening sequence to prevent warping.
Carefully lift the cylinder head away from the engine block and remove the old gasket. Manufacturers emphasize following the specified bolt sequence during both removal and installation.
5. Inspect the head
This is the stage many DIY mechanics skip.
Check for:
- Cracks
- Warping
- Valve damage
- Erosion around coolant passages
Use a precision straight edge to measure flatness. If it’s outside specification, the head should be skimmed by an engineering shop before refitting.
6. Clean the mating surfaces
The sealing surfaces must be perfectly clean.
Do not:
- Use abrasive grinding discs
- Scratch the aluminium head
- Leave old gasket residue
A plastic scraper and brake cleaner work best.
7. Install the new gasket
Place the new gasket onto the locating dowels in the correct orientation.
Never apply sealant unless the manufacturer specifically requires it. Modern MLS head gaskets are designed to be installed dry.
8. Torque the cylinder head
This is the most critical step.
- Install new head bolts.
- Tighten in the specified sequence.
- Use both torque and angle tightening.
- Never guess the settings.
Refer to the official workshop specification for your exact engine code.
9. Reassemble & refill
Reinstall:
- Timing components
- Cam cover
- Fuel system
- Intake & exhaust
- Cooling system
Then refill with fresh oil and coolant before bleeding the cooling system.
Common mistakes to avoid
Reusing old head bolts
They stretch during installation and may not clamp correctly a second time.
Skipping the flatness check
Even a slight warp can cause another gasket failure within weeks.
Incorrect timing
Always use the proper locking tools before removing the timing system.
Dirty mating surfaces
Any residue can prevent the new gasket from sealing properly.
Not bleeding the cooling system
Air locks can cause immediate overheating after the repair.
How long does the repair take?
| Experience | Estimated time |
|---|---|
| Professional mechanic | 6–10 hours |
| Experienced DIY | 8–12 hours |
| First-time DIY | Full weekend |
The DV5 is a compact engine, so patience and organization are more important than speed.
FAQs
Can I replace a DV5 head gasket without removing the engine?
Yes. On the Vivaro, Dispatch, Expert, and Proace, the head gasket can generally be replaced with the engine in the vehicle, although access is tight.
Should I skim the cylinder head?
Only if measurements show it’s warped or damaged. Always check flatness before reassembly.
Do I need new head bolts?
Yes. The DV5 uses torque-to-yield bolts, so replacing them is considered essential for a reliable repair.
What causes the 1.5 DV5 head gasket to fail?
The most common causes include overheating, coolant loss, cooling system faults, and prolonged driving with elevated engine temperatures.
Final thoughts
Replacing the 1.5 DV5 head gasket is a challenging but rewarding repair when done correctly. By following the correct timing procedure, checking the cylinder head carefully, and tightening the bolts to specification, you can restore reliability to your Vivaro, Dispatch, Expert, or Proace without replacing the engine.
If this written guide helped, be sure to watch the full YouTube tutorial for the complete visual walkthrough.
