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[Abiton]

Thanks deviator, I missed this helpful reply.

I have got new genuine everything, except tensioner which I'm going to gamble on, and water pump which was done 2 years ago.

It's not a V6, it's a humble 2.0, so a bit easier, and only one HG. 

I was correct in my diagnosis at least - took the head into work on Friday and had a guy (cheers Mike!) at the next-door Porsche garage have a look/measure; and he confirmed that coolant had got into pot 4, but the head was fine to stick back on with no skim. 

Head's back on now, 'just' got cams to go back in, (new) timing belt to go on and then all the stuff I've had to disconnect/remove to replace.

Any words of wisdom w.r.t. cam belt would be much appreciated just now (one of tomorrow's scariest tasks).  Haynes confuses me a tad, I have to be honest.  Guess I'll just keep tweaking it 'til it seems spot-on after the obligatory 2 smooth turns of the crank.

Wish me luck please folks. 

[Abiton]

Well it's done, and it's all looking good. 

Gasket was amazingly intact, with just a small area of the fire-ring on pot 4 showing the passage of coolant past it from the big central channel at the rear of the engine.

The engine's now running better than it ever has during our 3 years of ownership. 

Advice to fellow 4-pot owners:  If you're losing coolant and you can't find where it's going, do yourself a favour before the heater matrix and radiator give up; get it checked for 'zorst fumes in the coolant, or simply shine a torch down the spark plug holes looking for wetness that ain't oil. 

Parts guy at Vx reckoned I'd've paid £800 and upward if they'd done this job, so thanks to TB and the forum generally for giving me the confidence to have a go myself. 

[NaughtyNigel]

That's great news. I hope it keeps running well for you. We had a new head gasket fitted to our Astra a year or two ago, and it has run fine ever since. (Cost £450 at a local indy).

I am still trying to psyche myself up to tackle the head gasket on my 2.5 V6. 

I know I can do it, and I know it will be worth it, but its a lot of work to do without proper facilities.  :-/

NN