Yozza

I have recently taken the head off to fit a new head gasket. However, I had the head skimmed and had to strip out the injectors, cam, etc. The begger isn't starting after a day on the tools so is there any obvious places to start looking? The engine turns over but doesn't fire on any cylinders. Does the fuel need to be purged after standing for a couple of weeks? The other potential culprit is the fuel injectors, I'm not 100% confident that these are accurately aligned, Haynes specifies dimensions from a machined datum to +/-0.08mm. Despite the measurements in Haynes, the datum referenced isn't in line with the injector datum so it's not possible to measure using a calliper. Reference: Engine is a 1.9 tdi (115hp) Any pointers greatly appreciated :-) Yozza

Thanks for the replies and apologies for the lack of engine info. I have the locking tools and finally got the camshaft to lock at TDC, I was lacking in patience (again). I've built it all up now but she is resisting (a new post is on the way)....

Hi folks, I shouldn't have to ask this question but it's not abundantly clear in the manual. I'm putting the cylinder head back on and setting up the timing. There are two pairs of timing marks behind the camshaft hub, is it the pair with the narrow width that should be aligned with the 4Z mark? Should the camshaft timing tool (6mm diameter bar) go through the camshaft sprocket and hub into a locating hole in the cylinder head? If not, what is it's purpose? Thanks, Yozza

Ok thanks, In the last few days I've bitten the bullet as I caught the temp when it was high, lifted the bonnet to find the head gasket weaping - DOH! I've stripped the head off and water pump. The pump is the plastic impeller type which I'm confident is the root cause, the sympton being a very hot block and forcing the head gasket. I've checked the head with a straight edge and it looks good so I've got a gasket. Euro do 3 thickness's, I've got the thickest one as there was some confusion about the identification marks (holes) in the original gasket, it has 3 obrounds (slots) and 2 circular holes. The new gasket has only 3 circular holes, so I'm not sure if they are both the same thickness. Have I got anything to lose if I fit a slightly thicker gasket than the original if I'm not having any machining done?

I'm not sure when the overheating issue started (I've only had the motor a week) but I managed to get a print out from the Fraud garage for the service history, the service says: "over heating - suspect water pump" @ 117k miles "engine over heating" '@ 118k miles "coolant leak" @ 119k miles Looks like Fraud never got to the bottom of this issue, so I'll have to fix it (hopefully).

Hi seatkid, thanks for the reply! I'm confident the car hasn't had a tuning box in the past and it's not been remapped. The water pump was fitted by Frauds so it should be OEM. I'll try the thermostat first and see how that fairs. If is was something serious like head gasket or head, wouldn't I see this issue ever time I got the engine up to temp and 'loaded'? I did have a closer look inside the coolant top up tank and it was looking low on coolant (I recently topped it up) and some dark residue in there. Is it possible for the garage to test the gaskets integrity while it's steel on the vehicle?

Hello, this is my first post on this forum so apologies if this topic has already been covered. I recently bought a '02 Ghia Mk2 1.9tdi with 124k on the clock (with FFSH). It has a few issues (all of which I'm hoping are relatively minor). The most pressing issue is an occasional rapid rise in coolant temp, during all instances I have been on the motorway and well into my journey when the needle will rapidly rise up to the red marker, I reduce speed to 50mph and the temp will rapidly fall back to nominal (90 deg), it has occurred 3 times over the space of 400 miles. Coolant levels are ok. It had a new water pump not that long ago so it 'shouldn't' be the impeller spinning on the shaft issue which I've read about on here? I'm really hoping it's not the head gasket because it happens so infrequently. My thoughts are a dodgy stat or maybe an airlock being moved or sediment that temporarily obstructs the coolant flow? Can any of you Galaxy mentors suggest a possible root cause? Thanks, Yozza (Galaxy mentee)