Tdi Auy Engine Overheating Adventures .....

[AndyBWales]

Starting having problems with my TDi a few weeks back .... overheating (you will have heard this many time before!) ... intially water loss ... then lots of steam / pressure etc etc ....

 

But ... Ill start with the good news .... Ive fixed it! .... eventually!

 

However after reading many of the posts on here, and finding alot of them very useful I thought it was worth putting something back, and hopefully adding a few helpful hints along the way.

 

So .... overheating .... :huh:

 

changed the water pump .... still overheats :(

changed the thermostat ... still overheats :angry:

found a small leak in the hose from the EGR to the auxilliary water pump so fixed that ... still over heats :D

changed the expansion tank cap .... still over heats ..... :(

tried bleeding uphill / downhill / over the hill etc .... still over heats .... :blink:

 

So ... the big one ... the head gasket .... off comes the head ... new gasket .... new bolts .... cleaned the EGR and turbo while they were off .... goes back together .... starts first time (phew) .... no overheating! .... just pulled the caravan to Dorset and back ..... still no overheating. :D

 

So ... full of self satisfaction .... and happy that the neighbours wont have to wonder why 'that car' is on axle stands again ... a few helpful pointers along the way :

 

1 - Get a proper hose clamp tool .... ~

Edited June 1, 2009 by AndyBWales

[seatkid]

Well done Andy, top marks! :angry:

 

Did you inspect the head gasket to see where the leak was?

Why do you think it happenned? Abuse or tuning/remap?

How many miles has it done?

 

Thanks for taking the time to post your result with useful tips for others may go down the same road!

[gregers]

WELL DONE THAT MAN :angry: :blink:

 

i have pm nik to see if he wants to add this to the faqs.

[roy202]

Starting having problems with my TDi a few weeks back .... overheating (you will have heard this many time before!) ... intially water loss ... then lots of steam / pressure etc etc ....

 

But ... Ill start with the good news .... Ive fixed it! .... eventually!

 

However after reading many of the posts on here, and finding alot of them very useful I thought it was worth putting something back, and hopefully adding a few helpful hints along the way.

 

So .... overheating .... :huh:

 

changed the water pump .... still overheats :(

changed the thermostat ... still overheats :angry:

found a small leak in the hose from the EGR to the auxilliary water pump so fixed that ... still over heats :blink:

changed the expansion tank cap .... still over heats ..... :D

tried bleeding uphill / downhill / over the hill etc .... still over heats .... :(

 

So ... the big one ... the head gasket .... off comes the head ... new gasket .... new bolts .... cleaned the EGR and turbo while they were off .... goes back together .... starts first time (phew) .... no overheating! .... just pulled the caravan to Dorset and back ..... still no overheating. :D

 

So ... full of self satisfaction .... and happy that the neighbours wont have to wonder why 'that car' is on axle stands again ... a few helpful pointers along the way :

 

1 - Get a proper hose clamp tool .... ~

[AndyBWales]

Well done Andy, top marks! :angry:

 

Did you inspect the head gasket to see where the leak was?

Why do you think it happenned? Abuse or tuning/remap?

How many miles has it done?

 

Thanks for taking the time to post your result with useful tips for others may go down the same road!

 

 

Had a good look at the head gasket, the cylinder block and the cyclinder head to try and see what was going on, not helped by a coating of oil coming down through the head bolt holes, but think I could make out evidence of leakage between the edge of the cylinder and the water ways on number 4 cylinder at least.

 

Car has done 125k, not remapped / tuned .... and other than the usual ... not abused ... maybe it was just time for it to go?

[AndyBWales]

Andy

so did you get the head pressure tested or just take the chance it wasnt, im pretty sure thats why it recomends to take the pulley off?

 

Didnt get the head tested ... actually seemed in pretty good condition ... very light pitting in a couple of places ... but Ive seen alot worse on other engines .... so just took a chance and put it all back together.

 

Im sure if you need to strip the head you will need to remove the pulley.

[NikpV]

Thread added to FAQ :angry: