99 Tdi, Doesn't Overheat, Heaters Work Fine, But D

[Afndiesel]

Hi all, just got a 99 galaxy and all works well but I have noticed the expansion tank has a lot of pressure and the top rad hose is hard, should I be worried????, I've checked flow and the little pipe that goes to the top of the tank and they seem free flowing once cap is released. Any help would be greatfully appreciated

[GreenSharanTdi]

Hi, if you know a friendly MOT man get him to check for exhaust gasses coming from the expansion tank when running with the cap off, if you get a reading i'd say head gasket. Recently been through the same thing myself, tryed new cap etc but ended up being head gasket failure. Only other possibility is an air lock in the system which is possible if you've recently had coolant change etc. If it is an air lock, a quick drive with a loose fitted cap and the heater on full till it blows hot normally cures it. Best of luck!

[Afndiesel]

Thanks, I think your eight about the head gasket, I've tried everything, I even hear like a short farting noise when I turn the engine off even without the cap on but it stops before I can get under the bonnet,bloomin thing

[GreenSharanTdi]

Mine was an uneven flow out of the small return pipe, it'd kind of spit rather than a constant flow, also slight foaming in the expansion tank. All returned to normal after head gasket done

[Afndiesel]

Yes, sounds exactly the same,mines like it has rabies, I've loved the afn and ahu engines as my last four cars have had them and all done over 300k (passat was 340k used cooking oil and original clutch and exhaust) hence why I went for the galaxy, this one at 160k I classed as low milage, luckily I've got the head off my old alhambra so a few days swapping isn't going to cost me much as I can do it myself, I am just gutted.feels like an old friend has let me down

[GreenSharanTdi]

Yes it is frustrating when they let you down, but they're great when they're running! .I got my gaskets etc from darkside developments, all seemed top quality and they were very helpfull. Just make sure you make note of the holes or notches sticking out the front of the old head gasket to ensure you order the same thickness (you probably know that anyway). I didn't bother getting my head skimmed as it was completely flat still and it hasn't been an issue. If you do have to get it skimmed make sure you increase the thickness of gasket to replace what you have skimmed off. As I said, not trying to tell you how to suck eggs as you probably know more than me but it's a lot of work to have to do it again!!!

[Afndiesel]

I did worry about the head skimming but a company near me that specialises in it said unless it's overheated it would be ok,they measured it anyway for free.interestingly the head that came off the high miler was amazingly good,no cam wear, no bore wear and valves only took a couple of turns to grind back in. However the sludge in the inlets was horrific and easily halfing it's inlet capacity, the egr will definitely be blanked off when it goes back on.

[GreenSharanTdi]

Yep, I binned the EGR cooler and blanked the inlets etc off and joined the water pipes together, also cleaned the valve and blanked off the pipes to stop it working, didn't go the whole hog with a replacement pipe as was a bit strapped for cash but it made a difference.

[Afndiesel]

Well it's all done, love being able to do things myself but a ballache fitting it in around family and work. Took an age to pull diesel through and in the end we towed it in second gear. fine now but I'm paranoid and not used to the temp sitting at halfway. Seems noisier but haven't got any of the sound deadening in yet. I had better make sure the fans work now.