Bleeding or Gasket problems?

[Snowmark]

Fitted replacement engine (2.1DJ on Carb). Having problems with the cooling system that I think are water jacket seal problems but second opinions most welcome.....

Bled the new system and drove 20miles - the expansion tank was overflowing through the drain holes and the header tank was half empty.
Have since tried bleeding again then driven 20 or 30 miles at a time. Every time I get back the expansion tank is above Max and the header tank has drop by a third.

When revs are applied I get large air bubbles from the top pipe on the expansion tank (the one that runs down from the bleed rail) - I suspect that the water jacket seal in the Drivers side head has gone and is sucking air in under load- is this possible?

Or, is it just a totally vague hope that there was air still in the system and it’s just kicking it out when under revs (long shot, I know).

It has a new SA rad from BWs, dalek cap and thermostat changed. Temp gauge is rock solid where it should be.....but then I haven’t driven more than 30miles with making sure header is full.
Thanks for any help or sympathetic words


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[Aidan]

system should self bleed the remaining air locks in 30 miles up and down hill really so you may have a 'gasket' issue and products of combustion in the coolant, a sniff test will confirm

[Snowmark]

Took it for a sniff test earlier in the week - no combustion gases registered.
Is it possible that it’s drawing air in through the water jacket seal?


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[shepster]

Is it possible that it’s drawing air in through the water jacket seal?


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Surely if it could draw air in then water would be coming out?

[Snowmark]

There is a very small leak - seems to get significantly worse when revs applied


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[itchyfeet]

Mark

if I remember you did the sniff test 2 days after it was driven and there was some question if the gasses would stay that long or if it was warm enough when tested, perhaps you should drive it to a garage and have another done.

http://forum.club8090.co.uk/viewtopic.php?f=37&t=168379" onclick="window.open(this.href);return false;

[itchyfeet]

There is a very small leak - seems to get significantly worse when revs applied


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why would a leak make the top up tank level increase significantly, I'm sure you said before it was overflowing?

[ajsimmo]

That's classic compression seal leaking symptoms. A see through bleed rail can help identify which side.

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[Snowmark]

Paul - the air/Gas is being fed directly into header tank from the bleed rail, you can see large bubbles emerging from the top pipe in the header tank. This is then forcing the expanded coolant out of the header into the refill tank, hence the level rises.

As the sniff test was inconclusive I assumed that it was drawing air in from somewhere - you’re probably right, I should get another one done. As I mentioned, I didn’t have a huge amount of confidence in the garage which did the first one.

Anyway, most of this seems to be inconsequential- the conclusion, whatever the cause, will be that I need to drop the engine out, replace with my old DG then rebuild it once life allows. I’d love it it this wasn’t the case but everyone’s replies are pointing to this course of action


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[Snowmark]

That's classic compression seal leaking symptoms. A see through bleed rail can help identify which side.

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Does it make any difference which side it is or would you just strip both heads and replace all seals and gaskets?


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[itchyfeet]

Deffo do both sides.

[ajsimmo]

If you're taking it out to rebuild it, you've already decided to do both sides. You only do one side in situ if it's a "fix it as quickly and cheaply as possible" job."

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[Snowmark]

Might as well do the job properly - then, at least, next year I’ll have a van I’m confident in. Just means the respray may have to wait until the following winter.

That’s assuming the heads come off ok.....


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