1990 1.6TD T25 COOLANT PROBLEMS

[jack7b]

Anyone that can help....
I think I'm on verge of solving this through work myself and WIKI. The story so far......
As I arrived in Devon for Easter coolant light starts flashing. On return journey after top weekend overheats in traffic and get towed home Coolant has backed up into filler tank and resevoir is nearly empty - no leaks anywhere. Cannot hear fan working either.
Get back and have a look at the thermostat - it fails to operate in boiling water. That explains fan not kicking in...I think. New thermostat fitted - I fill up resevoir to brim, run the engine and repeat process. No air is coming back into resevoir. Happy days I think so head off to Gower. 14 miles later light is on again and the needle is 3/4 towards overheating. Again the resevoir is low, no leaks and filler tank is full and venting through top.
The heater throughout the 14 mile is working then not etc.
Having read tthrough WIKI I reckon that I just haven't filled coolant back up properly and I haven't bled it at all properly!
Now have a half full reservoir, a 3/4 full filler tank - where should I start the bleed / filling process (not sure if I have over or under filled it).
Any advice greatly appreciated
Jack

[Red Westie]

I'm keeping my fingers crossed for you but this could end up being a head gasket (engine pressurising the cooling system) try and get it properly bled before considering that though.
Martin

[Bilbo Blue]

Had exact same with mine. Turned out to be a cracked head. Only way to find that out for sure is to wip the head off and get it pressure tested.

[ringo]

Had exactly the same with mine.

Turned out to be a dodgy gasket on the hose to head connector - i fail to remember the technical term for it.

Instant gasket sorted it though

Ringo

[jack7b]

Thanks for the replies.....the cap had gone on the resevoir as well (we pressure gauged it) and now after all that it seems the head gasket has gone - I just hope it's nothing worse like a cracked head. Hopefully will be able to get it done this week.

Thanks again for the help

Cheers
Jack

[jack7b]

Finally come round to the fact that the cylinder head gasket needs replacing....gutted as the more i read about it the more depressing it looks and the last thing i want is a van off the road for the summer!!!

Any top tips for this venture welcome

I'll keep you posted

[pocolow]

As a matter of interest what mileage has your van done?

[mrhutch]

I had exactly the same.. ended up changing EVERYTHING sensors, caps etc... before biting the bullet and admitting that the head gasket had gone. Put a 1.9 TD in it !

[oldiguana]

same symptoms here owduck n i hung on for nearly 2 years doin short journeys n keepin it topped up,mine was deffo head gasket but changed it myself and made all the timing tools to keep costs down due to bein flat broke n outta work....cost me less than £100...so not too bad really...

[jack7b]

As a matter of interest what mileage has your van done?

It's done about 135000 although when I bought it I was shown reciepts for recon engine at 100000 miles so in theory this one has done only 30K. I think the thermostat went first, then head gasket then cap when I drove for a little bit with the light flashing as my mate had done it and it "went for miles and then I just topped coolant up" - live and learn!!

On a plus - the head is off - 2.5 hours, cheers to my mate Chris. The gasket has gone so v satisfying to see that

The head is cracked though, across the ports on the 2 outside cylinders so big debate in my head now is "should I buy new head"?????

My brain is saying yes and do the whole thing properly then sit back and enjoy 1000's of miles of camping without any hassle - £420 new...........not too bad eh?????


Jack

[jack7b]

Should have said that the cracks are real small but cracks all the same

Anyone recomend a descent cylinder head specialist??

Cheers
Jack

[ringo]

I read somewhere that cracks are normal - but whether this is the same type of crack that you have i dont know. I think it was Harryman that mentioned this. Probably best ignore everything im saying....

I would consider changing the engine to an AAZ if your going to spend that sort of money. However, theres no telling that the AAZ engine wont need its gasket changing too...

Ringo

[oldiguana]

ah duck,when i took the head off marladys 1.9 diesel there were small cracks between vertually all the valves....spoke to quite a few guys n a few on here that said it should be ok...........n mine was fine...but im with ringo.....dunna take our word for it.....its just our take on an age owd teezer

[jack7b]

Thanks Ringo and oldiguana,

Took the plunge for a new head - there were cracks into all the precombustion chambers too and therefore couldn't have the head faced up.....I kind of wanted to replace the head anyway.

Just got to get the gubbins off old head and get it back on - Bit concerned about timing as I haven't got puka tools for it (FI Pump pin, one to hold camshaft drive - just got a bit of metal for the camshaft recess).......am I going to have an epic? We lined all the pum up when we took head off so in theory if we get engine back round to marks we put on then we should be in business.

Cheers
Jack

[oldiguana]

eyup duck,your gonna need a few tolls to do it right really,i made all mine as im as tight as a ducks a**e but couldnt have done it without them...but youll need to get the pump locked in position with the correct size pin,the one on the back of the cam needs to be smack on,some sort of tool for holding the cam sprocket when tightening the cam bolt and youll need a timing belt tensioning tool aswell.......