Hairline crack in engine block - t25

[dansk]

Hi,

So after having an ongoing heating issue with our lovely t25, and having spent a fair sum replacing a cracked head gasket, we've had the van in the garage again and they think there is a hairline crack somewhere in the engine block - it's building up pressure too quickly and leaking steam. Given our lack of ken in motor mechanics we could really do with a bit of guidance. We're told that its probably not possible, or worthwhile, finding and then fixing the crack and probably we need to buy a second hand or recon engine. They have warned us its a risk getting second hand engine, fifty-fifty it might turn out defective. Is it worth getting a second opinion? I do trust these guys, they are vw specialists and sound pretty cool, have helped us out on other things, but then again, in retrospect why they didn't advise changing the engine instead of paying more to change the head gasket, should they have spotted the pressure problem?

If we do go for a new engine, what do we need to look out for? Is there any chance we can recoup a bit selling off the old engine, with its new head gasket..? Looking for some bearings here to help us make the right choice.

[Oldiebut goodie]

I would have suspected a cracked head before a cracked block.
Brand new/reconditioned short engine is available @ £1500 here. http://www.ebay.co.uk/itm/VW-T25-1-6-TR ... 2c70a1f071 Parts will be required from your current engine.
Weigh this up against the costs involved in further testing/dismantling/rebuilding of the current engine.

Which is what I personally would go for if I didn't want to go for a cast off unknown secondhand engine/block and head.

Finding a hairline crack which opens up with the heat and pressure is not easy to do especially if your engine presented with the symptoms of a leaking head gasket - which they should, but not definitely, have been able to confirm by examining the old gasket.

[dansk]

When you say cracked head do you mean the head gasket? If they missed the problem when they fitted the new head gasket, can I have faith that further testing etc can fix the current engine?

We bought the van with a recon engine, which with the trouble its been, I'm having doubts it would be worth investing 1500 instead of taking a risk on something like this.. http://www.ebay.co.uk/itm/Volkswagen-T2 ... 0522934831" onclick="window.open(this.href);return false; - is that really that much more of a risk?

I came across vw engine place in deptord which is near me, http://www.thevwenginecompany.com/" onclick="window.open(this.href);return false; - could they be worth checking out? They have something called a turnkey service that sounds like it might be worth trying with current engine if its not too expensive..

[Oldiebut goodie]

Cracked head means the cylinder head not the gasket - the gasket provides the seal between the cylinder head and the main engine block and seals the waterways, oilways and the piston bores. Further testing may or may not reveal the problem which may or may not be repairable!

Reconditioned can mean different things to different reconditioners - the one that I linked to tells you exactly what is new,TRANSPORTER 1.6 TURBO REMANUFACTURED ENGINE. NEW HEAD, NEW GERMAN KS PISTONS, NEW BEARINGS, NEW OIL PUMP, TIMING BELT AND FITTING KIT. It is remanufactured rather than reconditioned and will be as good as a new engine.
Some say it is reconditioned but that may be with used but good parts.

If you want to go down the Tdi route as you can't do any of the work yourself you will have to find and pay someone who can do it. (There is no mention of these engines having been reconditioned or anything)

You haven't defined the original problems that you have had with the engine so I, or anyone else, cannot really begin to understand what your symptoms were and possible causes - stabbing mosquitoes with a needle in the dark comes to mind.

[dansk]

Those pesky mosquitoes so difficult to catch the buggers... Thanks for helping us understand a lot of this.

I didn't spot the tdi thing, not necessarily something we are after, just meant the link as example of cheaper second hand engines available. I get that we'll most likely get what we pay for.. Ŵe could have maybe afforded almost new engine a few months ago, but after spending out on repairs so far, I think we could manage a grand tops.

So what happened.. Without going into to much detail, we sprang a leak in Devon, and the RAC found that the cooling system was kaput. Took it to the garage and they identified cracked head gasket, which was replaced at expense. The garage tested the vehicle several times as I still thought it was running a bit hot but it always tested ok. Second some fuel injector pipes sheared off and we had them replaced. Then in France, long drive, hot weather and hills, the radiator tank ran dry without warning. We bled radiator as best as we knew how and limped back, engine power felt much reduced. the garage thinks its hairline crack and say the pressure builds up too quick and it leaks steam. The engine has also had a couple of small diesel leaks which were fixed.

We just want our camprvan working nicely again, doesn't have to be super turbo boosted.

[Oldiebut goodie]

Where is the steam leaking from - the gasket? If so the head has most probably warped due to the overheating. You haven't said if this was checked when the gasket was replaced. I personally would have checked it at the time and would expect a garage of repute to have done the same. To be fair to the RAC they are not too hot (pun intended) on the idiosyncrasies of these old vans and probably wouldn't know their way round the cooling system fully.
Injector pipes shearing off is usually because someone in the van's history has removed the antivibration clips off them.

To give you an idea as what changing to a 1.9 1Y (non-turbo) diesel would cost - I spent around £750 refurbishing and installing a 1Y in mine doing all the work myself, the hours spent actually doing the work would be worth around £750 I would guesstimate. So a total of around £1.5k +

If it is the head that has failed I may have one that you could have - I would have to take it off the block and have a look at it. As far as I know it is good. I would ask the garage whether they checked yours for warpage when they did the gasket.

I also have the block but it has a crankshaft from a non turbo CS engine in it and so it would need the crankshaft from your engine fitting and setting up, I also don't know how much wear there is on the bores and pistons - really I wouldn't advise you using it as you would have to rely on someone else rebuilding this part of it. So if your block has cracked there is one here but it would cost to bring it back up to reasonable specifications.

[dansk]

Wow, thanks for the offer. I am going to see the garage tomorrow morning and I will certainly ask them about the head and try and pin down exactly where and what they think is going wrong. The head gasket was only changed a couple of months ago.

Actually the RAC guy turned out to be a bit of vw nut - he certainly seemed to know the ins and outs of the vw system and taught us how to bled the radiator

Thanks!

[Oldiebut goodie]

Why aren't you in bed asleep?