Trying to ID cause of cooling system issue 1.9DG

[ride_east]

Hi All,

Fitted a re-con engine from VW Engine Co. a bit over 2 years ago to my Holdsworth Villa III 1.9DG, but I've now got pressure & gas build up in coolant (when cold). So likely blowing exhaust past the upper seal rings. The van drvies ok, until I have to stop and bleed the rad after half an hour, so this issue needs fixing. I listed the van for sale a couple of weeks back (on this site), as I'm trying to finish doing a full time degree, which is leaving me skint and with no time to work on it. But it's not had much interest and then my son found out... "Dad, you can't sell the van!" So upshot is he's persuaded me I absolutely MUST take the engine out and fix it myself.

So... I can drop the engine out, and reckon I'll send it to VW Engine Co. to pressure test & analyse where the exhaust blowing from and rebuild top end, BUT... It's had a head issue before (coolant from rubber gasket) - 18 months after the new engine was fitted) I think there's an underlying cooling problem. I've replaced the cooling system bit-by-bit - new rad, steel pipes, thermostat, thermostat housing, temp sensor (since broken), lower temp (Golf) fan thermoswitch, etc and flushed the coolant system twice (and did my best to check for blockages), the rad fan kicks in fine. But I think (guesswork) it's overheated on the nearside head and that's cause the leaks both time. Once I've got the engine back in, is there anyone I can take it to in the Bristol area who could look over it with me and test the system? I'd be glad to pay someone local to Bristol to give me a hand with this but can't afford big garage bills at the minute, so won't be taking it to one of the two Bristol Specialists.

I've had it 8 years and put an LPG system on 7 years ago - it ran fine on LPG for many years but I mostly run on petrol now as it's hard to get LPG locally. I did wonder if the LPG vaporiser unit which draws heat from the n/s head coolant pipe could be causing an issue, or whether I could have a failing water pump (but can't see how this could be the problem if it warms up quick, runs ok and fan kicks in and out on cue).

Any suggestions for causes or local help to either put the engine back in or to check over my work (or even to help me top-end rebuild rather than send to VWEC), gratefully received. As I said, happy to pay for your time. Either post back or drop me line on 0770 409 0183)
Cheers,
Ben

1987 T25 Holdsworth Villa III 1.9DG

[Aidan]

VW engine shop are about as much use as a chocolate fire guard, imho

Send your engine to Andrew at Campershack if you want it done properly, won't be the cheapest but likely the best result

Other people's experiences may be different but your backstory tells you they don't do the job properly and they are not an honest company

Also after you've spoken to Andrew talk to little Mick if possible at Elite VW, Mick does honestly know his onions (he doesn't actually do the rebuilds - big Mick's son does) and I'd much rather trust Elite on build and Warranty than VW Engine shop, The engine shop or VW Heritage's engine rebuilder; I've had 3 wbx rebuilds from Elite and they were all still running around 10-15 years later - I know times have changed but a proper conversation about what you have, what you want and what you can afford should get you a decent result ime

[R0B]

Like others, I had a terrible experience with the VW engine company. As Aidan says, Andrew at Campershack would be your best bet.

[ride_east]

Thanks for the advice Rob and Aidan, sounds like I need to get in touch with Campershack and take it from there. Will see what they say. Cheers for your help. Ben

[ajsimmo]

Did I see the Batlight in the sky?

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[Oldiebut goodie]

Holy Cow Batman!

[ride_east]

Yes the bat light is on! Just been on the Campershack website and it's down due to relocation. Weather allowing, I'm gonna drop the engine out on Saturday. My number is 0770 409 0183, any chance you could give me a call/text.

Cheers,

Ben

[R0B]

Give Andrew (campershack) a ring 07813324365

[ride_east]

Just spoke to Andrew at Campershack. Really helpful. Managed to download the Bentley Manual on his advice and going to have a crack at a top end rebuild. He mentioned a video about a machining issue that was causing a problem with new heads fitted to WBXs (a lip that impedes a good seal with the fire rings and needs to be machined out) but I can't find a link to it. Anyone know where to find this video - I want to rule this out as the cause of the problem.

Thanks all for your advice and help with this.

Ben

[ajsimmo]

https://www.facebook.com/share/p/15UYVW38VG/

Or ifyou can't open it, a direct link to the first video
https://youtu.be/_7tjOX0UZwg?si=YxsG_jN2G9Cupd_4

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[300CE]

As others have said, Andrew at Campershack is a top chap and know's his stuff.  Does sound like failing fire rings as i had the same problem and did a top end rebuild in 2018 and she's still going strong (touches wood!) - i've attached a thread that i put up back then which might help, however, there are also other members that have done the same job recently (maxstu being another):

viewtopic.php?t=163364

 

[Siegfried]

Hi.
Had the same issue with the VW Engine Company. First engine lasted 4.5K miles - low pressure on two cylinders, second one 7.2k - intermittent overheating, third engine lasted 2K miles shattered valve adjusters.  Had third engine rebuilt independently - Thousands out of pocket....

[DoubleOSeven]

That header lip is outrageous!

https://www.youtube.com/watch?v=bTPT6cP97m0

AMC heads - no thanks.

 

[ajsimmo]

That header lip is outrageous!

https://www.youtube.com/watch?v=bTPT6cP97m0

AMC heads - no thanks.

 

They've sorted it on the new stock. The last 6 from Brickwerks have been fine.

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