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Kristianskaffe's MK7, 2.4 TDCI, RWD

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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Mon May 08, 2017 9:49 pm

Hello boys..

Back again after two weeks of working flat out.
I haven´t had time to work with the wires, but a very very nice gentleman wrote, that he had a present for me. And what do you know.... some days ago I recieved new wires for my turbo along with a description and a little tool for the wires to get me going. I can´t thank him enough :)

On the downside, on thursday I was between jobs and was at a parking lot pulling out into traffic. I noticed white smoke coming from the back, but as I had driven 50 km. I figured, that it couldn´t be me.. driving along the van was dodgy and somewhat weaker that normal... I did not notice anything and after 5 min. I had a stop for about 20 min. (planned)
Van started sort of ok, but cut off. Started again and I drove off.. 2 min. after that I lost power (no torgue) and could not find out why. No warnings, no sounds, no nothing... but suddenly I noticed that the temp. gauge was off the chart!! Turn it off right away and I realised I had no coolant fluid what so ever! I really dont know why because I didn´t noticed any leaks after I found that last one some weeks ago...I had 2,5 liters with me and that only covered the bottom :/ Found 0.5 liters of water in the car and drove slowly to the nearest gas station, only 1 km. from there. Filled it up with water and everthing was fine again? I have driven 400 km. since and no sign of it losing fluid... strange...

After that I experienced something I thought I had fixed... I have some sort of hiss when the turbo kicks in. It´s quite loud. Last time I found that the steel bands/clamps that hold the tubes from the turbo and on to the intercooler was not tight. I could turn them 8-10 times and I figured the leaks was coming from somewhere there. Acutally it stopped but after this high temperature it´s back again. I have checked all the connections and I really pulled and pushed and can´t seem to find anything. I have found no holes or anything in the tubes.
I have, on the other hand, found something that looks like sod in one of the corners on the intercooler. It could look like a leak, when exhaust is coming out, making the sod to stick there... I´m thinking about covering both cornes with Gaffa tape to see if they act the same way. If there is a leak, my guess is, that it will blow off the tape or at least loosen it... Any other suggestions? The sound is not there when just driving along, but loud and easy to hear when the turbo and torque kicks in.

Oh and yes, I also have that uneven idle thing mentioned in another thread...
Have a nice evening...
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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Wed May 10, 2017 3:07 pm

Oh my... Now I had the bad start/white smoke again.
Driving around town, stopped for 1 hour and wouldn't start properly.
Managed to get it going and now it runs again but I had very much white smoke and other cars waving and signalling...
Topped up the coolant.. And now back to normal...

https://youtu.be/Z5e3cH1-SlE

Head gasket?

No wiring done yet. My daughters confirmation is friday, so I'm pretty tied up..

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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Thu May 11, 2017 2:56 pm

Anyone has a clue on why this is on/off?

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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Mon May 15, 2017 9:40 pm

So now it seems that the van is going from max coolant to the minimum mark in about 50 km. of easy driving on the motorway :/
I get a friend over tomorrow helping me with the wires, so hopefully I can get the wires changed for the turbo and all...
Also found completely new intercooler for 20 pounds, so "had to order that" ... as it hisses like mad when accelerating.... yes yes I know.. don´t buy anything before asking... but I think the intercooler is bad, as I have searched all tubes for faults, holes and what have you and found nothing....

We will se how this goes...

oh yeah... my mechanic says, that if he needs to refurb the cylinder head, I´ll be looking at 500-600 pounds... how does that sound to you..? AND since we maybe are going there, is there something I really should be doing at the same time? I hope its not that :(
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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby loot » Mon May 15, 2017 9:48 pm

You are having intermittent running problems with turbo fault code possibly wiring so try and work with that, the heads are very reliable on these so don't waste 500-600.

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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Airthies » Mon May 15, 2017 9:54 pm

Best thing is to get a pressure tester for coolant system if you can and see if you can find your leak.
Are you sure coolant is going through engine as some leaks will only show when hot and under pressure. And have known coolant to evaporate rather than leak into the ground, depending on where it's conning from.

But as loot says concentrate on one thing at a time. Try to sort your turbo issue then move on to the next.
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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Mon May 15, 2017 10:02 pm

Airthies wrote:Best thing is to get a pressure tester for coolant system if you can and see if you can find your leak.
Are you sure coolant is going through engine as some leaks will only show when hot and under pressure. And have known coolant to evaporate rather than leak into the ground, depending on where it's conning from.

But as loot says concentrate on one thing at a time. Try to sort your turbo issue then move on to the next.


yes, def. starting with the turbo as the wires are shouting at me to get fitted :D Hopefully it´s done tomorrow, and then I´ll see how it goes.. The intercooler takes some days to arrive anyway
Sure hope I can find out which to pull out and which to put in... but once I get started I hope it will be easier that it looks :)

Thank you very much :)
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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Fri May 19, 2017 7:26 am

Hi boys...

More white smoke...

Sorry to day, that I have not been able to fit the wires yet... the good part, is that it´s because of lots of work, happy customers and more to do :D
But the next week is proving to be one, where it goes down.

But this weekend, it´s time for my youngest daughter and her class to go on a father/son-daugter trip to a shelter in the woods.. As I´m driving all the stuff, food and luggage I wanted to be sure that the coolant was ok. I had been driving along all day, small trips and one longer. No sign of anything.
The van had been standing for 3 hours, so it should be cooled off (come back to that)

So i took the lid of the container and gave it a splash of water. It was between min. and max, so no worries. Started the van and it sounded ok. I drive about 1000 m. and then I saw the temperature been already almost 90 degrees. I thought that was quite fast, but then again it was warm. Looked out of the rear and saw lots of white smoke... I did not go above 1500 rpm and had been driving like a 90 year old.
Pulled in and stopped the van. Took the lid of to see if I could see a change in level or anything. Tried to start it and it cut off. Couldn´t start it for 2 or 3 times...
Took of the lid and then it started and I could se the coolant was very..hmm.. what to say... "in motion" .. like looking at a geyser... with no springs though :D
Lots of smoke still, but no bad noises, no nothing.
Had the lid off for 2 min. and put it back on... and then it stopped again... looks like I have the same amount off coolant as before...

Can you try to help me with this... For one the temperature... can I have air in my system, that needs to be bleeded... and could it be worth a complete change of coolant. My previous van I did that, and the coolant was nasty... here it looks ok and red, but with a milky look to it.
If I have air in the system, that still does not explain the white smoke... and I not saying it is because of the coolant, but what else could it be. It has been something with the coolant everytime... and why does it come and go, and what could be causing it... it´s very very odd... as the van drove fine this time..

If you still say "get the wires done", well then ok, but honestly... then wouldn´t I have had that problem before?

Have a great day!!

Kristian
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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Airthies » Fri May 19, 2017 9:59 am

Doesnt sound good.
I would sort this issue first but on the boost side I'd of left the intercooler till turbo electrical fault before ordering an intercooler
It does sound like you're getting coolant transfer somewhere.
Is your egr water cooled? I know you we're talking of fitting a new one but even new stuff can be faulty... try bypassing that if it is water cooled and see if that makes a difference.
From my limited knowledge on these I understood they were fairly reliable this way but not impossible it's a head gasket or crack somewhere.
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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Fri May 19, 2017 10:05 am

Yeah yeah yeah... Intercooler is received so :D

Egr is replaced already some time ago, so should not be that.. And it is on/off and both when hot and cold.. Dont know if it is water-cooled... I'll bring the Haynes in the tent tonight :D

Darn it.. It is really annoying. Worst part is that I'm starting to doubt the van and I really need it to be stable...

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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Sat May 20, 2017 11:22 am

OK boys.. I need help here..

Van had not run for 16 hours, fired it up and it started sort of ok. I had a feeling, that the coolant needed to be checked.
I got white smoke for 10 seconds and then it was gone. Looked at the temp. gauge and driving in the woods (shelter-trip with my youngest daughter this time) in 2. gear, not doing over 15 kph. the temp. rose to 90 in 1200 meter. Stopped it, and the coolant was very low.. But after taking the lid of, it "exploded" back to being right between min. and max. I put in a some drops to get it to max and drove home, about 10 km. and it drove really well. No smoke, no nothing and 80's mix tape on the stereo ;)

Came home, unpacked and wanted to see how things were, before parking it at the parking lot... Hmm and then it was very low again.

I took the lid of again and this time the coolant didn't "come back"

https://youtu.be/eYQWuZjuBx0

Now... 2 times before I experienced that after filling up the coolant it would not start.. And guess what..

https://youtu.be/0py2OlDQE4o

Then, like the last time and after trying 4-5 times.. I take the lid of (done that in the video) and it starts right up..
The coolant is bubbling away (is that supposed to do that?) and after putting the lid back on everything seemed fine.. Until I started it again...

https://youtu.be/j5m14S8eTH0

This time I couldn't get it to stop, and I live in a place with 50 small houses and almost only people being 130 years of age, I not that much alone when I smokes like that... Meaning 20 sec. after I have 4 pensioners around me looking and so on... So I stopped..

Now.. What the heck is wrong with this van...

The excessive white smoke must be coolant.... Doesn't it? If then... Head gasket or could it be a leak some where else causing this.. But why is it not consistent...

Any tips and tricks for troubleshooting will be greatly appreciated. I do have a tools for testing for the head gasket. Can't remember the name for it, but it's that thing you put on the coolant container, measuring if any exhaust goes that way... Done that long time ago and it came out fine.. Now could have changed... It's at my mechanic, so either go to him or buy a new one for testing..
Or what to do?

Please..

Have a great weekend!

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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Sat May 20, 2017 11:42 am

On a danish forum I've found someone stating that bubbles in the coolant, together with white smoke should be a clear sign of problems with the head gasket. They mention that it could use coolant too and get warm.. Not all fault have to be present.. So.. It sounds like it.. :(

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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Sat May 20, 2017 2:39 pm

Just tried to start it again... Coolant is still at max... No smoke what so ever..

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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Sat May 20, 2017 4:51 pm

My bad... Drive 100 m. and it was smoking again...
And stopped completely after 1000 m... the smoke that is
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Re: Kristianskaffe's MK7, 2.4 TDCI, RWD

Postby Kristianskaffe » Mon May 22, 2017 10:25 pm

So today I drove to my mechanic after driving around with white smoke on/off, filling up the coolant every 100 km.
The leak test showed CO2 in the coolant almost instantly :(

My mec. said that he has tested several times for it at the very beginning because the seller told me that it did use some coolant... but it never did until now, and the tests back then showed nothing. He would have taken out the whole engine to refurb. it, if it was so.

So now it looks like I have a head gasket problem... I have most of the symptoms..

I need som advice here. As you all know I have changed the turbo, the EGR, the clutch and flywheel. I have changed an injector and cleaned the whole intake. I have changed the MAP and MAF and today also the intercooler.

Now, if we agree on the problem beeing the head gasket, my mec. says that I´ll be looking at, at least 600 £... and the nuts and bolts look very rusty and old, so a lot of things can go wrong and if some of them snap and other problems occur, it´s maybe 1000 £... and then the turbo problem is not even fixed...

Of course I´m the one who should end up with a van with all the trouble.... I really hate not being able to se and end to this... every time I think I´ve narrowed it down, somethingn new come up... This time it´s not just a small thing :(

Is there something, if I go on with this, I need to be doing at the same time?
Is there something I can check, fix or should look at, while gutting it.
Do I consider another engine?

All thoughts are welcome :)

Kristian
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