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Author Topic: Leaking coolant from auxillary heater  (Read 1047 times)

Offline christiant

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  • Model: Galaxy Mk2
  • Spec: 02 TDI 115 Zetec
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Leaking coolant from auxillary heater
« on: July 27, 2018, 09:16:20 PM »
My galaxy behaved weird again today, it is now mostly all sorted and has proper power for the first time which allowed me to drive it a bit faster under load. Drove it 700kms about 450 mile trip. Stopped at a petrol station, waited a little at idle for it to cool down then cut engine off to refuel. By the time I was back at the pump I saw a puddle of coolant under the heater. The pipes were dry going to the heater, it was coming from somewhere higher up around the actual body. I undone the cap, some pressure escaped, I didn't need to top it up, the level went over the max, once I released the pressure it never leaked again for next 100 miles or so. It didn't over heat or pressurize, the pipes weren't very hard or anything. Which leaves me with another dilemma, is it possible that it pressurized, I panicked and didn't check the pipes at the first place, only after I completed the trip, or is it possible the heater is just shot... Had compression checked very recently and was nice and even....

Offline johnnyroper

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Re: Leaking coolant from auxillary heater
« Reply #1 on: July 27, 2018, 09:34:22 PM »
so when you released the cap did the level drop down again?

It’s very possible you could have head gasket issues as the AUY does suffer with it.
I would check water pump impeller make sure it is still connected securely on the shaft and also the restrictor in small bore hose to top of expansion bottle make sure not blocked.

As for the leak on aux heater I would link it out for now while you determine if it has any head gasket issues.

Offline christiant

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Re: Leaking coolant from auxillary heater
« Reply #2 on: July 27, 2018, 09:51:23 PM »
Did replace water pump with one with metal impeller when I did the camshaft job along with timing belt etc, so I can rule that out as it was very recent. Once I took the cap of the level shot up, but that could be normal due to coolant expanding. The level was normal prior to taking it off. When I put it back on and drove the 100 miles and checked again, the level was fine... If the head gasket is gone, I would expect a CO2 test would be best? There is some chance I didn't bleed it a 100%. It does sit at 90c on the gauge constantly. I have a diesel compression tester and it has good compression 21 bar on all cylinders... I have a leak down tester but only for petrol... Probably could find a way to modify it and use the hose from the diesel compression tester to test it. Is the AYU prone to cracking heads/blocks? And are the heaters prone to leaking coolant? I am planning to try to bypass the heater for testing purposes.

Offline christiant

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Re: Leaking coolant from auxillary heater
« Reply #3 on: July 27, 2018, 10:25:00 PM »
Is the restrictor in the small return hose to the expansion bottle? Could the cap on the expansion bottle be playing up not releasing pressure when supposed to?

Offline johnnyroper

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Re: Leaking coolant from auxillary heater
« Reply #4 on: July 28, 2018, 12:05:44 AM »
AUY is prone to gasket failure and not usually cracked heads etc.
Even if gasket is at fault the chances of a c02 Test showing anything up are slim

It is possible there could be air in system after coolant drain for pump etc,the restrictor in hose helps vent air back to bottle. Yes the restrictor is in the small hose that goes to expansion bottle,if you take it off bottle and from T piece spray some wd40 down and push out with a long screwdriver. Run a 2mm drill bit through it and refit.

I would doubt the expansion cap is at fault as the system should not get to the pressure for cap to have to release any,if it does then that suggests the system is over pressurising.

Check restrictor and bypass heater and see how it goes is my advice

Offline christiant

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Re: Leaking coolant from auxillary heater
« Reply #5 on: July 28, 2018, 06:24:25 AM »
Will try the restrictor, my heater matrix was blowing steam too, but that was some time ago as I put some rad seal in it and it seems to hold. It does look like someone had the head off before I got it, it's very clean and the gasket looks new. They might have not done a good job. Since putting rad seal in it I have done 6k kms but it was low on power due to camshaft, turbo and fuel issues. While having those addressed I had the injectors out  and put in new seals, the actual bores had grooves on one side, even though they seem to be holding fine. Is it worth doing a head gasket considering the condition of the injector bores or would it be better to source another engine or maybe head? This engine has now got a lot of new parts...

Offline christiant

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Re: Leaking coolant from auxillary heater
« Reply #6 on: July 28, 2018, 08:11:31 PM »
Thanks for the advice, the restrictor thing was partially blocked by rad weld, freed it however I don't have my hopes up much. I'm pretty sure head gasket has been done by previous owner not too long ago, is it worth it re torquing the bolts as I read with the search they tend to stretch or not worth the risk? It didn't pressurize today nor did it leak, but I drove it much less. I might just go ahead and do the gasket but I just had the b***dy thing apart 10 days ago and I have to start from scratch again. It's a shame because it drives so sweet now... It has a very high mileage but the whole car is in good shape.

Offline johnnyroper

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Re: Leaking coolant from auxillary heater
« Reply #7 on: July 28, 2018, 10:55:12 PM »
As you found the restrictor blocked I would run it for a while and see how it goes rather than messing with head bolts/changing the gasket.

Offline christiant

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Re: Leaking coolant from auxillary heater
« Reply #8 on: July 30, 2018, 07:17:36 PM »
I removed the restrictor because I am unsure of the orientation it is supposed to go. When I took it out it fell on the floor and didn't note which way it came out. I was a bit worried about it. One side is dished inwards, the other side is flat. Does it matter as it is just a piece with a small hole? And can I drive without it? So far it hasn't had issues.

Offline johnnyroper

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Re: Leaking coolant from auxillary heater
« Reply #9 on: July 30, 2018, 07:23:28 PM »
Can go either way it is just a 2mm hole in centre.

Not sure what issues it could cause but i suppose the return is restricted for a reason so best to pop it back in

Offline Chrispb

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Re: Leaking coolant from auxillary heater
« Reply #10 on: July 31, 2018, 12:04:43 AM »
Some cars have the restriction in the connector on the bottle, the idea is to let a small quantity of coolant and any air return to the top of the bottle.
If you leave out the restrictor the flow will take the easier path and flow through the bottle and straight back to the engine rather than being pushed through the radiator.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
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