Coolant Loss from A6 Avt 1.9TDI SE 115 AJM

[Garthy13]

Hi looking for some guidance please

My 2001 1.9TDI 115 AJM (157K) has been losing coolant to an inch or so below minimum on the header tank after a decent single hot run. It takes longer to drop to this level with a series of shorter trips. What appears to be coolant was seen under the header tank and on the coolant pipes at the rear of the engine bay.
I have just got it back from Audi and they have so far failed to diagnose. No signs of any external leaks. They found the EGR valve leaking oil. A block test was ok. A pressure test over 3 hrs showed it drop from 2 bar to 1 bar, but still no external leaks. They have recommended removal of old pipe work and certain components in the first instance i.e. possibly a blockage in the system which is then dumping coolant under pressure on a long run through the 'release valve' (is there such a valve?)
They also mentioned that the 'sniff' test possibly showed that the head gasket may be in the early stages of failure.
I had the water pump changed with the cam belt last summer for info

I would appreciate any help.

Thanks! Ian

[Crasher]

I am afraid that on the AJM this is a classic indication of head gasket failure.

[Garthy13]

Thanks Crasher

Is it safe to continue driving and topping up while I shop round for a price to have the work done?

[Garthy13]

Also just wondering if the head is failing why there is clearly coolant leaking into the engine bay under the header tank....can see dried coolant on the pipes. Thanks again.

[Crasher]

Yes, it will be better used around town though. DO NOT be tempted by any “cure in a can” solutions, they just block everything up. Also, do not go for whoever quotes the least, that is not going to get the job done properly. The head will need a light resurfacing and on a PD that means pulling the glow plugs and injectors (so new glow plugs and injector seals) and preferably the valves as well as they are very close to the surface. The header tank may be cracked due to system pressure, it is a common clue.

[adamss24]

I'll be buying a new genuine head cast if i were in your position ! I know a polish chap who bought a x reg audi a6 with a suposedly blown turbo, car been standing for 6 months. I brought the car to his house for him from Oxon then he's got a cheaper mechanic to do work on the car (my quote seemed too much for him as it was on a tight budget!). He spent £200 on a turbocharger, fitted-it and the car was blowing oil from one piston (that's what it said !), then the mechanic took the head off, rebuilt it with new valves and lifters + seals then, on refitting the same problem: engine blowing oil from 2 pistons and bad iddle after 20 sec. or so ! He's mechanic took the head off a 2nd time and he found oil in the bowls of 2 pistons and with the glow plugs off the engine blown oil trough the spark plug holes (he checked the rods/pistons seals by pouring petrol in the pistons ?), then he's fitted a 2nd hand head on wich he swapped all the parts from the old,rebuilt head. Fitted it on and still the same problem... Now, the chap is 2 grand out of pocket and the "mechanic" does not answer his phone anymore, shure enough i am not keen to try to repair a bodged job ! The chap did not took my advice as it looked too expensive at first ended costing him twice what the car's worth ! Take my advice: either fit a new head or get a known good engine and pray it wont have the same fate (they are a ticking time bomb)...Funny is that i knew of a good, low mileage passat with the same engine wich had a damaged wing and bonet going for not much money (ended up buying it myself as it was too good to miss !) but he still pursued trying to fix the old engine...I still dont know the outcome of the situation, i am not interested either as the chap was a **** anyway...but most likely he bought a short block and try to bodge a decent engine out of the spare parts he's allready bought.

[Garthy13]

Crasher and Adamss24,

very many thanks for your comments. My old bus is a lovely torquey load lugger that has serviced me well, I've had all belts, water pump and the suspension replaced on all corners recently. I'd rather spend brass on having this job done properly and get another 100K out of her. Awaiting a quote from Audi for the job in the first instance........hmm, oh well. Cheers.

[Crasher]

I fear the pricing from Audi will be rather a lot, you would be better served finding a reputable VAG specialist nearby. If it turns out the head is toast (as Adamas24 says, this is common) then they will insist on using a genuine head which is £1k bare, for less than half that you can get an AMC copy had which I think are excellent.

[Garthy13]

Thanks Crasher!

[Garthy13]

Thought I would update this thread to assist those with the same symptoms that my old bus was exhibiting

I went to 'Tutt's' VAG specialist in Dorking after speaking with owner Arthur who was very approachable and helpful.

Arthur carried out a block test which failed in ten minutes. Crasher was correct with his diagnosis of the head gasket. After much soul searching and wondering whether it was time to get rid and buy a new motor. I swallowed hard and as I'd recently had the suspension replaced on all four corners I gave the go ahead. Arthur located coolant crossing the gasket into number 4 cylinder. New gasket, cambelt, rollers and tensioner, waterpump etc and little change out of a grand (as expected!). The old bus is as good to drive as ever, hopefully I'll get another 100K out of her!