Ibiza FR TDi 2005 ASZ Head Gasket Failure

[Corgi]

I have an Ibiza FR TDi PD130 (ASZ engine on 88k) and it's losing coolant only after motorway 80+mph runs by blowing it out of the Coolant Expansion bottle. The bottle isn't cracked nor is the cap not working correctly.

A coolant system pressure test showed it's dropping pressure in a way which it shouldn't - I saw the pressure gauge dropping when the mechanic did the test. The engine has no apparent external leaks(other than at the expansion bottle) nor is there mayonnaise or a sweet smell out of the exhaust. It has no warnings with Vagcom either.

I'm going down the Head Gasket Failure route as advised by my trusty mechanic and it's booked in to have the HG done next week. I'm praying the head isn't cracked and if not am expecting a bill of around £600 - nice.

Doing some research on the different forums it looks like this is a relatively common fault on the PD130.

I wonder if anyone else has had the same thing happen to their PD130 engine? When the HG is being done should I be taking the opportunity to get any other work done, say on the head?

Thanks in advance guys.

[Corgi]

Bit of an update, following my mechanic checking the engine over yesterday morning to do his best to find something other than a HGF, my engine's head has had to come off and is now ready to be picked up by the cylinder head engineers from my mechanics garage.

The engine techie place do the pressure check and cylinder head work and return it with suitable gaskets following skimming et al. Despite the costs involved, so far I'm pretty confident in the people carrying out the work. I'm also praying that I am getting this HGF job done before any super serious damage has been caused.

I have checked out the option to get a replacement engine fitted however unless it would be a re-manufactured or new engine, how would I know the secondhand ebay engine would not be either a crap engine with inter galactic mileage, or that it might bin its HG straight after I'd bought it and got it fitted. Plus I didn't want to have to be getting my V5 changed to have the engine number amended. I just thought it'd be best to get my engine fixed as a result.

So far It's cost me £100'ish for timing belt kit and water pump, £35 for oil, £20 for G12++ coolant and deionised water, £5.50 ish for an oil filter and £300 as an advance payment to my mechanic. So that's £460 so far. I'm budgeting for another £150 - £200 but hope that'll be it! Finger's toe's and anything else that can be crossed eh...

It all depends on the condition of my cylinder head I guess. Chocolate cams is a term I dread at this point as I have no idea whether my cam and the associated items are seriously worn. I presume that will take the job well over a grand if there's a problem or two with the head :(

This whole thing is making me want to look for a different manufacturer to VAG for my next motor...I know all cars have faults but this is a kick in the 'you know where'. This Ibiza is my fifth VAG car and I like them but this HGF and what I read about PD engine design is making me look elsewhere.

BMW 120d is a car to research for me atm.

PS I'm posting my story here for the benefit of all on the forum and hope it will illustrate further what happens when PD130 engine's head gasket's fail. I am getting the old head gasket off my mechanic and will take a picture to try to show the leaking part. From what 'Crasher' says in other posts that isn't always possible to see.

[Corgi]

In addition to the HGF it turns out my camshaft bearings were knackered (the term used by the cylinder head rebuilder) although the camshaft was still fine...looks like I caught it just in time with the head gasket failure. I have also taken the opportunity to replace the lifters with the black nitrided type.

All this on an engine which has a fully documented main dealer service history up to when I got it at 65k and since then has had oil changes with top quality oil every 5k (now on 88k). Not great is it.

http://www.vwaudiforum.co.uk/forum/[IMG]http://i185.photobucket.com/albums/x213/I_am_Red_Panda/ASZ-Cam-Bearings-88k.jpghttp://i185.photobucket.com/albums/x213/I_am_Red_Panda/ASZ-Cam-Bearings-88k.jpg