passat coolant in exhaust

[marctdi]

Hi,
I am new to the club. I have a 1997 Passat TDI and am having trouble. The car has 130000 miles. It is getting coolant in the exhaust. I have had the head gasket replaced 2 times and it is still happening. It runs perfect, but after 60 miles the coolant light comes on and it needs filling. I had the belts replaced with the water pump at the same time. Could it be the turbo? Any thoughts?
thanks

[Crasher]

Was the head pressure tested last time it was off?

[Eddie]

I agree with crasher pressure test it and if its been off twice may need a slight skimming(some ppl dont tighten them correctly)

[Crasher]

On the subject of re-facing a TDI head VAG's opinion of that is
"Reworking diesel cylinder heads is not permissible".

[Eddie]

Surely the tolerances cant be that close to take of a couple of teeny weeny thou

[Crasher]

You are allowed 0.1-mm distortion and any more than that means it is a big paper weight according to VW and I don't argue with that, I just fit a new Mahle or KS head.

[Eddie]

are we talkin breaking into oil galleries if you skim any further tha 0.1mm or do the valve seats suffer sounds very unservicable to me with tolerances that low.Oh the old days when you just fitted a thicker copper head gasket to keep comp as standard then it would blow again 6 mnths down the line lol

[Crasher]

You can't even skim the head 0.1-mm, that is the allowable tolerance for re-assembly without skimming. I don't know what their reasoning is; it can’t be cam timing (moving the centre line of cam and crank closer together advances the timing) as TDI cams are on a cone fitting. It used to be an issue with the indirect injection engines due to the steel pre-combustion chambers which caused machine shops problems with their cutting tools.

[Eddie]

Yeah the old austin 2.5 diesels had a habit of dropping pre-comb chamber bits onto the piston crown they used to crack and drop down the bore then the head would crack between the valve seats and open up a water gallery goodnight vienna

[Crasher]

I have had a few AAZ engines do that, one was our own hack of a Golf 3.