Still leaking coolant!!!

[Canadianbugin]

Originally Posted by middknight1

so, anything look.....maybe, off to anyone? notice the center ports on the manifold? should i be concerned about this? would attempting to reshape be possible? i have the tools to slightly reshape but i dont have the tools if i punch a hole through the welds.

The ports look the same as mine...I ported mine mildly with a Dremel and had no problems as the welds are very heavy duty on the flange.... You might want to check your exhaust manifold as the other points or joints were the pipes are connected are a problem for leaks though... as these points were braised and separate and cause other CELS.... As i 've heard from a lot of AEG owners they have also had to change this manifold for the same problem of the other tubes comming unwelded. I am in the process of sandblasting my original mani and am going to Tig weld these tubes and have the manifold ceramic coated ... GL....KP...

[middknight1]

[QUOTE= I am in the process of sandblasting my original mani and am going to Tig weld these tubes and have the manifold ceramic coated ..[/QUOTE]

nice!!!! yeah going to use a dremel as well. alright good so little more work on the mani then. the scotchbrite well is going to finish cleaning everything very nicely as well.

[Canadianbugin]

Originally Posted by middknight1

nice!!!! yeah going to use a dremel as well. alright good so little more work on the mani then. the scotchbrite well is going to finish cleaning everything very nicely as well.

Cool your makin some headway then.. With exhaust manifolds i do it the easy way with my angle grinder and wire wheel...

[middknight1]

right on my friend. i was a little more "old fashioned" using a wire brush and some good ole elbow grease lol. wire wheel and angle grinder, right angle drill, regular drill would have been much much faster! oh well lol vacation starting today. will get the head while i am gone. maybe start working on saturday but more than likely on sunday.

[Canadianbugin]

Originally Posted by middknight1

right on my friend. i was a little more "old fashioned" using a wire brush and some good ole elbow grease lol. wire wheel and angle grinder, right angle drill, regular drill would have been much much faster! oh well lol vacation starting today. will get the head while i am gone. maybe start working on saturday but more than likely on sunday.

Cool good luck and keep us posted...

[middknight1]

i started working on her again back on sunday. got the head back on, exhaust hooked back up, lower intake back on. kept getting interrupted by two 4 year olds and 5 year old wanting to watch and ask questions, your typical kid stuff lol! i stopped working i have decided to replace the coolant flange so thats on order from germanautoparts.com....ecs doesnt have the right one i need....while waiting for that tomorrow i will take care of putting the timing belt and drive belts back on get that out the way....my hood strut finally decided to quit on me too so might have to spend the 25 and get a new one. a very large flat head screwdriver works for now lmao!! i also decided against replacing my fuel injectors for the time being hoping that replacing the ignition coil pack will solve my #2 misfire that i get occasionally. its slow going but i gotta work around work and family so its just slow going takin my time.

[middknight1]

had an extra hour before work today so i got the timing belt and drive belts back in place. engine turned freely with no hang ups so good signs good signs. looking to finish everything up tomorrow hopefully...keeping my fingers crossed on that little deadline!

[middknight1]

got everything buttoned up today. runs smooth, quieter than before. i am still boiling over in the expansion tank. i have added just under a gallon of coolant, lil over 4L, and i get a nice plum of steam coming out of the oil fill with the cap off. i know that there is condensation that builds up in that area but that much? nothing out of the tailpipe. red temp light flashes after about 15 20 min with the a/c on. i am not getting hot air out of the vents. am i just not gicing enough time for the coolant system to become completely filled, or do i have something else more major going on?

quick review of whats been done:
head remachined and taken care of by Franks VW TDI
new head gasket kit from ECS Tuning
Breather hose, therm and housing, coolant flange, ac cut out temp sensor, ult water pump kit ESC tuning, all new hardware, ign coil, plugs, everything is torqed in accordance with the Bentley manual.

thanks ahead everyone!

[Canadianbugin]

Originally Posted by middknight1

got everything buttoned up today. runs smooth, quieter than before. i am still boiling over in the expansion tank. i have added just under a gallon of coolant, lil over 4L, and i get a nice plum of steam coming out of the oil fill with the cap off. i know that there is condensation that builds up in that area but that much? nothing out of the tailpipe. red temp light flashes after about 15 20 min with the a/c on. i am not getting hot air out of the vents. am i just not gicing enough time for the coolant system to become completely filled, or do i have something else more major going on?

quick review of whats been done:
head remachined and taken care of by Franks VW TDI
new head gasket kit from ECS Tuning
Breather hose, therm and housing, coolant flange, ac cut out temp sensor, ult water pump kit ESC tuning, all new hardware, ign coil, plugs, everything is torqed in accordance with the Bentley manual.

thanks ahead everyone!

Sound's like your makin some headway.... Hopefully it is just air in the system....

[middknight1]

alright so continued to add coolant, heat the car up till the red light of death came on, let her cool a bit then popped the top on the exp tank, let her drain back into the engine, top off to the marks and repeat process. did that a few times she seems to be acting right. no more boiling, or the red light. will give her a test drive tonight after work. had to buy a new tire since the valve stem on the old decided to fail. can't wait to get her on the road for the final checks!!! the ignition coil was giving me my misfire on cylinder 2. she was cracked and the electrodes were in pretty bad shape going into the coil itself. wire electrodes seemed fine but that definitely was not the issue there. i will let everyone know how the drive went. thanks again for everyone's input, advice, and recommendations.

edit: still don't get the large fan to kick on. i know there is a thread around here somewhere....already replaced the sensor on the flange, anything else cheap and quick i should check before replacing the fan unit?

[Canadianbugin]

Originally Posted by middknight1

alright so continued to add coolant, heat the car up till the red light of death came on, let her cool a bit then popped the top on the exp tank, let her drain back into the engine, top off to the marks and repeat process. did that a few times she seems to be acting right. no more boiling, or the red light. will give her a test drive tonight after work. had to buy a new tire since the valve stem on the old decided to fail. can't wait to get her on the road for the final checks!!! the ignition coil was giving me my misfire on cylinder 2. she was cracked and the electrodes were in pretty bad shape going into the coil itself. wire electrodes seemed fine but that definitely was not the issue there. i will let everyone know how the drive went. thanks again for everyone's input, advice, and recommendations.

edit: still don't get the large fan to kick on. i know there is a thread around here somewhere....already replaced the sensor on the flange, anything else cheap and quick i should check before replacing the fan unit?

Check all the wiring and connections as corrosion could be an issue as well...... GL.....KP...

[middknight1]

i'll give that a check in the near future. she's been running alright without that fan running. not using ac too much this time of year but of course will be getting warmer real quick out here in the desert lol

[Canadianbugin]

Originally Posted by middknight1

i'll give that a check in the near future. she's been running alright without that fan running. not using ac too much this time of year but of course will be getting warmer real quick out here in the desert lol

Cool....parden the pun...lol...Hopefully here too....

[middknight1]

lmao it was totally appropriate!