Lyts1985

Here we go... I'm basically looking for some suggestions or to confirm my fears as I can't figure this one out... It's a 2.0 TDCI 115, 04 plate, with 116k on the clock...

My car is losing coolant regularly. 2 litres (roughly) every 100 or so miles... I can't see any external leaks, hoses etc, and a Ford mechanic agrees (take that how you will!) They did a pressure test on the cooling system which came back fine but said a sniff test would be pointless on a diesel (?). The mechanics advice was that he suspects a head gasket failure as he noticed substantial white smoke when starting from cold...

He's right - when the cars been sat overnight there's a shed load of white smoke, then when I check the coolant level it has indeed dropped. The smoke clears after say 15 seconds of rough running but then runs perfect and doesn't lose any more coolant during running...

My limited knowledge tells me that water is running in to the engine overnight hence the rough running and smoke, but if the head gasket were gone would it really leak in to the cylinders overnight and not during use?? What else could cause this as I could do without a £1000+ bill right now...?

Unsure if it's related so I'll ask the question... There seems to have been, at some point, a leak around the EGR valve as there's something running down the bottom hose? Thought it was only exhaust gas going through the EGR?

Finally (honest!) there appears to be fluid (water??) around the injectors and the surrounding area... Normal?

I'd greatly appreciate some technical bods opinions on this... Thanks!!

swain78

Hi mate does sound like gasket gone. Mine went 6months go on my 2.0zetec focus. Instead of spending 500 odd on gasket repair. Look at www.stealseal.co.uk. its 40 a bottle. But works great. Ive hammered crap out of mine since putting it in. No water loss. Increase in power. Was hell of a saving for me as i couldnt be arsed to change gasket lol

swain78

im bad its www.steelseal.co.uk lol

DanW@FastFord

iTrader: (1)

No offence, but the last thing I'd do is chuck that stuff ˆˆˆˆˆ into my engine!!

Head gasket failures are rare on TDCIs to be honest. What does the smoke smell like? If it smells really diesely then it's not water! Quite a few smoke in the morning as they can overfuel on cold start and chuck out a big lungful of white smoke.

It does sound like it's loosing a lot though. Is there any sludgy mayonnaise on the inside of the oil filler cap? Or any oily gunk in the header tank? If it's the latter the oil cooler can leak, and cause oil and water to swap places.

I'd also consider replacing the header tank cap before doing anything drastic - just in case it's letting water out once pressurised.

Are you sure it's water around the injectors and not diesel? Smell it!!

If there's a wet residue on one of the boost hoses, then it's probably a split hose, Does the car make a 'whoosing sound' when it comes on boost? The EGR-intercooler hoses split for a pastime.

Lyts1985

Hard to say what it smells like... Doesn't smell of diesel that's for sure - maybe a bit sweet?

Nope no gunk on the filler cap or in the header tank. Interesting idea about the header cap, cheers mate.

Haha that's a fair point about the injectors. Will have to check that! It looks like dirty water though... Hmmm... Lol

Nah no whooshing noises and the EGR hose has recently been replaced due to a split. I didn't think any kind of fluid went through the EGR so I was surprised to see this residue running down it...

Cheers for the tips.

DanW@FastFord

iTrader: (1)

Unburnt diesel is quite 'sweet', well, kinda like barbecue lighter fluid. It'd make your eyes sting if you got a face full of it!

There is no fluid running through the boost hoses as you correctly pointed out, but because of the wonderful way EGR valves work damp sooty shit gets pulled through the engine and leaves that oily residue that coats the inside of all the pipes and intercooler. You'd be surprised at how much sooty liquid can come out of an intercooler when it's taken off!

If yours is a Euro 3 (no electrical connectors on the EGR valve) then get it blocked off! Unless you have one of the rear EGR cars - if so then I'd put money on it being the EGR cooler that's leaking into the engine, but if it's an 04 I'd imagine it has a front (non cooled) EGR.

I'm just sceptical that it's the HG as it's not a common occurrence on TDCis, I'd go as far as saying it's very rare! The oil cooler is often a prime suspect (and its failure is often confused with a HG failure) but the pressure in the engine is such that it tends to force oil into the water, rather than allowing water to 'leak' in the engine.

It could also be leaking from where the coolant goes through the turbo - that's where mine leaked. Because it's right at the back of the engine, and there's loads of stuff in the way I only noticed it when the car was up on the ramps and I was taking the cat off - I'd never have noticed it otherwise.

Def replace the header tank cap, and have a really good look for leaks. Sometimes it may be such a small hole that it only leaks when you're on the move and the fluid is heated and under pressure. Take it for a good run, and check it over carefully once hot.