New Cylinder Head

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Originally Posted by BathurstTom

With the chirp, try pouring a little water on the inside of the belt as it is running. If it quiets it down - replace the belt or use some rubber conditioner on it.

Is the noise coming from the Injector pump? If so, check the lift pump. About to do mine - it doesn't have the odd thump noise, but it sounds like a tappet and is spilling some deisel over the front diff etc.

I have read other reports on the web where people attributed a thump noise to the lift pump - the noise is from the injector pump because it is starving for fuel. Is your motor down a little performance (especially uphill) and won't rev past 3k?


Tom

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pretty sure thump coming from the water pump area. lift pump is pretty new, changed it when i had the timing belt done.the vacuum pump is still the same one from when i bought the car but seems quiet and screwdriver stethoscope trick you cant hear the thump in the pump. the injector pump is about 1 year old too. havent been revving it past 3k anyway as the works are just new, wanted to test everything and break it in gentle until i knew all worled. but yea when you go to higher revs it is a bit shaky and loud with no bang. thing i thought about last night though is when i first went for test drive after completed, ran smooth as silk and felt more powerful and very quickly started running rough after a few drives, and shaky and the belts making noise etc. once ive checked everything i need to im going to limp it to rovertech anyway and get them to do carbon test and few other checks anywya for peace of mind. has been a good experience but at the end of the day nothing beats a professional opinion face to face with the car instead of me trying to pin point stuff. guess thats difference between weekend mechanic and someone who does this as a living.

currently 1 million degrees in perth so need to wait a few days before i look at it. going to run it without the belt again and see if the thump is still there. i need to also find the source of the leak before i do any proper testing. if the new expansion tank is split ill have to put old one on for now. hopefully just cap like Newt says. going to try old cap as well as i know it worked. theres a far bit of water down radiator so hopefully it wasnt this that leaked. barely lasted 3 working hours if it's this.

Have you checked the valve clearances again , will be doing mine on the weekend which will be about 500klms since doing the head.

Did you try putting some water on the inside of the belt - two minutes work to rule in or out the belt. The age of your injector pump has no bearing on whether it is starving or not - try the screwdriver stethoscope trick on the top of the injector pump. Again, very little effort required to help narrow it down.

Tom.

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Originally Posted by loanrangie

Have you checked the valve clearances again , will be doing mine on the weekend which will be about 500klms since doing the head.

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nah only checked the lash caps to see if they were intact. and yes they were. i did the clearances when i did the head just now, straight after putting the rocker gear back in. so only did about 40kms max since i did them. will check them again for good measure though. maybe i didnt do a nut up enough. weekend job though. when it cools down. wife bout to pop one out, so spending quality time with her right now. Leona Landy has had plently of attention from me recently.

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Originally Posted by BathurstTom

Did you try putting some water on the inside of the belt - two minutes work to rule in or out the belt. The age of your injector pump has no bearing on whether it is starving or not - try the screwdriver stethoscope trick on the top of the injector pump. Again, very little effort required to help narrow it down.

Tom.

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will do this also, when im checking clearances. on weekend.

I might add that I have just replaced the head on my tdi. Header tank split - familiar tale? :) I too have a ticking noise that I thought was tappets - adjusted three times now with no difference. I have replaced the vacuum pump no difference (other than I don't run out of vacuum now) - still ticking away. After reading many posts here and elsewhere, I listened to the Injector pump - that's where the noise is! So I changed the filter and I noticed that it had no pressure in it. When I changed it last time (~5000km ago) the fuel was under pressure when I popped the bleed screw. Not only was there no pressure, but the filter was only about 2/3 full. Have lift pump and will fit it asap. My fan belt is also noisy again too - it was like this before with an old belt. Water would quieten it - as it does again. New belt ready to fit too ;)


Tom

So what caused the split tanks?

if you get the mounting wrong or the mounting points are twisted out of postion and youve had to do any twisting or forcing to get it to mount up they fail early.

I've seen them fail inside of 2 weeks.

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Originally Posted by Blknight.aus

if you get the mounting wrong or the mounting points are twisted out of postion and youve had to do any twisting or forcing to get it to mount up they fail early.

I've seen them fail inside of 2 weeks.

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Can't remember but may be a possibility that it did wiggle a bit to go in. Had that German house mate over with ham fists and seem to recall he tried to put that in.

I filed one of the mounting holes after as it didn't line up right and that made it go in.

tinkered around again today. topped up cooling system again, put my old expansion tank cap back on. whilst playing around with the heater hoses i noticed one was moving around easily. turns out the one going to top of head was loose as and almost pulled it of by hand accidentally. i tightened it up now.

would this cause anything to be sucked into the system and pressurise it? there was a little bit of coolant around but barely anything. just wondering if this may have cause previous problem. the old expansion tank seems to be working better too. i took her for a run warmed it up proper, after i got back you could hear the pressure coming out of the cap. the new one didnt do that now that i recall.

ive attached a video of the expansion tank right after i filled the car and was still cold. water moving round, some little bubbles. im assuming this look all normal? water is meant to be circulating through this all the time, not just hot?

going to be driving it to work again just short trips and keep an eye on it. still dont know where the coolant came out from last time. still not comfortable relying on her.