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  #1  
Old 12-10-2009, 10:54 PM
Christo Davids Christo Davids is offline
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Default 2.5 TDI Radiator Loosing Water

Hi Guys,
My ford 2.5 TDI's radiator is loosing water. Not lots, about 1.5 - 2L over 1000km, but I need to get it fixed
I have replaced the following, and problem still persists: (All original Ford Parts)
New Thermostat
New Radiator Cap
New Viscous Fan
Radiator cleaned by radiator fitment centre

Radiator pressure test OK
Radiator Head Test OK - no water in oil and no exhaust gas in the radiator

I have checked for visible leeks but can't find anything
Truck currently has 120 000km on the clock and used daily. Runs beautifully, no issues other than the water loss...
Any suggestions?
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  #2  
Old 12-12-2009, 06:08 AM
dervdave dervdave is offline
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Default

Heater pipes or matrix or thermostat housing ?
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  #3  
Old 12-12-2009, 07:15 AM
JULIUS JULIUS is offline
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Check your hoses for a white build up around the openings that indicates a leak or you may have a very small crack in the seam of your radiator and the water is coming out as steam.You may have to buy some dye and put in your radiator to figure it out.
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Old 12-13-2009, 10:28 PM
Christo Davids Christo Davids is offline
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Thanks guys, buying the dye ASAP to try and find the leak
Leak is very small - but still bothers me. Hoses all look fine, no white residue, etc. Will report back when I find it - I'll try and strip the bakkie next weekend to see if I can find the problem
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  #5  
Old 12-16-2009, 03:59 AM
Christo Davids Christo Davids is offline
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Took the bakkie to the agents today:
Compression test OK
Glyco test OK

Pressute test at 1.6 Bar: No external leaks - heater OK, radiator and hoses OK

They then put the truck on a pressure test for 1 hour at 1.6 bar (normal operating pressure 1.1bar) - dropped 5PSI over the hour - re-pumped to 1. Bar and started motor, revved motor - pressure increases as RPM increases, drops again as RPM drops - they reckon I have a hairline crack in the head between water ports... Will be able to tell once had is removed...

I'll get this sorted in the new year, engineering works closed now, so will have to live with it as is for now...
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Old 12-16-2009, 05:48 AM
JULIUS JULIUS is offline
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Yeah,I thought about that also but it was last on my list.What's happening is the water is coming out the pipe as steam or it's coming out the overfill tube of the reservoir from the built up pressure.Look under your truck for water but it may only come out while you drive because of the extra pressure.
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Old 01-10-2010, 08:52 AM
Christo Davids Christo Davids is offline
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Replaced the head, as well as water pump, viscous fan, water temp sender unit, etc. Truck pulls like a train again and EGT is beautiful - 620 degrees celsius in front of cylinder 4 in the manifold when driving 120km/h up long hills, flat road EGT at 380 degrees celsius at 130km/h...
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