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Have you checked the coolant level? And if required topped it up in the correct way so as to remove any air in the heater circuit?

Who’s discovery was this…..go to 5 mins

I can see how the confusion can occur but whilst doing the HG job I removed the inlet and exhaust manifold and it was one of the studs holding those on (screwed into the aluminium head) that had been replaced by a bolt. The (non) leaks I referred to would be past the inlet/exhaust gasket.

On my car there are only cylinder head bolts, and all threads were good (in the block).

just did the HG on my 300tdi and a PO had used a bolt where a stud should have been and it stripped when I did the bolt up (only then did I realise it should be a stud). i fixed it by making a new stud out of a bolt, I made sure it had a longer thread than standard so it could engage with what...

Done 50km so far and no sign of pressurisation in the cooling system, so I guess no crack in the head, only time will tell if the HG will hold up. Some observations: 1) all valve clearances were non existent post new HG, suggesting the erling type HG ends up thinner than the MLS. 2) I buggered...

Its back together, too late to do a road test, coolant started leaking from the expansion tank cap after 15 mins on idle, but i am hoping that is because i brimmed the tank during adding coolant. i could not get it to start at first, but eventually worked out to turn the engine ( until the...

Well spotted, I meant 004’ but not 015’ it should read 0015’ in my prior post it was surprising how little torque on the single bolt was required to “bend” the head flat, just one hand on a short 1/2” drive wrench.

Sorry missed the question, but no I am not lapping the valves, I looked at one exhaust seat and it was perfect so I am leaving it as it is.

Elring gasket and a gasket set were delivered last week and today I got the head back on with bolts only slightly tightened, I will torque them tomorrow once I have worked out a diy angle gauge method. Pic is of the head bolts once I had got them all nicely moving on their threads, a bolt...

I know its a gamble but I intend to risk that there is a crack or warpage and just fit a new gasket. I am retired so redoing the job is not a biggie, albeit I don’t want to break down miles from home :(….. The existing gasket has held up well to a few overheats, (yes yes some were “user error’)...

You mean the blackened area on the block surface between 2 and 3….which extends from the fire ring to water holes? See edited pic…

Yep, looks suspect, but not the cause of a pressurised expansion tank?

Pic of head

Hi, I’ve had the ‘96 300tdi nearly 10 years now and its over heated a few times during that time, shortly after buying it I did a poor belt, expansion tank and hose replacement job and did not properly refill it hence no heater (my fault) and a really bad overheating incident followed, then that...

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Its a long time ago but i think the sensors lever out with a small screwdriver (rather than just tug on the wire!). The issue actually is that they tend to work there way out of position by themselves, and cause an ABS light due to poor signal, so owners periodically tap them back down again...

There are reports on the net that 300tdi engines can destroy themselves when the turbo bearings wear and allow engine oil into the inlet.....the only way to stop carnage is to block off air supply, or somehow stall the engine. . Whatever you do I guess you need to be prepared for thiS...

Loose wire on fuel cut off solenoid? (If it has one)

Hi porky, our cars might be more similar than one would expect, mine has a mechanical injector pump, no EGR, but has got ABS (dammit) and SRS (dammit) and IF it has got an ecu it has not given me trouble yet and I don’t know where it is. It might have a DDS unit to disable the engine via the...