pwood999

pwood999

Well-Known Member
Full Member
Found the cause of coolant leak on Wife's FL1 TD4. Wasn't the thermostat housing or water pump. There's two holes in a small core plug in what I think is the upper camchain cover ?

Does this end cover come off (reasonable easily I hope), with the engine in the car ?

Pete

IMG_1292.JPGIMG_1293.JPG
 
Maybe some metalic powder bicomponent resin will cure the issue without complications.
At least I would it this way.
Stefan
 
Can't picture where that is !
Have just stripped a failed TD4 engine so can help with what comes off. The timing chain cover with the removable hex plugs in doesn't have water behind it.

Give me a clue where to look and I will check out my, now, box of bits !!
 
It was all rusty crud over the holes before I cleaned the core plug. Before I drained it, the coolant was coming out quite quickly.

There was also brown coolant all over the outside of the stat & pump housing. Both gaskets were quite flat, but had no obvious leak points.

Is there coolant behind that core plug ? I need to have another look and check if it's in the end of the cylinder head. That will have to wait for Thursday because I'm at Excel in London tomorrow.

Leaking Core Plug.png
 
Just found a decent picture of the TD4 head. Looks like the core plug is in the end of the head. Where the timing chain runs is not like the usual cover casting :-(

Now wondering if I can drill a hole, & lever it out. Then I should be able to clean up the edges & tap a new one in like on most engines. I've done plenty of core plugs in the past, but usually on accessible engines !!


1725994922968.png
 
pwood999 said:
Just found a decent picture of the TD4 head. Looks like the core plug is in the end of the head. Where the timing chain runs is not like the usual cover casting :-(

Now wondering if I can drill a hole, & lever it out. Then I should be able to clean up the edges & tap a new one in like on most engines. I've done plenty of core plugs in the past, but usually on accessible engines !!


View attachment 325756
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That won't be fun with the engine in situ. It's hard enough to access the thermostat and coolant rail in that area, but this plug basically behind the water pump/thermostat, where there is little room to swing a spanner, let alone swing a hammer.
 
Will let you all know hopefully Thursday. L & R engine mounts are off at moment, so I can jack the engine up as far as possible. Otherwise it’s gonna be head off . . . . . . . Either the TD4 or mine depending on wifey.

[Update]
So this morning I jacked up the engine as far as it would go, and moved the power steering reservoir to one side, and with the water pump removed there appears to be enough room the drill the plug & lever it out. I also measured the diameter about 5 times with a digital vernier, and got around 22.8mm to 25.0mm each time from different angles.

If anyone has a TD4 head or engine in their shed/garage/garden, etc. can you measure the head core plug please ?

CME have done my daughter's Corsa head, so will be picking that up plus a selection of core plugs on Friday. We will see how it goes.
 
Last edited:
Progress today. . . . . old core plug out & new one installed. It can be done with engine in car, but needs jacking up as far as possible. Biggest challenge is tapping the new one in. In case anyone needs to know it's a 24mm plug.

Pics 1 & 2 = The leaky holes front & back of core plug.
Pic 3 = the 6mm hole I drilled to lever it out !!
Pic 4 = new core plug installed.
 

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