New box of tricks came through today.

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Nice shiny new throttle body heater! mine has been leaking for around 4yrs!! LOL ;)

The leak has been somewhat stemmed by me covering the old gasket in RTV, however it still leaks enough to drop the level in the expansion tank..
And its annoying!

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To pull it off the throttle body has to come off 4x 8mm for the body to manifold, then 3x 5.5mm bolts for the heater itself, lastly disconnect the throttle position sensor and crankcase breather and its out! ;)

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The throttle body itself needed some cleaning, I just rubbed he mating surface with some cutting compound to remove any rough spots.

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And as Haynes says etc

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Job jobbed and after a good run its leak free..

:)
I was in a bit of a hurry when I did mine, just removed the breather hose to gain access, strangely the leak was a pinhole in the casting, panicked a bit when I saw steam coming from
the front of the bonnet, was a very fine jet of coolant hitting the rad.
 
And to add insult, got the traction failure message on the dash a couple of times. Went away with a restart, but guessing that's a wheel bearing issue
 
Sure it's a knocking & not an exhaust manifold leak?
Can sound exactly like a noisy tappet.
Once had a knocking but not exhaust manifold but inlet manifold
In 2 other cases on different engines one a 2'6 RoverSDI and the other a 300tdi were head gasket to outside air. Both engines ran OK but knock, knock on reving
 

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