Cracked Cylinder Head?

[chalky]

Hi All,

My regularly serviced '97 SGL-3 has developed a recent issue: it drinks as much coolant as diesel. There are no obvious drips or cracked pipes but there are two oil leaks at either end of the engine right where the block meets the head. The one at the fron end of the engine is considerably worse than the one at the back.

I guess this is quite conclusive, but was wondering your what your thoughts might be. Obviously I would be glad to hear there is a small screw or something that can be tightened which fixes the whole thing, but I guess that’s not going to happen.

What are my best options? Do I repair it, if so what is it likely to cost, or is it a now a pile of expensive scrap metal. I have heard that a car with a repaired head may suffer from related issues from then on.

Thanks for your help, Joel

[mikeonb4c]

Hi All,

My regularly serviced '97 SGL-3 has developed a recent issue: it drinks as much coolant as diesel. There are no obvious drips or cracked pipes but there are two oil leaks at either end of the engine right where the block meets the head. The one at the fron end of the engine is considerably worse than the one at the back.

I guess this is quite conclusive, but was wondering your what your thoughts might be. Obviously I would be glad to hear there is a small screw or something that can be tightened which fixes the whole thing, but I guess that’s not going to happen.

What are my best options? Do I repair it, if so what is it likely to cost, or is it a now a pile of expensive scrap metal. I have heard that a car with a repaired head may suffer from related issues from then on.

Thanks for your help, Joel

Welcome chalky.

Done properly, an engine with head repair should go on to give normal service for many miles (several owners on here can confirm that). On this score its worth reading old advice by Simon Jones on the importance of 'flatting off' the top of the block to ensure a good mating surface. Also using gasket sealant (Wellseal I think he used but have a search for that word as you should then discover his advice). Avoid buying cheap heads off ebay. The Bongo Fury shop does a ready to go kit with all necessary parts and these can be posted straight to the garage so all parts and labour remain under their warranty.

Until a Bongo with a replacement head has done a decent number of miles, I think its likely it will be less attractive when it comes to selling (worry about whether a good job was done).

In my opinion, these vehicles are too special (the Autofreetop especially) to just regard as scrap just because the head has gone (many jobs on many cars would cost just as much to mend, but a decent Bongo holds its value well). I've seen Bongos with heads that are gone still attract a decent price (considering) as someone else is prepared to get the work done if it helps them save on overall purchase price. Some people even scrap for spares and do well, but if the Bongo is in overall good condition I wouldn't do that.

Good luck - sorry to hear of your troubles.

[francophile1947]

If the "bad" oil leak, at the front of the engine, is on the driver's side, it's probably the EGR system - they're nearly all like that
Get a pressure test done on the cooling system and get the garage to check the coolant for traces of exhaust gases. The pressure test should show up any leaking hoses. If exhaust gases are present, I'm afraid that's not good news. Is it running OK or chucking loads of steam out of the exhaust?

[mikeonb4c]

If the "bad" oil leak, at the front of the engine, is on the driver's side, it's probably the EGR system - they're nearly all like that
Get a pressure test done on the cooling system and get the garage to check the coolant for traces of exhaust gases. The pressure test should show up any leaking hoses. If exhaust gases are present, I'm afraid that's not good news. Is it running OK or chucking loads of steam out of the exhaust?

Good advice. The oil issue and hte coolant loss could be completely unrelated. Also, if coolant is being lost into the combustion chambers at a serious rate, I'd expect to hear that it have out clouds of white vapour esp. when starting in the morning. Is it doing that?

It's just possible that you have (1) oil leaks as John describes and (2) coolant leak from a pinhole or somesuch and that is easily fixed. Travel in hope bu stay in the braced position - it aint over until the fat lady gets tested for compression and trace gases

PS - have you got a low coolant alarm fitted - always recommend those for peace of mind

[Simon Jones]

I had a head gasket fail & the symptoms were quite different to yours. I was loosing coolant but that was due to the combustion gases getting into the coolant system, so it was being forced out the overflow on the header tank. While its possible you have a crack / leak on the inlet side of the head which is sucking coolant in to the engine, you would also get a lot of white smoke & it would run quite rough too.

I think you have a leak in the coolant system somewhere which is much easier / cheaper to fix. There are a few key areas to check:

- Radiator - easpecially where the top & bottom plastic ends are crimped on
- Rubber hoses - split or pin hole, or starting to bulge or weaken
- Steel pipes - rusty / pin hole
- Water pump seals - leaking at the front of the engine

Get in touch with Haydn Callow & order some UV dye that shows up using a suitable lamp, so you should be able to trace the leak (if that's what it is).

[chalky]

Wow, thanks for the advice, really interesting reading.

Don't get me wrong about the scrap metal thing, we love our Bongo and would hate to give up on her. Having owned various "family cars" in the past, nothing has ever quite ticked the boxes like the Bongo. I have three young kids and they love the picknics with the top up and it has served us well on many trips to the continent. The car is in very good condition as I travelled the length and breadth of the country to find the right one. It was like brand new with 30K miles on the clock when I brought her three years ago.

In answer to some questions, no the car does not billow out white smoke when running. It does splutter a little 10 seconds after starting (summer or winter) but I think this may be a glow plug issue? Otherwise the car runs perfectly well without fault, pulls very well and returns good MPG.

I have had it back at the garage today and they have said, like some of you, that the oil leaks are completely normal for a turbo diesel and nothing to worry about (yes it was on the drivers side). They checked on the ramps for any obvious leakage but they reported nothing. Currently from their point of view I should go ahead with the work at a cost of 1500 quid. Ouch!

I will, as you suggest, get the compression and coolant tests done. My only isse here is time as the kids are back to school in a couple of weeks and my local, trusted, garage, are booking into mid May. Any recommendations on good garages in kent? I live in Faversham.

Many thanks and speak soon, joel

[mister munkey]

Even an untraceable weep can get you through a pint of coolant a week if used on a daily basis. I've been getting through that for nigh on three years until finally finding the b*gger three weeks ago. Theres 17 rubber hoses on the Bongo, its just finding the right one!!

[Simon Jones]

They checked on the ramps for any obvious leakage but they reported nothing. Currently from their point of view I should go ahead with the work at a cost of 1500 quid. Ouch!

Personally, I would totally exhaust the leaky pipe / pump / radiator / heater matrix options before splashing out on removing the head. There is a lot of plumbing on the Bongo including the rear heater matrix. There are something like 18 rubber hoses plus several steel pipes & all the joints in between - so plenty of scope for water under pressure to escape.

A typical example can be seen here: http://www.igmaynard.co.uk/bongo/forum/ ... =3&t=39683

Ask them to do a UV dye test first, even if it comes back negative, you will have some reassurance that the rest of the system is in good order.

Sorry - can't suggest anyone in the Kent area for a second opinion.

[chalky]

Thanks for this, suddenly it's not looking quite so grim as I expected.

[mikeonb4c]

Good advice from the others. Hard to see how a seriously sick Bongo could be running as well as yours appears to be. The fat lady is still singing I reckon

Fit a low coolant alarm though - you know it makes sense

[Doone]

If you can't see obvious leakage of coolant, it's possible that's it's evaporating against the block. Check one of the small water pipes for a pinhole... probably easiest if you put some dye in the system. Do an internet search for 'coolant dye', it's widely available.
There's a good picture of a pinhole leak squirting coolant out under pressure, SEE HERE

[dreamwarrioruk]

you on commision for the coolant alarms mike.

[mikeonb4c]

you on commision for the coolant alarms mike.

Absolutely not - ask Haydn! But I DO believe it is daft not to fit one. And every time I read of the latest disaster, my feelings are re-confirmed.

[dreamwarrioruk]

only jesting mike.

regards to this one, it could be a pinhole leak like what dabs has. or like mine with a porous pipe, which had no squirting trail.
i had a seal go in the turbo water jacket that was a nightmare to find.

[mrsdreamwarrior]

you better get that seal out before it blocks everything up,poor thing will want somefish by now