Some simple fixes I tried before going further were:
1. Trying a new cap - as it might be releasing less than 1bar.
2. Remove the thermostat.
3. A pourus radiator.
4. Air in the system - so filled it up by the rad.
5. Back flushed the radiator.
6. Pressure tested the entire system and looks for leaks. These may be drawing in air.
After a bit of investigation it turned out to be the dreaded head gasket. To explain in more detail, the water was building up a pressure into the coolant system slowly as I drove. When it reached 1bar, the limit on the cap, it blew about a litre out the back of the tank.
A diagnoses I easily reached by taking the cap off > replacing it > then holding the main coolant hose and revving the engine from the bonnet area. I could feel the pressure build up my hand but didn't see it blow out the cap (which it did after about 30mins of driving). There was also
small bubbles coming through into the reservoir. I certainly couldn't afford a dealer to do it and most garages said no chance when I mentioned the problem.I've never done a cambelt before (brakes and oil pumps were my previous best!) but was willing to try, so I bought a Brookes workshop manual and did as much research as I could.
I got some morale support from a friend who is mechanically minded (the picture says it all) and off I went:
Some things I learnt along the way:
- Plan to get it skimmed 'well' in advance. It's not always the 1/2 day job they tell you!
-Leave the lower cambelt cover on if you can. The belt can the manoeuvred out.
-Mark the cam belt pullies with tipex for peace of mind. If you leave the drill bit in the injection pump not a lot can go wrong. PM me if you need to know how to find the flywheel mark. ]
- Check the weather before starting. I did it on my mothers drive and after horizontal rain had to go to B&Q to buy a plastic sheet (£2), aka roof.
- Hit the dampener pulley off with a piece of wood and a hammer if it's stuck.
- Clean (and I mean clean) all the edges with a scalpel blade until spotless.
- Take photos of all the electrical connections. I forgot where some went after a week and had to resolve problems with earths and immobilisers going off.
- Leave all the injectors loose when trying to start it and do them up when it does to bleed air out.
I can write loads on this but as they say .. a picture says a thousand words:
