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 Posted: Sat Jun 20, 2015 5:19 pm |
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Joined: Jan 29, 2011
Posts: 6526
Trade Rating: +10
Location: Westhoughton, Lancashire
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My 2003 TU3 developed a misfire below 1200 rpm when the engine was hot. The fan was coming on at 107 and cutting out at 104, so thought temp sensor might be on the way out. When it was changed the car ran at normal temp but the misfire was still there. Checked the cylinder compression and all were around 14 bar (210-213 psi) so all pretty normal. Spark plugs showed no signs of a problem and pressure was staying in the expansion bottle over night.
PP2000 bought up a number of faults, ignition, air temp, inlet air pressure, injector but I did notice a bit of emulsification on the oil cap and the coolant was starting to look dirty.
Took the rocker cover off and was met by this
Head off time and was met with this gasket
] 
I've never seen a head gasket rotted that much at 76k miles.
About 2 years ago I had oil in the coolant and put some K-seal in. This may have accelerated the rotting, but did it's job, even if temporarily although there was no oil in the coolant this time so may have worked.
Head going in for a skim on Monday. Valves will be reground and then car will be rebuilt. New water pump and timing belt are going on too since the engine is almost stripped
Hopefully this will solve the misfire. I'll update on Tuesday when the engine is running again.
Goes to show that although the computer may point to faults, they may not be that obvious and possibly more to it. A sniff test would have pointed towards the head gasket, so better to cover all bases before just throwing parts at it.
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Posted: Sun Jun 21, 2015 5:59 am |
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Joined: Feb 07, 2010
Posts: 7093
Trade Rating: +11
Location: Suffolk
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I am suprised the compression test passed with a gasket that bad, though be it you have faults for injectors so dont be suprised if it does not fully fix it. Either way avoid ever putting k seal in again, that stuff is a temp fix and can lead to a lot of issues in the future!
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| Team Impossible Possible
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Posted: Sun Jun 21, 2015 11:24 am |
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Joined: Jan 29, 2011
Posts: 6526
Trade Rating: +10
Location: Westhoughton, Lancashire
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That's what was baffling me Addaz, Can only think that it was something to do with being a cold engine when I was cranking it over and with the misfire only coming when the engine was hot, it was all down to expansion.
Cleaned the head up today ready to go in. Badly pitted between the 2 coolant holes.
and around the cylinders
Not sure how much the deep pitting will affect the head skim as it seems to just sit in water (right hand side of engine)
but if they won't skim out, then recon head at £200 is on stand by
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Last edited by macca1411 on Sun Nov 22, 2015 1:37 am; edited 1 time in total
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Posted: Sun Jun 21, 2015 1:43 pm |
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Joined: Feb 07, 2010
Posts: 7093
Trade Rating: +11
Location: Suffolk
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For your needs, i dont think you will see any issues. But i would consider a thicker gasket and a larger skim to try and remove as much as possible
Whats your anti freeze content like and last change?
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| Team Impossible Possible
The only way of finding the limits of the possible is by going beyond them into the impossible - Arthur C. Clarke
Forged 1.6 Turbo
Click to see more
144Bhp @ 7PSi - 193.9Bhp @ 13psi
206 Gti Race Car
Click to see more
For all Race/Track Preparation, Feel Free to PM Me!
Whether its for a custom ratio gearbox or track-day alignment, I can help! | |
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Posted: Mon Jun 22, 2015 4:38 am |
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Joined: Jan 29, 2011
Posts: 6526
Trade Rating: +10
Location: Westhoughton, Lancashire
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At the last change about 12 months ago the antifreeze was still a bright pink. Flushed and replaced with a 50/50 mix.
Seems to be the gasket has just gone with old age. Where it sits in the coolant on the underside has just rotted away. It has been on the car for the last 12 years so the constant barrage of boiling water is going to take it's toll on it.
It seems like a daft design to just have a gasket with nothing on either side of it. It's as if it was built so that the rings will keep the cylinders sealed, the outer edge stops fluids escaping, but the rest of it is all surplus material. Nearly as bad as a K series, at least Peugeot left enough edge for the gasket to clamp to.
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Posted: Wed Jun 24, 2015 3:41 pm |
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Joined: Jan 29, 2011
Posts: 6526
Trade Rating: +10
Location: Westhoughton, Lancashire
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Got head back today. They made a good job of the skim and threw in a thicker gasket
The car is now rebuilt.
Engine running fine. No fault codes are coming up.
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Posted: Wed Jun 24, 2015 3:59 pm |
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Joined: Nov 27, 2010
Posts: 11520
Trade Rating: +10
Location: What's it to you? ? ?
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Excellent result 
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Wed Jun 24, 2015 4:27 pm |
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Joined: Mar 06, 2015
Posts: 99
Trade Rating: 0
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Wow...that is a naughty gasket! When you get the oil leak on these 206's...this is also the gasket right? As it is a common thing. If you have no oil water mix...should you leave it or think about changing? No skimming needed if it hasn't failed....say via like over heating? Sorry if they are noob questions.
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Posted: Wed Jun 24, 2015 4:35 pm |
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Joined: Nov 27, 2010
Posts: 11520
Trade Rating: +10
Location: What's it to you? ? ?
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| MrMac wrote: |
| No skimming needed if it hasn't failed....say via like over heating? |
Always a good idea to give an aluminium head a skim unless your 100% sure its perfectly flat.
Also let the machine shop supply the head gasket so its the correct thickness.
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Wed Jun 24, 2015 4:40 pm |
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Joined: Mar 06, 2015
Posts: 99
Trade Rating: 0
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And a rough cost of such a thing?
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Posted: Wed Jun 24, 2015 4:44 pm |
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Joined: Nov 27, 2010
Posts: 11520
Trade Rating: +10
Location: What's it to you? ? ?
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| MrMac wrote: |
| And a rough cost of such a thing? |
You would need to ask your local engine repair centre / engine machine shop for a price.
FWIW a TU head is pretty simple & they would have done loads over the years so cheaper then something more exotic.
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Thu Jun 25, 2015 12:44 am |
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Joined: Jan 29, 2011
Posts: 6526
Trade Rating: +10
Location: Westhoughton, Lancashire
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I went to Wigan Engine Services and they charged £40 for the head skim with valve grind.
All in with fluids, head set, bolts, water pump and timing belt it came to about £160, although that was partly due to a good relationship with my local factors
As MrBSI says, it was pretty simple to do. All in it probably took about 6 hours and that was my first time doing a head on a TU3 and I was surprised at how few tools were needed. Think it was 10, 13, 16 and 22mm sockets, female torx E14 socket, pliers and flat screwdriver and a torx bit. Torque wrench and angle gauge for the head bolts and a 10mm bolt to lock the camshaft and a 6mm pin to lock the crank
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Posted: Thu Jun 25, 2015 7:56 am |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Hoping they skimmed as much as they've thickened the gasket, or at least very close to it
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