200tdi overheating on highway - Defender Source
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  #1  
Old August 8th, 2016, 09:39 AM
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Chad Blackburn
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200tdi overheating on highway

My 91 RHD 200tdi D90 is is overheating when on the highway. In the city it runs nicely.
I've hypothesized that having the turbo engaged for an extended period of time is the culprit.
Anyone have a similar experience?

Replaced thermostat
Flushed radiator

We have some evidence that it's getting hot for sure.
50mph and above.
Tires are 31inch.
I have the standard gearbox I'm in 4th and 5th gear at highway speeds.
The temp starts to creep up when I hear the turbo start to spin up for a extended period of time.
Mechanic confirmed that the viscous fan is functioning properly and the shrouds are in place.
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  #2  
Old August 8th, 2016, 09:52 AM
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Go get it nice and hot and then check for cold spots on the radiator with a thermo-gun. You might not actually be getting hot…might just be the gauge/sender acting up. Electric fan or mechanical? Shrouds in place? Gearing/tire size? Speed you are driving on the highway? Too many variables to just know outta the box what's wrong.
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  #3  
Old August 8th, 2016, 10:10 AM
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I would check the viscous unit on the fan as a first stop. And see above for important questions. You need to provide a lot of details for us to help.
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Old August 8th, 2016, 10:11 AM
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  #5  
Old August 8th, 2016, 10:25 AM
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Don't forget about the other coolers in the system. Intercooler and oil cooler. Problems with those could also contribute to insufficient cooling.
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  #6  
Old August 8th, 2016, 10:28 AM
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Quote:
Originally Posted by east high View Post
Don't forget about the other coolers in the system. Intercooler and oil cooler. Problems with those could also contribute to insufficient cooling.
I'm highly suspect of the intercooler. What are some trouble shooting steps for the intercooler and oil cooler?
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  #7  
Old August 8th, 2016, 10:36 AM
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Hmm. Probably clogged fins would be what I would check first. A leak in the intercooler pipes would be revealed as poor performance. I'm just spitballing with the oil cooler, but you might check for obstructions in the oil filler housing ports and hoses next time you service it. Check the rad fins in that area too. Basically anything that prevents heat diffusion will cause the engine to overheat.


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  #8  
Old August 8th, 2016, 10:48 AM
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if you are running hot on highway with all that rpm pushing fluid and large amounts of air circulating , then it is possible that you have internal combustion issues.
back to baseline, make sure that thermostat, cooling fan and its clutch, radiator, heater core, and water pump are in good working order, no obstructions or kinked hoses.
above all verify that the sending unit is working properly otherwise any diagnosis is futile.

there is a difference in "running hot" which may be up to 210, overheating "210-220" and "boil over" over 220.
keeping an engine at a constant safe temp "180 to 205" and running properly is one of the biggest challenges manufacturers face in controlled conditions, then add the uncontrolled real world plus wear and tear and were lucky not to blow an engine very time we drive .

not a lecture just a basic idea of where to start and how to proceed with a proper diagnosis and why?.

good luck.
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  #9  
Old August 8th, 2016, 10:52 AM
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do you have a EGT gauge fitted/? a proper temp gauge with numbers?

did you you or your mechanic do the newspaper test on the cooling fan when HOT to check the viscous unit is correct?

fueling been buggered with?

has the intercooler been cleaned? I have four units in the scrap bucket with missing fins. They lose efficiency with age.

Is/has the water pump been checked, using any water.

Is this a new happening? how have you owned this vehicle.

how old is the radiator? been cleaned&checked. as a 200 tdi runs cooler at speed than idling.

both of my twohundys run at 85-90 up hill and dale all day long usually towing a trailer
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  #10  
Old August 8th, 2016, 10:55 AM
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Overheating 101:

The standard cooling system working well is capable of vastly OVER COOLING the engine. To prevent over cooling the thermostat slows the flow of coolant round the engine to keep it all up to temp.

As the engine works harder it generates more heat but the effect of moving forward creates vastly more cooling effect and again the thermostat regulates to keep the engine warm

The viscous fan is to provide additional air movement and if it cut in on the highway then it's trying to cool something that's already well up at the top end of what its capable of.

I would check the cooling system for in order:

1. does it pressurize? It won't cool effectively if it's not ... do your hoses firm up?
2. Are the fins blocked restricting air flow
3. Is the radiator restricted ... they silt up at the bottom ..
4. is the thermostat opening properly - probably OK because it's good in town
5. viscous fan - unrelated to this problem but checking all is in good condition might as well add this to the list!

Additional heat can over stretch a decent cooling system ... head gasket leaks can inject huge amounts of heat into the coolant ... fueling and EGT could also add excess heat.

If the truck is running well i'd suspect the cooling system, especially if its a bit old.
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  #11  
Old August 8th, 2016, 10:57 AM
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You say "standard gear box " what ratio transfer case do you have ?
A 1.6 will cause problems you describe @ highway speed with a tdi.
RPM are so high that coolant flow is so fast through radiator that it
doesn't transfer heat.

------ Follow up post added August 8th, 2016 10:59 AM ------

Quote:
Originally Posted by cpblackb View Post
I'm highly suspect of the intercooler. What are some trouble shooting steps for the intercooler and oil cooler?
highly doubt that is your issue
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  #12  
Old August 9th, 2016, 12:41 PM
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My truck use to heat up slowly on long highway halls even with a new stock radiator. I replaced it with the Uprated Allisport unit and it runs cool now.
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Old August 10th, 2016, 11:40 AM
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Quote:
Originally Posted by TDI Guy View Post
My truck use to heat up slowly on long highway halls even with a new stock radiator. I replaced it with the Uprated Allisport unit and it runs cool now.
Tell me about this Upgraded Allisport radiator. Can you share a link to the part?
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  #14  
Old August 10th, 2016, 11:45 AM
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You should not ever need a larger radiator. I have fueling cranked up and tow a trailer over the mountains. It never, ever gets too hot.

Fix your problem. Do not look for bandaids. It is not your intercooler or oil cooler.
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  #15  
Old August 10th, 2016, 01:11 PM
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Mine use to overheat and it was a brand new crate motors with new rad and intercooler.
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  #16  
Old August 10th, 2016, 01:50 PM
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mine gets hot on long 65mph+ drives. this is with a 1.2LT230.
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  #17  
Old August 11th, 2016, 09:50 AM
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YEs just on long hauls on the highway at 65+ With the uprated rad its all good.
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  #18  
Old August 11th, 2016, 12:18 PM
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Quote:
Originally Posted by BostonAndy View Post
mine gets hot on long 65mph+ drives. this is with a 1.2LT230.
Andrew did you get the temps from an ir gun?
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  #19  
Old August 11th, 2016, 12:26 PM
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I'm guessing your viscous units are not working. Once you work it really hard, the fan is what manages the temperatures.

I have a variable speed electric fan and an EMS. I can see the exact temperature and when the fan is at different speeds.
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  #20  
Old August 11th, 2016, 12:52 PM
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Quote:
Originally Posted by 1of40 View Post
Andrew did you get the temps from an ir gun?
no IR temps for this. Its only happened a few times and it's when I get into the flow of traffic and see that i'm hauling ass. gauge drops quick after I let off.
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