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  #1  
Old July 3rd, 2011, 08:08 PM
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Julien Dalbin
05 Tdi 90
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4.6 gurus ?

After a major maintenance on my wife 4.6 D2 I'm getting a few bugs.
Basically I disarm all the top part of the engine less the heads.
Did not want to change the head gasket as the truck has only 40 K miles
so I guess that can wait a little more. All parts were cleaned very well, all
gaskets and o-rings are new, injectors cleaned, new spark plugs and wires,
exhaust manifolds wrapped, engine harness got hi-temp sleeving, new valley
gasket, new valve cover gaskets, etc...

1. Engine won't hold rpm on first morning start. Before that maintenance
when you cold started it, it will climb to 1,500 rpm, stay there for 30 s and
then level around 800 rpm. Now you have to do it with gas pedal.
2. Coolant circuit is getting pressurized really quick, much before engine will
warm up. If you run it for a couple of minutes it will build up some pressure.
3. I'm getting codes P0130 (02 sensor circuit malfunction) and P0171 (too much
02 in exhaust).

Other than that it's running real smooth

Thoughts ?
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  #2  
Old July 4th, 2011, 12:51 AM
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Tony Sims
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1. Sounds like a vacuum leak.

2. The only thing that should create pressure in the coolant system is heat. However, if the cooling system is not properly sealed, the lack of pressure can allow the coolant to boil. This usually requires more than a couple of minutes, more like 10 or 15 minutes of normal operation at the least. Check for any leak from the work you did.

The only other source of pressure in the cooling system is a leak from a cylinder -- like head gasket failure, cracked head, slipped liner...

3. You had the intake manifold off, yes? Possibly did not get a good seal back to the heads, there is unmetered air getting sucked in the intake track. Ref answer to 1.
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  #3  
Old July 5th, 2011, 09:31 AM
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Julien Dalbin
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Thanks for all the good information.
Still looking for the vacuum leak, the main vacuum hose is probably the only hose I did not change. However, it's in good condition so I'll check every vacuum connection.
I'm making my own device to pressure test the coolant circuit, with an old coolant tank cap, bicycle pump and a few hoses. How much pressure am I suppose to pump in the circuit ? 15 psi ?
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  #4  
Old July 5th, 2011, 09:52 AM
eliaschristeas
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elias christeas
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the cooling system runs on 15 psi. a little confused though. what did you actually tear-down to? why did you do it? aside from high idle at start what else was going on?
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Old July 5th, 2011, 01:54 PM
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Julien Dalbin
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Quote:
Originally Posted by eliaschristeas View Post
the cooling system runs on 15 psi. a little confused though. what did you actually tear-down to? why did you do it? aside from high idle at start what else was going on?
Had a few small coolant leaks (throttle housing, radiator small hose to tank, etc...), the valve covers were leaking, the valley gasket was leaking, old plug wires, etc... I was also getting random misfires.
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