Big engine problems

Over the last 6 month's I've done a load of jobs on my turbo x. I've taken the baffels out of the exhaust and it sounds fantastic, I've also re-designed where the boost pipes are located so it is a much tidier job and not as low down as before.
The main reason it came off the road was because of the leaking core plugs. I made a real fuss of this job replacing with new, cleaning the surfaces and sikaflex'd them in. I fired the car up for the first time last night and all was well, started instantly and purred beautifully.

Once warm I gave it some revs, and to my dismay it started spraying coolant out of the core plugs again under boost. So there must be something seriously wrong, and the boost pressure must be leaking. Either the head gasket has gone (about 3000 miles) or there is a crack in the block. I'll look a bit further on Wednesday night when we have our regional pub meet with a few off the chaps. A mate at work is lending me a 'sniffer head gasket tester' - I've never heard of one but it tests the coolant to see if any exhaust fumes have entered. Either way, I'm pretty gutted after loads of work. Looks like I'll be at Brooklands in the rusty Gran Finale - if I get the MOT done in time!

If it's a cracked block or head is there a way of testing the coolant system with the engine cold to see if the crack is affected by the engine warming up and opening up a gap? does the leak get worse as the pressure builds up on the turbo boost?

Yes and yes. Had a brief look tonight. Took the cap of expansion tank and revd it when it was warm. No bubbling in the tank. I'm going to buy one of those little inspection mirrors tomorrow so I can get a better look at the leak. You can't see much in there with all the turbo kit attached

Well all is revealed. Bought an inspection mirror and found the block of the uno turbo engine has rusted through lack of antifreeze in a previous life. Just what you need at the start of the show season. The leak is from something no bigger than a pin hole in the water jacket. I've done a bit of research and I think this wonderful block sealer stuff on the market will simply clog up my water system and make it overheat. So its turbo off, waterpump pipe off and begin cleaning up the surface. On various forums, JB weld seems the product of choice so I'll give it a go and hope that it will hold for this season.

So my sweet, sweet balanced engine will have to be ripped apart again, hopefully in the Autumn. Choices though - which block?

Punto, another uno, x19 or attempt the 1.9 conversion????

Rob, my Uno Turbo cylinder head started pissing out water just below a spark plug out of a pinhole sized hole in the ally water jacket. I drained it all off and cleaned it up and used liquid metal glue.
I have a brand new Uno turbo spare engine in a crate sitting here, but its still going 8 months and 2 track days later!

I'm not sure how easy yours is to get to, if you've got to strip it all down then you might aswell do it properly, if you can get to it give it a try.

It's very easy to get at. I have a removable alloy boot floor that once lifted gives complete access to the engine bay. I replaced the core plugs over Christmas thinking they were the fault. It just means taking off the turbo and metal water-pipe (again)and trying the JB weld product. Luckily I've had an offer of a Mk2 block for nothing so the plan is to bodge it for this season and rebuild it all in the Autumn.

Hi Rob,

Glad to hear you're still going to Brooklands chap - look forward to catching up with you then. If JB weld fails, and there is no reason why it should, you could always drill, tap and thread lock a grub screw in?

Cheers

Darren

Ps - Wales driving route sorted for weekend of June 7/8 - 130 miles over Epynt and Élan Valley - chat more at Brooklands!