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Hello all. I've tried to outline all the relevant stuff regarding this ongoing problem...

1998 T4 1.9 TD ABL 170000 miles.

-New head at 163000 miles after major overheating event. Pistons and rings also replaced.

-New turbo at 168000 miles as it blew. New cam belt and water pump and refurbished fuel pump fitted. Head removed again and gasket replaced as signs of exhaust gas in coolant. EGR blanked off where it bolts to exhaust manifold, and EGR bits removed from fuel pump.

The problem: exhaust gases pressurising coolant so that some is lost and some blown out when expansion tank cap is undone to release pressure. It has done this since the new head was first fitted but is now worse. Coolant now very discoloured. Engine running well otherwise.

Questions: can this be caused by anything other than blowing head gasket? As I said it is a brand new head and the second new gasket to be fitted so I am doubting it can be the head. Could this be caused by a crack in the block somewhere? If so can this be diagnosed without stripping the engine?
Could these symptoms be caused by the way I blanked off the EGR valve?

Really hope someone can help here...

All the best

Lee
 

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Stop wasting money as all the ABL i came in contact with had problems with overheating. Best solution is to buy a 1.9 tdi mk3 golf and swap the engine over. No more overheating issues, more power and also better fuel economy !
 
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