Ok so I changed out the radiator & thermostat + housing over the weekend..started her up ran it burped it all sweet temp was good and no leaks.

Nek minnut (next day) started her up again...drops from the bottom of engine bay.

Turns out a drop every second from turbo water inlet and another at waterpump feed. (see pics attached)

Im stumped as to how this was ok the day before? All I can think is that refilling it with 8 litres of subi coolant killed some corrosion (as you can see the turbo inlet is corroded to all hell) and doesnt have much of a lip thing on it to seal when I removed that hose last night...was also full of rusty gunk and yeh not looking too good.

Car has done 144,000kms would I be right in guessing from the pic of the old thermo housing possibly this car never had the 100,000km timing belt and waterpump replaced? inside the waterpump when I removed the thermostat looked pretty much the same as the old housing.. hence possibly the subi coolant acted well killed some corrosion which part of was near the lip seal of the inlets thus causing me to have leaks now?

Really upset cos I have this booked to go over the pits Thursday..low budget and doesnt look like its gonna happen.

If anyone has an old TD04 or a spare inlet to help me out with at least that part of the problem would be greatly appreciated.

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I'd hate to see the inside of your heads & block

Was there no corrosion inhibitor in it previously?

What condition was the thermostat in?

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Car was parked and unused for 3 years.

Had radiator water/coolant dropped and replaced just prior to me purchasing it but seller realised then it had leak in rad..turned out to be hairline crack in side tank as I tested when removed.

Thermo was ok, I tested it in boiling water opened up no problem but still I replaced that and the housing.

Removed the 2 problem area hoses last night, cleaned inside of hoses and pipes, scraped rust and gunk off and cleaned with foil and water (creates reaction to clear rust)

Reinstalled hoses clamped and tested ok

Thread can be closed.


*started at 7 finished at 11.30, drank rad fluid when removing water pump hose and had an eye wash, 1 lamp fall onto my phone and smashed my phone screen and lamp globe but....the car is running! oh what a night

Always good to use proper hose clamps in these situations too.

The OEM ones that come off with the pliers will be more prone to leaks that a Tridon one for example, that can be tightened with a screwdriver.

can you please make sure you flush those fluids again in about 1000km... the shit built up in that engine would be horrendous

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Lol. Such a clumsy git Joe.

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Yes I swapped the turbo one around from the clamp to the screw one - the water pump one I had to leave as is for now but will replace in future.

Yep I plan on....just trying to get it licenced atm spent some $$ last week on 8 litres of subi fluid thermo, housing, gasket ect...but I agree im probably going to change the water pump and do a timing belt kit to be on the safe side

If the car was sitting that long also make sure you clean the earth points even adding another from the chassis to engine and Negitive terminal to engine is a good idea.
Will help in reducing corrosion and also with the electrical system especially if car was left untouched for 3 yrs in condensation (morning dew) etc.
Probably be a good idea to clean all the connectors with electrical contact cleaner . Sounds like a pain in the ass but will aid in not having sensor faults etc from bad connections and earth.

Good luck with the pits if your turbo continues to leak I have a 40000km old good condition tdo4 spare you can have for $80 also have a spare new water pump and thermostat housing if needed you can have cheap.