MYSTERIOUS OVERHEATING EVERY 100km (no sign of any leak)

[Sentech]

I'm quite new to this forum, having only owned my 2001 Carnival 2.9 Tdi a few weeks. Overall I'm impressed with the vehicle but until Thursday I hadn't exactly driven very far.

On Thursday evening my temperature gauge suddenly wound itself off the scale, I'd driven about 100 km but as luck would have it I was on the return journey and about 5km from home.

Friday morning I poured in 5 LITRES of water, drove the car .......... no problem, then in the afternoon same problem .................. "WAIT A MINUTE" where's all the chuffin' water going I can't see any obvious leak.

After some investigation, following all the pipes I arrive at the rear of the vehicle.

That rear heating system is a great innovation but the two rubber pipes that come out of it join two steel pipes attached to the chassis ............. these two pipes were looking suspiciously corroded ................ low and behold I'm losing water ......... not at an astronomic rate but enough to lose me 5 litres of water every 100km.

Pulling on the old coveralls to look deeper into the problem I took hold of said metal tubing and it broke off in my hand, a faceful of diluted glycol that's been in the heating system a while doesn't taste very nice I can tell you.

Removing the spare wheel, then using a hacksaw I'll shorten the metal tubing. Then with a few new lengths of 16mm water hose (bent to 90 degrees), two lengths of metal tubing (16mm) to rejoin the hoses, I will cure this problem.

Just thought I'd share this experience on the forum because it's bound to happen to someone else sooner or later.

Cheers

[John Kelly]

Originally Posted by Sentech

I'm quite new to this forum, having only owned my 2001 Carnival 2.9 Tdi a few weeks. Overall I'm impressed with the vehicle but until Thursday I hadn't exactly driven very far.

On Thursday evening my temperature gauge suddenly wound itself off the scale, I'd driven about 100 km but as luck would have it I was on the return journey and about 5km from home.

Friday morning I poured in 5 LITRES of water, drove the car .......... no problem, then in the afternoon same problem .................. "WAIT A MINUTE" where's all the chuffin' water going I can't see any obvious leak.

After some investigation, following all the pipes I arrive at the rear of the vehicle.

That rear heating system is a great innovation but the two rubber pipes that come out of it join two steel pipes attached to the chassis ............. these two pipes were looking suspiciously corroded ................ low and behold I'm losing water ......... not at an astronomic rate but enough to lose me 5 litres of water every 100km.

Pulling on the old coveralls to look deeper into the problem I took hold of said metal tubing and it broke off in my hand, a faceful of diluted glycol that's been in the heating system a while doesn't taste very nice I can tell you.

Removing the spare wheel, then using a hacksaw I'll shorten the metal tubing. Then with a few new lengths of 16mm water hose (bent to 90 degrees), two lengths of metal tubing (16mm) to rejoin the hoses, I will cure this problem.

Just thought I'd share this experience on the forum because it's bound to happen to someone else sooner or later.

Cheers

Hi
This is a very common problem. Had the rearmost metal pipes replaced under warranty.They were corroding after only 3yrs. People have tried replacing the whole lot with rubber hose or r/hose/copper pipe etc. Got underneath and plastered mine with spraygrease, and hope for the best.

Regards John.

[Sentech]

UPDATE

Having removed the rear wheel I took a long hard look at the problem these pipes are about 1.5 metres in length (including all the bends). They're only held on with 3 bolts, so I removed them for a closer inspection (cleanup). The more I cleaned the more holes appeared, eventually there were more holes than a sieve.

One quick trip to the local harware store, two 2 metres lengths of 16mm electrolytic central heating tubing, some re-fashioning of the clamps to hold everything back in its original place and the jobs a goodun.
Incidentally I phoned the local KIA agent for the interior filter (sits behind the glove compartment and cleans the incoming air), they quoted me 51 euros excluding 19% VAT. ??????????

Anyone on the forum know where KIA parts can be purchased at realistic prices ???

Cheers