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2008 V8 FSI Coolant leak.

1.8K views 4 replies 2 participants last post by  Spiegelglatt  
#1 ·
Ggg

2008 V8 FSI had expansion tank rupture. I replaced with VW OEM new part (updated part number) purchased from dealer parts. Also replaced cap. Lower hose had pine hole at nipple so I shortened pipe and refitted. Leak gone.

I also cleaned everything up and washed down the motor and underside to get rid of coolant.

Drove for a few weeks with no leaks or coolant smell.

Came home and found coolant on floor again…small stream less than 1” wide by 24”. No change in coolant level still at max. No hoses show leaks. Traced to insulation between new expansion tank and plenum metal. The insulation is soaked and dripping down to floor. There are no hoses that go through this. However a few weeks ago this was soaked when the expansion tank went.

I accidentally forgot to push the overflow tube back into the fender when I installed. I found no trace of fluid in pipe or inside expansion tank under cap (visible exit).

I am stumped because 1) I am not missing any coolant. 2) what is on the floor is coolant. 3) I can see where it is coming from but there is no source in the insulation. Insulation is soaked even up to top above where anything is even located in the engine bay…so wicking up I guess from someplace.


The picture below was once everything was out but before cleanup. The insulation I am talking of is visbable front and center.

Thoughts?
Image
 
#3 ·
Yeah, maybe the drops of coolant was from the liner/insulation being soaked from the original leak but keep an eye it for sure!
What does the dealer charge for the new expansion tank and cap? I’m fairly certain mine (08’ V8) will eventually pop soon :ROFLMAO:
 
#5 ·
oh man, the cap was like 60 bucks and the expansion tank was over 200. I try to forget the exact amount. Lol

It is definitely good to be proactive on this…would have been a tow if not for happening in my garage. The other sign this is common is the dealer had it in stock! 🤔 so must be happening now that these are older AND the new one had an updated part number meaning they changed something (hopefully for the better).
 
#4 ·
Oh and a “free tip” for anyone doing the expansion tank replacement. There is a bracket just to the bottom (out of the picture I posted above) that has a bunch of electrical connectors going through it. It is held on by a strut tower bolt that is a stretch bolt. I decided not to remove the bolt (just is dumb design) to wiggle the tank out-but I removed all the electrical connectors and then bent the entire bracket so it is out of the way (allowed me to remove tank and replace new one). The bracket won’t hold one of the connectors now (bent in the middle of one) but I also didn’t have to remove a stupid stretch bolt, pay 6 bucks for a new one and re-torque.

I believe what happened above with the secondary “leak” was the coolant wicked into the insulation when the expansion tank blew up (like Niagara Falls) and it took it a while to travel down the firewall behind the heat shield…only way I can explain it. Washed and still no trace (plus no more lingering coolant smell).