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MarkOver 12-14-2013 02:21 PM

New 5.7 Hemi engine needed for my new GC
Went in for the "blue smoke on start up" TSB and general software update, the car has done 6500 klms. Got a call from the dealer saying that they're replacing the radiator as well as it was partially blocked with casting sand! I did notice the temp creeped up a bit in heavy traffic, not over half way on the gauge though.

Anyway, picked the car up from the dealer and noticed was a bit noisy on start up. Hmm, never heard this before. Told the service manager and he asked me to come back the next day as all the mechanics had gone home. Driving a short distance home, engine light comes on and goes into limp mode. What the hell did they do to my car?

Next morning, noisy start up and low oil pressure warning! Shut the engine immediately, I checked oil level, it had plenty of oil, actually was 3/4 inch over. They can't even fill oil levels correctly! Start the engine, oil pressure fine but still noisy and deliver back to the dealer in limp mode.

Again, after a couple days got a call from the service manager's secretary, in a polite casual way, she said they will need the car for another month, they've ordered a new replacement engine and thanked me for my patients!!!! Huh, what just happened?

After a few more "robust" discussions with the General Manager, they gave me a courtesy car but I'm still waiting for their head technician to explain what failed (they said he had just left for the day). I've got some theories what happened, but Ill find out more early next week and post their "explanation".

Looks like I'm travelling the Victorian High Country in the Nissan Pulsar (courtesy car) this Christmas break rather than the GC. Not sure if it's going to handle some of the tracks that I was planned to take!


Peter_K 12-14-2013 02:43 PM

I don't get the radiator part. Casting sand? Radiators aren't casted like that. Casting sand from the engine block? That'd be one heck of a screw-up. And how did they determine that?

The temperatures you describe seen pretty normal. The 5.7 will creep up a but in stop and go or low-airflow situations but generally right before the halfway mark on the gauge the fan kicks in and brings it down.

Very strange indeed.

MarkOver 12-14-2013 03:08 PM

Re: New 5.7 Hemi engine needed for my new GC
Yep, casting sand from when they manufacture the engine block, ended up in the radiator. Wouldn't have been much then, but enough to warrant a replacement radiator. I don't think it's related to the engine failure as the oil circuit is different from the cooling circuit. I suspect they stuffed something up when the had changed the engine sump over with the updated one that has the oil windage tray built in as per the TSB requirements. Who know's what the monkeys did.

13ovsummit 12-14-2013 04:30 PM

Re: New 5.7 Hemi engine needed for my new GC

Originally Posted by MarkOver (Post 945349)
Who know's what the monkeys did.

And it sounds like they aren't planning on telling you the real story either.:motx:

Peter_K 12-14-2013 05:15 PM

I seriously doubt there was casting sand in the block. With the number of cleaning, machining, and heat treating steps they go through it would be so improbable to have enough left in the block anywhere to gum up anything.

Two more probable possibilities:

1) Coolant additives coming out of suspension because of incompatible coolants mixed or contamination of some sort.

2) They punctured or damaged the radiator while doing the other work (which they might have messed up as well given your other issues now) and for some reason don't want to admit to it. I have seen that one before.

jasecoop 12-14-2013 05:35 PM

That really sucks. They should also give you similar car in my opinion. Mine is back at the workshop after 1100km. If I need a courtesy car I'd need more than a pulsar to tow my boat

Qmulus 12-17-2013 08:02 PM

Re: New 5.7 Hemi engine needed for my new GC
This not unprecedented. An Audi tech friend of mine told me of a new A4 that the owner complained of having no heat. The tech replaced the heater core, which was full of sand. Then it started overheating, so the replaced the thermostat and radiator, which also had sand, but it still overheated. Then they replaced the head, which had sand in the passages. Still had problems. Sooo, in the end it got a new long block under warranty along with ANOTHER heater core and radiator flush. Problem solved.

The theory is that something had blocked the sand from coming out of the block when it was cast, and it slowly came out as the car was driven, finding its way all over. It ended up costing Audi a ton of money in warranty and likely one very frustrated customer (and service tech).

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