Thread: TD5 Fuel Cooler leaks.

Hi M2,

Is it definitely the fuel cooler? on a D2 it is under the inlet manifold plenum and runs along front to back, about 8 inches long and cylindrical. it is an unusual leaking place for these. Most fuel leaks on these come from the fuel pressure reg which is at the back drivers side of the cyl head, behind number 5 inlet port.

Any more info?

JC

There was another thread just two/ three days ago on exactly the same subject. The guy was quoted $800 .............they are avaiable from the UK for less than $300.00 delivered.

Originally Posted by justinc

Hi M2,

Is it definitely the fuel cooler? on a D2 it is under the inlet manifold plenum and runs along front to back, about 8 inches long and cylindrical. it is an unusual leaking place for these. Most fuel leaks on these come from the fuel pressure reg which is at the back drivers side of the cyl head, behind number 5 inlet port.

Any more info?

JC

Thanks Justin, it's a coolant leak, not a fuel leak. He'd just repaired his first coolant leak (twin brazed pipes somewhere) and then this one sprung a leak.

No worries, yes they can corrode through although I haven't yet seen one do it. I guess he has checked the hoses and fittings? I would get a second hand one if new is $$$$$, as they aren't usually a big prob. Also, if he has already had these corrosion issues so far, I would recommend fitting a new oil cooler BEFORE it gets eaten through and fills the cooling system with engine oil. Check George130's threads on this drama - NOT something you want to experience!!!

JC

How hard are these to remove?

My mate says he hasn't seen any corrosion issues while attending to coolant issues. He recently replaced the twin metal pipes under the radiator (where the drain plug is) as there was a leak in the brazed joint and saw no corrosion there.

The fuel cooler, he describes as a stainless cylinder with bakelite ends, and the coolant is leaking from where the ends clamp onto the stainless cyliner.

He's removed the hoses and all looks fine at the joints.

Does the mating service where the bakelite ends meet the stainless cylinder have sealant on it?

If not, can it benefit from some sealant? & what type?

Thanks for the advice so far. I'm relaying to him as it comes.


M2

We replace O rings on these every now and then. A bit fiddly, but possible. The over-centering clamps that hold them together can be a bugger to do up again. From memory, the O rings we use are BS225 available from CBC.

Hi Bigjon,

My mates inquired about the O rings and was given the following specs for the p/n quoted.

• ID 47.625mm
• OD 54.7mm

He thought that sounded a bit small, and wondered whether you could confirm, the p/n or size. He's hoping to do the job over the weekend, so he'll go ahead and get them & hope they're the right ones. Any confirmation would take some anxiety off his mind

Thanks, M2

I don't have a proper O ring measuring tool, but using vernier calipers gives a reading somewhere around that.