Thread: EGR cooler replacement Puma 2.2

To remove, it's 6 bolts, but those 6 bolts are above the bellhousing, at the back of the engine. On the hot side at least there will likely be some annoying inteerference by the cat converter, IIRC.

How certain are you that it's the EGR cooler?
Other suspects could be fuel cooler, but I'd suspect this would be coupled with lots of white exhaust smoke as coolant burns off.

The manual suggests pressurizing the system to identify source of leak, but no help if it is leaking into combustion chamber by head gasket, fuel system (possible to hydraulic engine).
EGR cooler may be able to be diagnosed with coolant system pressure and removal of the elbow hose just below the butterfly valve / intake manifold- water should leak out if you have a crack in the heat exchanger here.

If you do it yourself sing out. I'll drink the beers. You can put the kids to work removing all the fiddly bolts in the small spaces. It will be character building.

>>>the OBD2 scanner showed coolant temp going to 110 and the oil temp going to 120

Hi Dave,

is your OBD2 scanner giving you an oil temp reading? I am using ultra gauge on my 2012 2.2 and I aren't seeing an oil temp option. Is this a post 2012 feature or is your scanner better than my ultra gauge (or both)?
The highest I have seen the coolant temp on my vehicle is 97. Alarm set at 96.

Thanks

Kerry

FWIW my oil temp reads -87 degrees sometimes.
I think the wiring to the sensor can be a bit cantankerous sometimes. Nanocom.

Originally Posted by rgty_kmj

>>>the OBD2 scanner showed coolant temp going to 110 and the oil temp going to 120

Hi Dave,

is your OBD2 scanner giving you an oil temp reading? I am using ultra gauge on my 2012 2.2 and I aren't seeing an oil temp option. Is this a post 2012 feature or is your scanner better than my ultra gauge (or both)?
The highest I have seen the coolant temp on my vehicle is 97. Alarm set at 96.

Thanks

Kerry

Hi Kerry, I have a wireless OBD2(OBD-AUS OBD2 Car Scan Tool Bluetooth Diagnostic Scanner Code Reader ELM327) scan tool which has the oil temp as an option.

I have removed EGR coolers from both my 2.2's both leaked around the 100000Km mark.
The cat will mask this as it seems to cool the steam in the exhaust.
You can pressure test in vehicle by setting up a regulator and hose.
Remove both coolant hoses connect hose to one fitting on cooler from regulator and give it 7psi and close tap to hold pressure if it drops you have a leak.
I am in Muswellbrook if you want me to test it for you.
You can also remove both hoses from the cooler and fully remove one and loop the other to the fitting that is open from the removed hose.
Mark

Its a reasonably common fault on the Defender TDCi 2.2lt. The heat exchange on the EGR cracks internally allowing exhaust gas into the cooling system.
pressurizing of the cooling system is the symptom and can be easily checked by bypassing the heat exchange on the EGR, simply loop a coolant hose from each line that goes to and from the egr.

I've had prolly 3 or 4 come in that others had said the engine is shot and needs replacing or the heat gasket is gone.

The Ford ranger 3.2 does the same old thing.

P.S actually I remember a couple of them the temp gauge went off the scale which prompts limp mode.

Just to finish this thread. The EGR cooler was leaking. I bought genuine but would have been cheaper to sell some organs. Fixed the problem now with new thermostat the engine temp never gets above 92 degrees up hill, and stays around 89 at 100km/h level ground.

I can only say that having the OBD2 running all the time saved the engine from damage as a flashing red symbol set to my own threshold made me stop and investigate. The normalised temp gauge is not worth a cracker!

Truck has just turned over 205,000 km. I should have cleaned the intake manifold but had to assemble quickly to go on holiday. Interestingly I have been adding the 2 stroke marine oil and the inlet manifold only had a thinnish layer of carbon after looking with a borescope. Will do it after the Christmas break

Adding marine 2 stroke oil was an old suggestion when the EGR systems were first introduced to common rail engines.

Originally Posted by DazzaTD5

Its a reasonably common fault on the Defender TDCi 2.2lt. The heat exchange on the EGR cracks internally allowing exhaust gas into the cooling system.
.

Do you think the EGR bypass from BAS eliminates this risk?

A nice video about it.
Blanking The EGR Valve 2.4 2.2 TDCI Land Rover Defender Ford Transit - YouTube