2005 D3 TDV6 loosing coolant on long trips

[Blumr2]

Hi All, bit of a fun one and been all over the forums from headgaskets, thermostat, hoses and her coolers even but no luck.

Over the past 4 months only on Longer trips Newcastle to Sydney or day trips of 200-300 Kim’s she will pressurise the coolant enough to have a few drops about the top of the overflow tank and engine bay but not that much and then when cools overnight needs about 200-400 ml to fill the bottle back to the cold fill line.

short trips to work and about it doesn’t do it, the longer trips are highway and with works you don’t really get over 80 much.

Ive had her back to the 4WD place I purchased from last Jan and we have TK tested without any signs, checked the thermofan coupling, replaced the thermostat, all hoses to and from, the plastic housing in the valley and pressure tested over night, left and driven, pressure tested again and it hasn’t show any signs of leakage. I would expect egr cooler pipes are rare to go and even rarer to pressurise just enough on long trips but could explain coolant leaking into the exhaust and vanishing? There are no leaks on the garage floor and she starts and runs well.

They have suggested a head gasket or crack that’s only appearing after a long run ? but we can’t get any conclusive proof, suggested a S/H engine swap as an option as playing with heads on these could be more trouble than it is now ?

Any thoughts or experience out there, also anyone verify if the later ford territory 2.7 tdv6 are the same? There are a lot of 2011 and later avail and I believe you need to swap the sump pan but the rest should be usable. [bigsad]

[PerthDisco]

Check plastic coolant pipe junction part at top of V on motor under the intake air piping. Drips for a short while and coolant probably evaporates on engine.

Has destroyed many an engine when it fully splits. If not already replaced yours would be guaranteed ready to blow any minute.

[Tombie]

Get some tracer for the coolant, drop it in and later a simple UV light will show it up if external.

[DiscoJeffster]

Get some tracer for the coolant, drop it in and later a simple UV light will show it up if external.

To think a repairer could do this before replacing the engine etc

[PerthDisco]

DISCO3.CO.UK - View topic - Coolant appearing to leak down the back of the engine (https://www.disco3.co.uk/forum/coolant-appearing-leak-back-engine-152035.html)

Worth a read

[Dagilmo]

Different symptoms but.....

I had some coolant going somewhere (can remember where) and the guys at Rovertech said very unlikely head gasket as they 'never' go. Turned out that the ERG coolers were corroded and leaking. Removed the coolers and fixed problem.

An engine change seems an extreme option for coolant loss at this early investigation stage.

[DazzaTD5]

*When coolant evaporates off the outside of an engine there will always be some white to pink dry residue somewhere.
*Have a look at the cross over pipe towards the back top of the engine, it has a plastic bleed screw that can leak or crack.
*If that's the leak, replace it with a brass plug, see pic.

[Blumr2]

Check plastic coolant pipe junction part at top of V on motor under the intake air piping. Drips for a short while and coolant probably evaporates on engine.

Has destroyed many an engine when it fully splits. If not already replaced yours would be guaranteed ready to blow any minute.


thank you, can confirm it and all the rad soft pipes were replaced as they started to leak when first pressure tested.

[Blumr2]

Different symptoms but.....

I had some coolant going somewhere (can remember where) and the guys at Rovertech said very unlikely head gasket as they 'never' go. Turned out that the ERG coolers were corroded and leaking. Removed the coolers and fixed problem.

An engine change seems an extreme option for coolant loss at this early investigation stage.


I suggested the egr coolers to them as read it on the South African forums.. but thinking of blanking plates and looking at bypassing them, though I’ve read you need tonstill allow the coolant to circulate or can upset the thermostat.

[Blumr2]

*When coolant evaporates off the outside of an engine there will always be some white to pink dry residue somewhere.
*Have a look at the cross over pipe towards the back top of the engine, it has a plastic bleed screw that can leak or crack.
*If that's the leak, replace it with a brass plug, see pic.


I’ll check that but they had it for a few days twice now and pressure checked and tested, only sign and smell of coolant is from the overflow bottle on 300 plus km trips.

[DazzaTD5]

I’ll check that but they had it for a few days twice now and pressure checked and tested, only sign and smell of coolant is from the overflow bottle on 300 plus km trips.

So the expansion tank is leaking then? its likely due for a expansion tank and cap, the caps do get leaky when old.

[Discodicky]

I'd be removing the radiator and having it thoroughly cleaned. Cross flow radiators are notorious for blocking the lower approx 3rd of the radiator. The fact that it tends to only happen on longish trips tends to back this up as short trips would not get the entire cooling system up to its normal running temp for long enough periods and the cleanish 2/3rds section would handle the cooling reasonably well. You haven't mentioned vehicle klms however if they are "up" then the radiator would be due for a thorough clean out.

[Journeytower]

While reading your enquiry it reminded me quite quickly of a similar problem I had including all the possibilities, tests, checks , replacement radiator & expansion tank cap & the problem remained. My car was fine unloaded but after a couple of hours driving with the caravan attached I could smell coolant & sure enough when I stopped & checked there was expelled coolant around the top of the expansion tank & flowing down from there. I was suspicious as each time I checked & topped up the coolant the cap was slightly loose leading to replacing a couple of caps.

A suggestion from MR Automotive at Redcliffe in Queensland led me to resolution of the problem. I had previously fitted an aftermarket coolant tank due to a faulty temperature sensor.
They pointed out that they had the experience once of this same problem & traced it back to the expansion tank they had fitted, and no longer use. It seems that the economically priced tank was made of a plastic material that would lose it's shape or shrink or not expand at the same rate as the cap, whichever cap was used. When this occurred the cap would loosen slightly & allow coolant to escape.
Rather than replace the motor, which I was about to do, I replaced the expansion tank with a quality OE equivalent tank, Mahle in this case, and my problem was resolved.
I took the car with caravan on for a drive as hard as I could up the Dorrigo mountain & beyond to test it & was relieved to find no coolant leaks, but still guarded regarding success.
I have since done a few trips with the van on including recently out to Birdsville/ Bedourie etc & have not had any problem whatsoever with the coolant system or anything else.

My suggestion from what you have described would be to replace the expansion tank & cap with good quality items before spending any more big money on many of the good suggestions that people have made.

Thanks immensely MR Automotive.

Regards,
Wayne. Retired & tired mechanic that still does no know it all .

[PerthDisco]

due to a faulty temperature sensor.


Faulty level sensor I believe

[BradC]

My suggestion from what you have described would be to replace the expansion tank & cap with good quality items before spending any more big money on many of the good suggestions that people have made.

+1 to that. We had a replacement fitted after the level sensor failed and it took 4 return visits to diagnose a duff coolant bottle. Replaced with a quality part and it hasn't been an issue since.

Looked fine and held a static pressure test, but when hot it sprayed a fine jet of coolant out that got entrained in the air through the fan, spraying it over the front of the motor making it look like the leak was somewhere expensive.

[scarry]

MR auto replace the coolant reservoir and float assembly every time they do a coolant flush,and the plastic piece on the engine,using only OEM parts.

Cheap compared to continual issues that can result in engine damage.

[Journeytower]

Faulty level sensor I believe

Exactly correct. The level sensor was faulty, not the temp sensor. Typing before mind in gear [bigsad]