D2 TD5 Welch plug

**disco_thrasher** · 21st September 2010, 06:48 PM

I have found a leaking welch plug behind the exhaust manifold has anybody done this and are there any easy way of doing this and any tips will be much appreciated
thanks kelvin

**alien** · 21st September 2010, 06:55 PM

There is a little heater hose in that area too.
They have been known to get a hole in them.
Check it's not spraying onto the plug.

Sorry I can't help ree the plug.

**scarry** · 21st September 2010, 07:08 PM

Originally Posted by alien d2

There is a little heater hose in that area too.
They have been known to get a hole in them.
Check it's not spraying onto the plug.

Sorry I can't help ree the plug.

Search is your friend.JC commented on how it is fixed,can't remember,but i think manifold has to come off,etc

**Fluids** · 21st September 2010, 10:49 PM

Kelvin, I suspect I may be suffering the same issue ... about 250ml of coolant per 5000km ... after much searching I can see coolant (dried) around that welch plug behind the exhaust manifold

... I'm about to install an enginesaver, and will watch this closley ... I believe the manifold has to come off, no other option, and that's not on my short list right at the moment, so I'll keep a real close eye on it and address it as soon as I can.

500ml over the last 10,000km I consider to be minor ... but it's an early warning sign I guess.

I did see something on the forum here a while back about this, and if memory serves correct, it's just a case of remove the welch plug (it's threaded?), apply the correct sealant, and re-install.

Sounds to easy ......

**disco_thrasher** · 22nd September 2010, 06:21 AM

Originally Posted by scarry

Search is your friend.JC commented on how it is fixed,can't remember,but i think manifold has to come off,etc

search is your friend

when you can find what you need

yeah looks like a manifold job bugger

Hamish71 · 22nd September 2010, 07:27 AM

lol...Kelvin.....yeah bugger...you know you love it! Get to play with that VNT again

**strangy** · 22nd September 2010, 08:09 AM

Originally Posted by disco_thrasher

I have found a leaking welch plug behind the exhaust manifold has anybody done this and are there any easy way of doing this and any tips will be much appreciated
thanks kelvin

Try this TD5 Leaking coolant plug

cheers

Oops..forgot to mention manifold off.

**crash** · 22nd September 2010, 08:16 AM

Originally Posted by strangy

Try this TD5 Leaking coolant plug

cheers

As Strangy pointed out, check the link out and is an easy enough job to do.
I had my manifold off for other reasons so did it then, you could try without taking the manifold off but think it would be very tricky to do.

**disco_thrasher** · 22nd September 2010, 09:29 AM

thanks
maybe thats why my search for welch plug did not come up its stored under coolant plug

**Catmatt** · 22nd September 2010, 03:25 PM

Don't be too daunted by the job.....I've just had the turbo & manifold off and replaced the studs, 'never-cease'd' the threads, installed an EGR plate and fitted an EGT and relieved the webs to alleviate future cracking or manifold warpage.

It isn't a hard job to remove the turbo, manifold and associated exhausts bits with only 2 of the bottom nuts being a total 'pain in the confabulator' to get to. The fiddliest was the very front lower nut requiring moving the AC compressor to get at it.

I eventually used a 1/4 drive socket with a short extension bar and ratchet - usually reserved for my race bike that did the trick.

Typically of these jobs, it all went back on very easy and if there is a next time, I know I'll halve the time to strip it all down.

If you have a reasonable selection of tools - give yourself about 2.5 hours for the complete job.

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