Thread: fuel cooler leaking coolant

hi bullfrog,

Yes this unit is serviceable and they usually leak from the o rings on the ends, once you remove the plastic end you will see them. If you do a search there is a post on here in more detail, with the exact part number for the new o rings which can be purchased from a bearing store, trust me Ive done this myself .

Cheers bronson

Have a look at urban Panzers site, there is a step by step tutorial..

His site is www.discovery2.uk from memory..Its an easy job, the hardest part is getting those stupid bloody clamps off then back on.

Cheers Ean

O ring part number is BS225.

Easy task, takes longer to get the lower 2 bolts out of the cooler bracket than it does to replace the Orings.

JC

Have also found out that the much cheaper D2a replacement cooler can be installed on a D2 with a simple mod to one of the coolant pipes. $200 odd vs $800. Perhaps someone can supply the detail on the mod.

They usually only drip coolant when they are cold and don't leak when the engine is up to temp. The plastic plugs swell with the heat and seal it off.

I've done both our TD5s. The O rings cost next to nothing so why bother replacing the cooler.
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TIP do it in situ, you will appreciate the cooler still being bolted up when you have to pull out the end caps to get to the Orings. You only lose about a cup of coolant at most.

TIP, get some hose clamps to replace those silly clips, there next to impossible to get back on without ruining them. The hose clamps make it a real breeze.

Big O,

I disagree on the clamps on the cooler. I have found if you use medium size multigrips they engage well without damage.

Bullfrog,

Check that your cooling system is not being pressurised from a head gasket leak as a leaking fuel cooler can be a sign of an overpressured system. Do a search on how to check if your head gasket is gone.

I don't place any faith in those clips once taken off, if one clip twangs off and the end cap of the cooler blows out from pressure or even leaks where are you then??, looking for a bit of fencing wire to put it back together if you haven't cooked the engine already.

Hose clamps are the way to go especially if you don't remove the cooler to change the o rings.

Originally Posted by eckolsim

Big O,

I disagree on the clamps on the cooler. I have found if you use medium size multigrips they engage well without damage.

Bullfrog,

Check that your cooling system is not being pressurised from a head gasket leak as a leaking fuel cooler can be a sign of an overpressured system. Do a search on how to check if your head gasket is gone.

The original type multigrips are not a multiple use clamp. Designed for single use only.
Also be wary of cheaper type wot drive clamps as they can tend to strip the drive band as these need a bit of tension to clamp the cooler closed again. ABA clamps with a hex head are probably the best without going to threaded bolt band clamps.

Cheers

Andrew.


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