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.

[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

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.