Leaking valley thermostat housing and oil/fuel cooler seals

[haydent]

Yes 2010, Unfortunately Ive just discovered my valley thermostat housing and oil/fuel cooler seals are leaking so have started pulling it apart. So there's no appetite here for any upgrades, and we might even sell.

[mpcrandell]

What year is your vehicle? 2010 onwards RRS seem to have been fitted with the right knuckle part number anyway (LR045824).
Range Rover Sport 2010 - 2013 (l320) / Rear Knuckle And Suspension Arms (rear Knuckle And Hub)((v)fromaa000001) | Jaguar Land Rover Classic Parts

Yes 2010, Unfortunately Ive just discovered my valley thermostat housing and oil/fuel cooler seals are leaking so have started pulling it apart. So there's no appetite here for any upgrades, and we might even sell.

Two very common problems

Did both on my 2007 TDV8 about 4 years ago starting with being unable to find replacement seals and having to look at buying the whole unit

Did some research in the UK but there are no part numbers for the seals that mount the fuel cooler to the main body of the unit.

But found a supplier who could supply only the fuel cooler - took the risk and it turned up with the correct seals - if needed, I can dig out the contact for the UK supplier who was most helpful and it saved me about 1k from memory - but the current AUD value won’t help much at the mo and shipping costs/GST might mean your just best placed to sell as is and move on.

[haydent]

Two very common problems

Did both on my 2007 TDV8 about 4 years ago starting with being unable to find replacement seals and having to look at buying the whole unit

Did some research in the UK but there are no part numbers for the seals that mount the fuel cooler to the main body of the unit.

But found a supplier who could supply only the fuel cooler - took the risk and it turned up with the correct seals - if needed, I can dig out the contact for the UK supplier who was most helpful and it saved me about 1k from memory - but the current AUD value won’t help much at the mo and shipping costs/GST might mean your just best placed to sell as is and move on.

are you talking about a seal under the fuel cooler ? or just the seal marked 6a636

Capture.JPG

[mpcrandell]

are you talking about a seal under the fuel cooler ? or just the seal marked 6a636

Capture.JPG

No, that's the main seal for the whole fuel/oil cooler unit. what I am talking about is only the fuel cooler which is the centre "finned" unit.

Following photos show

1. the unit I bought,
2. the o-rings that do not have a workshop manual part number and were an informed "guess" by the supplier and
3. the quote in GBP from 2023 (thought it was longer ago) - not concerned about showing the address as don't live there anymore
4. the disassembled unit showing the location of the three o-rings

I'm sure there are others but Brookwells were the only supplier I found who could source the fuel cooler - everyone else could only source the whole fuel/oil cooler unit

LR006427cooler.jpgRRS Cooler (2) (1).jpgpm3F94.jpgunnamed.jpg

[haydent]

thank you, i think that is LR002342 as pictured (except you got 3 rings not 2 shown) did you have a coolant leak there ? are all 3 ports coolant ? did you replace your oil separator ? did you try disassembling the old one ?
Capture.JPG

[mpcrandell]

thank you, i think that is LR002342 as pictured (except you got 3 rings not 2 shown) did you have a coolant leak there ? are all 3 ports coolant ? did you replace your oil separator ? did you try disassembling the old one ?
Capture.JPG

Unfortunately, some of your questions are well above my pay grade - I had an excellent ex Range Rover Mechanic do the hard work - I was confined to procurement.

But, the 2 o rings you have circled in red are not the o rings - if you look at the photo provided earlier of the dissasembled unit, the three O rings are shown within the yellow circle - these are the o-rings that we could not find part numbers for but came with the fuel cooler unit. The leaks weren't coolant leaks, they were oil leaks that I left to the mechanic to deal with the detail - that's about as far as I can go to assist

[haydent]

So I investigated the parts once apart, and the cooler/heat exchanger cools does both oil and fuel, with coolant. The part LR002342 does have 3 seals for the bottom of the cooler as pictured, even though it does only show 2 rings in the parts catalogues.

To help with getting the rear plastic coolant manifold out, i removed one of the bolts for the egr to exhaust pipe on the passenger side and loosened the other, its a reach behind the engine but dooable, than pivot the pipe out of the way, that way its easier to put back together than completely remove it.

I also found you can rotate a hose clamp if the tang bits are in the wrong direction, by putting a m10 masher over one tang and using a screw driver through the washer hole as well to slide/rotate the clamp around.

I also found once a clamp is off , you can use a channel locks wrench on the coolant pipe to rotate it where it slides on to break the seal, then it pull of very easy.

This job should be done the same time as plastic head cover (inlet manifold) seals are done, as they seam to fail around the same age/kms due to similar sealing mechanism and likely seal material.