Thread: D2 TD5 Fuel Cooler Leak?

www.discovery2.co.uk - Leaking Fuel Cooler Fix and apparently not much coolant leaks out....

Hi All
I have just replaced the orings in the disco and you can get a kit from All4x4 in Newcastle it comes with a pair of o rings and 2 stainless adjustable worm drive clips.
Regards
Doug

Hamish
There is a current thread on this(in the D2 area).
BIG $$$ to replace,easy DIY job to replace the O Rings.
GOODLUCK
Andrew

There is a thread on here that quotes the part number of the o'Rings you need. I fixed mine by just buying the o'rings. It is an eay fix.

I cannot remember who the thread starter was but I am pretty sure it was Big Jon who provided the part numbers.

I used the link myself last Friday and changed the O rings.
The part numbers would appear to be correct, i do not have any leaks after the repair.
Apart from my now dripping water pump, Grrrr.
It is about a 2 hour job, max.
Those clips can be a paint though, file a 45 degree chamfer on a 1/4" sqaure nut and use long nose plyers and you will get them back on.
I also unbolted the cooler(4 bolts) but i left the fuel lines on.
It is fiddly but achievable.
Now im onto the damn water pump.

By the way all these leaks started after a coolant change???

Today I found my diesel cooler was leaking at the front o-ring in the normal place. As this has happened before, I decided to remove the cooler completely which proved to be quite a simple task.
Upon removing the front cap, I found sludges in the lower portion of the cooler and when I tried to flush it water would not flow from the other end through the cooler. When the other end of the cooler was removed I found what looked like a thermostat in it with a temperature mark of "82" on it (see photo).
After cleaning and inspection I tried testing the thermostat by placing it in boiling water. The thermostat does not move and therefore unserviceable.
There is no mention of this part any where. So will look for a replacement and update this thread.

I found the same thing with mine.
Removed the thermostat 3 months ago with no bad effects.

Diesel fuel temperature slightly lower when driving on a 30+c day

Diesel fuel heats up quicker.

Regards

Update:
Went to the local parts store and dug through the thermostats in stock till I found an eighty two degree standard dayco DT27A-BP. The element was the same size and shape.
On return the body of the thermostat I purchased was cut to remove the element. This was placed into the Diesel cooler end and the original land rover spring wound back in to retain it.
Now for the test!
1 does it seal? Yes!
2 does it open?
Boiled kettle and gently poured water into the cap (front end)
Yes, it works, the thermostat opens.

Total cost including o-rings $25.00 AU thank you Andy - Autowest is best.

Hope this help