Thread: TD5 fuel cooler o-ring headache

I'd give the O-rings a smear of some sort of O-ring lubricant, and gently tap it into place with a small rubber mallet, or something similar.
Be very gentle though.

REALLY!!!??

I went outside this morning to find this.



After taking off the TD5 Acoustic cover I found it leaking at the Fuel cooler.
WHY Do you Taunt me land Rover???

A quick search revealed this.

www.discovery2.co.uk - Leaking Fuel Cooler Fix

You can purchase two Orings and 2 clamps for $35 plus $11 delivery. What a joke!

[ame=http://www.ebay.com.au/itm/Fuel-Cooler-Repair-Kit-TD5-Discovery-2-Defender-/271422496858?pt=AU_Car_Parts_Accessories&hash=item 3f320aa05a&_uhb=1]Fuel Cooler Repair KIT TD5 Discovery 2 Defender | eBay[/ame]

Or $29 inc delivery
[ame=http://www.ebay.com.au/itm/Land-Rover-DISCOVERY-2-TD5-DEFENDER-TD5-FUEL-COOLER-SEAL-REPAIR-KIT-/181445642571?pt=AU_Car_Parts_Accessories&hash=item 2a3f00c94b&_uhb=1]Land Rover Discovery 2 TD5 Defender TD5 Fuel Cooler Seal Repair KIT | eBay[/ame]

Or you can ring the local parts bloke and get the orings Stated as BS225 in the above article. I will get some hose clamps when I can find some thin enough ones and do the fix. Best of luck and hope this helps.

Originally Posted by Gillie

Or you can ring the local parts bloke and get the orings Stated as BS225 in the above article. I will get some hose clamps when I can find some thin enough ones and do the fix. Best of luck and hope this helps.

As long as your O-ring compound is FKM (Viton) otherwise you'll be doing it again soon

Originally Posted by Tombie

As long as your O-ring compound is FKM (Viton) otherwise you'll be doing it again soon

There is always something to do!

Originally Posted by kipsplace

Hi. I have been attempting to replace the front O-ring in the leaking fuel cooler of my 2003 Disco TD5. Got that damn clip off by tapping with a screwdriver. Replaced the flattened O-ring with a new one but now I cannot get the plastic end piece of the cooler unit to fit back in far enough to position a new clamp (hose clamp - gave up trying to refit the damn LR clip) in front of the lugs. Is there a trick to positioning/forcing the end cap in far enough in to fit a hose clamp? I must be doing something wrong. Also, do you use standard stainless steel hose clamps to replace the LR cooler clamp or are there narrow-band hose clamps available. I'm baffled. Any guidance would be greatly appreciated.
Kipsplace

The smaller hose clamps are narrower so I used two small ones on each end.

I bought a repair kit from All Fourx4 Spares. 2x replacement clamps and 2x replacement o-rings. They post.

Originally Posted by kipsplace

Hi. I have been attempting to replace the front O-ring in the leaking fuel cooler of my 2003 Disco TD5. Got that damn clip off by tapping with a screwdriver. Replaced the flattened O-ring with a new one but now I cannot get the plastic end piece of the cooler unit to fit back in far enough to position a new clamp (hose clamp - gave up trying to refit the damn LR clip) in front of the lugs. Is there a trick to positioning/forcing the end cap in far enough in to fit a hose clamp? I must be doing something wrong. Also, do you use standard stainless steel hose clamps to replace the LR cooler clamp or are there narrow-band hose clamps available. I'm baffled. Any guidance would be greatly appreciated.
Kipsplace

I did mine while the cooler was still in the car. I do not recall having any issue with getting the plastic end piece back on. I used normal hose clamps. I think the other end on mine is starting to leak so will have to have a look at it.
As a side note my vehicle has been at the dealer for an unrelated issue and they have quoted me $1700.00 to replace the fuel cooler hoses and the fuel cooler - that is only for the PARTS!. Needless to say I will be doing this job myself.

Many thanks