TD5 Fuel Cooler leaks.

Hi Phil
Thanks for looking after Deb:cool::cool::cool::cool:
Phil,I dont want to alarm you,and the original poster,but closely monitor the pressure in your coolant hoses,if that top hose is at bursting pressure under full working temp,its possible head issues are on the way,BEEN THERE DONE THAT:mad::mad::mad::mad::mad::mad::mad:
Keep a close eye,it could be the warning you need to get it early.I picked mine up by the odd wiff of coolant smell that wasnt normally there,IT WASNT USING COOLANT.
GOODLUCK
Andrew

[quote=tombraider;552605]

"And considering the total number of leaks reported on this site equals <3 I'd say its nothing to worry about..."

It happened to mine and my investigations at the time suggested that it was pretty common.

I have also traced a water leak to my fuel cooler and have removed it for inspection. On disassembly there are 2 'o' rings, one at either end. These are rather large and I am now hoping to source some.

Has anyone done this or know what 'O' rings to get?

Photos to come

http://www.aulro.com/app/showphoto.p...4/ppuser/11735

Yep my fuel cooler was leaking for about 12 months before I got" Davis performance "to put on another reco one. For only $ 110. fitted I thought it was a bargain.
I took a while to get it fixed because it only leaked when we had a frost and it was only a cup full at a time. So I kept an eye on the coolant levels and had it replaced when I did the major service and changed all fluids.
By this time it leaked every night, but not under pressure, and it was loosing a lot more fluid each time.
There were other issues with the motor at the same time but thats another story and not related.

Quote:

---

Originally Posted by eckolsim

Has anyone done this or know what 'O' rings to get?

Photos to come

Message - AULRO Photo Gallery

---

I just got some BS225 Viton O-Rings as suggested earlier in the thread. I haven't fitted them yet, the night's arn't so cool at the moment and it has stopped leaking. I will be changing all coolant hases and coolant soon, so will do them then.

Is any one has a pic of the TD5 fuel cooler?
Thanks,
Amit

Hello to all, I want you let this message since thanks to your could
to repair my fuel cooler and as could not be otherwise you
I leave the photographs of the repair of my cooler.

Happy Year New for all.

Este es el enfriador de gasóleo.
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh4.ggpht.com/_8YEsJgM89d8/SV...0TD5%20002.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh5.ggpht.com/_8YEsJgM89d8/SV...0TD5%20003.jpg" /></a>
Quitada la primera brida
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20004.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh5.ggpht.com/_8YEsJgM89d8/SV...0TD5%20005.jpg" /></a>
Fuera la entrada delantera
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20008.jpg" /></a>
Aspecto del interior del enfriador
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh3.ggpht.com/_8YEsJgM89d8/SV...0TD5%20009.jpg" /></a>
Ahora es el turno de la salida posterior
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh3.ggpht.com/_8YEsJgM89d8/SV...0TD5%20010.jpg" /></a>
Brida quitada
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh3.ggpht.com/_8YEsJgM89d8/SV...0TD5%20011.jpg" /></a>
Extracción de la parte trasera
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh5.ggpht.com/_8YEsJgM89d8/SV...0TD5%20012.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh5.ggpht.com/_8YEsJgM89d8/SV...0TD5%20013.jpg" /></a>
Ambas partes juntas
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20015.jpg" /></a>
(Nótese que en la parte trasera tiene como una especie de válvula de retención con un muelle o quizás sea un termostato, en el pezón marca 86, ¿pudieran ser grados?
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20015.jpg" /></a>
Otra vista de la pieza trasera con el pezón y un detalle del 'panal' interior
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh4.ggpht.com/_8YEsJgM89d8/SV...0TD5%20016.jpg" /></a>
Iluminando el 'panal'
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh4.ggpht.com/_8YEsJgM89d8/SV...0TD5%20018.jpg" /></a>
Extrayendo las juntas
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20019.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20021.jpg" /></a>
Junta torica
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20022.jpg" /></a>
Las juntas estan deterioradas muy cuarteadas por eso comienzan a perder refrigerante.
Despiece
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh5.ggpht.com/_8YEsJgM89d8/SV...0TD5%20024.jpg" /></a>
Piezas compradas
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh5.ggpht.com/_8YEsJgM89d8/SV...0TD5%20025.jpg" /></a>
Una vez montadas las juntas toricas de vitón
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh3.ggpht.com/_8YEsJgM89d8/SV...0TD5%20026.jpg" /></a>
Montando las abrazaderas
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20027.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh3.ggpht.com/_8YEsJgM89d8/SV...0TD5%20028.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh5.ggpht.com/_8YEsJgM89d8/SV...0TD5%20029.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh3.ggpht.com/_8YEsJgM89d8/SV...0TD5%20030.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh4.ggpht.com/_8YEsJgM89d8/SV...0TD5%20032.jpg" /></a>
Pieza terminada a falta de hacerle una prueba de presión
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh3.ggpht.com/_8YEsJgM89d8/SV...0TD5%20033.jpg" /></a>
Detalle de las abrazaderas
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh6.ggpht.com/_8YEsJgM89d8/SV...0TD5%20034.jpg" /></a>
<a href="http://picasaweb.google.es/lh/photo/...dwebsite"><img src="http://lh4.ggpht.com/_8YEsJgM89d8/SV...0TD5%20035.jpg" /></a>

Las piezas utilizadas en esta reparación son dos juntas toricas de 49mm de diametro interior por 54 de diametro exterior más dos abrazaderas de 7 mm de ancho.

Pues esto es todo amigos. ;)

Thanks for the photos, I'll be chasing the O rings in a few days and repairing the fuel cooler ASAP.

With the cold nights (well cold for QLD) starting, I noticed some coolant under my front diff this morning. Followed it back and its the same problem as encountered by others in this thread, a leaking fuel cooler. Not as uncommon as first suggested it seems.

Will try the o-rings first and see if that fixes the problem and take it from there. With luck the o-rings will solve the problem.

Just a word of warning, after I discovered and repaired my fuel cooler leak I seemed to be chasing endless leaks appearing in different places.

It finally turned out that I had done the head gasket and the additional pressure it was putting into the system was slowly finding all the weak spots in the cooling system with the fuel cooler leak just being a symptom of the real issue.

When I replaced the head gasket I ended up replacing all of the hoses also as the whole system had been stressed and was now quite an age.

Get it checked for the head gasket. If the system pressures up too quickly it could be time to take it to someone professional for a run on the dyno.

Regards