Thread: TD5 D2 with EGR cooler caution

For TD5 D2s that have an EGR cooler installed, the power cable to the starter motor was routed (ex factory) over the plastic hose (rather than under) that returns coolant from the EGR cooler (at the front of the head) to the plastic bottle. Vibrations on a recent trip caused the power cable to bounce on the plastic hose and caused the plastic hose to kink then crack. The hose was also found to be quite brittle and IMO should be replaced anyway.

The diameter of the pipe on the EGR cooler is 10mm and the pipe on the plastic bottle is 8mm, so I used 3/8" fuel hose and retained the flexible connection and joiner at the bottle.

nice.

Pics Graeme??