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neirbossor

Member Since: 10 Jun 2021
Location: Aberdeenshire
Posts: 23

2009 Defender 90 Puma 2.4 HT Bonatti Grey

The coolant loss conundrum

Hello, I have an issue with my 2009 defender TDCI.
I first noticed a few weeks ago on my way home from work (about 25miles) that my heating just went cold. At first I thought heater controls but when I got back I noticed my coolant level was very low (Engine temp totally fine).
Now I am topping up my coolant every time I get to work and every time I get back, approx half an expansion tank level...I know I'm living on the edge but I have to go to work.

Anyway, here are the main details:
- Bad coolant loss (approx 500ml per 30miles or so, 60-70mph dual carridgeway driving).
- Engine temp totally normal, mid range all the time when warm.
- Engine oil is nice, no rise in level, no emulsion, no hint of anything untoward.
- No visible leaks (well none sufficient enough for this loss).
- Changed the expansion tank cap
- Put UV dye in coolant, still cant pick anything up.
- Carried out cylinder head test (colour changing liquid), test negative as far as I can tell CH is all OK.
- No visible smoke out the back.

The only other things I can think of is EGR cooler or maybe fuel cooler internal leaks. My EGR is blanked off at the valve (not the other side). I was thinking about blanking off the other side to rule that out.
Although I would have thought there might have been some visible steam if the coolant was leaking directly into the exhaust manifold.

Has anyone heard of fuel cooler leaking internally, perhaps from the cooling circuit back into the tank return..is that even possilble.

Where else could it be going?

15th Dec 2023 3:33pm

hornet

Member Since: 04 Jan 2010
Location: Western Europe
Posts: 335

If nothing is obvious, I wouldn't mess around for long and arrange for a pressure test of the system, ideally you can see where the coolant is leaking. There are so many possibilities.

15th Dec 2023 4:00pm

Ianh

Member Since: 17 Sep 2018
Location: Essex
Posts: 1802

Re the EGR cooler, you could remove the two coolant pipes and join them together , that would prove if it’s the cooler , and as your EGR is blanked it should not cause any issues.

Note the 2.2 does have issues with cooler leaking, whereas it’s rare on the 2.4.

Also have a look at the heater valve as well, it may be dripping when set to hot and engine is warm.

Worse case it is a head gasket, over the last few months there have been several topics on water loss and it has been the HG, yet like you there were no other tell tale symptoms or positive RELD tests.

15th Dec 2023 6:09pm

Mdm

Member Since: 11 Sep 2013
Location: Sunny Lancashire
Posts: 1542

if its losing that much water and it not coming out and going on the floor you aint doing the old girl no good.
get it pressure tested at a workshop as soon as you can and hopefully its a simple thing and not a head gasket or egr cooler fail

15th Dec 2023 8:39pm

RFT

Member Since: 13 Nov 2010
Location: Cheshire
Posts: 674

2010 Defender 130 Puma 2.4 HCPU Zermatt Silver

My 2.4 MY10 at 120,000mies started losing coolant exactly as you described, one new water pump later and all is mended now. 130 Puma HCPU with an Artica 240LR Demountable Camper

15th Dec 2023 8:47pm

neirbossor

Member Since: 10 Jun 2021
Location: Aberdeenshire
Posts: 23

Thanks, I have ordered the blanking plate for the exhasut side, hopefully be here before I need to run it again. I will do a run with that installed and if that doesn't fix it then pressure test it is I guess...

15th Dec 2023 9:46pm

neirbossor

Member Since: 10 Jun 2021
Location: Aberdeenshire
Posts: 23

RFT wrote:
My 2.4 MY10 at 120,000mies started losing coolant exactly as you described, one new water pump later and all is mended now.

Was there a visible leak from it?

15th Dec 2023 9:46pm

bear100

Member Since: 22 Mar 2010
Location: South Wales
Posts: 1874

2010 Defender 110 Puma 2.4 USW Santorini Black

had the same issues 2010 2.4, i bought a kit from Dr head gasket as recommended on here to test for exhaust gasses in the coolant, at first it passed the test but once driven for at least 40 mins and up to normal running temp the fluid would turn yellow

currency in having a head gasket swap and now the turbo flange has split

2016 Range Rover Autobiography 4.4 TDV8
2010 110 XS Utility 2.4TDCI
2010 Range Rover Sport TDV8 (gone)
2007 Discovery HSE TDV6 (gone)
1993 110 csw 200 tdi (gone)
1994 90 HT 300 tdi (gone)
1994 discovery 300tdi (gone)
90 hybrid 3.5 v8 (gone)
Range rover bobtail 3.5 v8 (gone)

20th Dec 2023 10:24am

neirbossor

Member Since: 10 Jun 2021
Location: Aberdeenshire
Posts: 23

Urgh...so blanked off the other side of the EGR..no change! I have ordered a coolant pressure tester hanging on to the last thread of hope that its an external leak that only manifests itself when I'm not looking.

If that doesn't show anything then looks like its the head/head gasket, really the last thing I wanted to deal with. Probably just as well replacing the whole head for the price of having to do that job twice should it be cracked.

I love the landy but its testing my love.

20th Dec 2023 6:55pm

neirbossor

Member Since: 10 Jun 2021
Location: Aberdeenshire
Posts: 23

So, got the pressure tester today, filled the system up and pressurised to about 15psi..and found the biggest coolant leak, spraying out of the oil cooler blanking plug out of the back of the water pump. Looks like a crack on the seam at the top. Strange how I didnt identify this on any other occasion..so its either the cause of my original leak or I have burst it during the pressure test. I have ordered another but no hope in getting it here before 2024, so will be off the road till then.

Click image to enlarge

21st Dec 2023 5:26pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 16946

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

That's a very common source of leakage.

21st Dec 2023 7:19pm

Ianh

Member Since: 17 Sep 2018
Location: Essex
Posts: 1802

As it’s just a hose blanking end cap it may be worth measuring the Inside diameter of the existing one,or spigot diameter on pump and doing a search for silicon blanking cap. you will find a lot from auto spares suppliers, then see if they have one of the correct size and can get it to you next day or in next couple of days.
It will likely be better quality and cheaper than a LR one.

21st Dec 2023 7:23pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 16946

As the Land-Rover part is a shocking £103 you might also want to take a look at this thread:

https://www.defender2.net/forum/topic87744.html

I found some sensibly-priced alternatives.

21st Dec 2023 10:17pm

RFT

Member Since: 13 Nov 2010
Location: Cheshire
Posts: 674

neirbossor wrote:
RFT wrote:
My 2.4 MY10 at 120,000mies started losing coolant exactly as you described, one new water pump later and all is mended now.

Was there a visible leak from it?

Not when I looked under bonnet, but once on ramp in garage with cold engine they spotted it on start up 130 Puma HCPU with an Artica 240LR Demountable Camper

22nd Dec 2023 1:26am

neirbossor

Member Since: 10 Jun 2021
Location: Aberdeenshire
Posts: 23

Thanks all, I opted for the s*itpart one as I could get it dispatched yesterday, super expensive for what it is , especailly when it doesnt need to exist in the first place.

22nd Dec 2023 3:13pm

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