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dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

TD5 coolant dropping in the expansion tank

TD5 90 coolant level has been drooping by haft an 1 inch in coolant expansion tank so time investigate just before lunch removed coolant filler gap and fitted mode gap with type valve fitted so that you can pump up coolant system to running presser 1.2 bar pox so looking all over pipe work- rad- heater box with no lacks ok next removed pipe work from top end EGR cooler. one 6mm bolt snapped

job for tomorrow with end open on the EGR cooler you can see OAT i.e. antifreeze clamp off two coolant hose and and remover the EGR cooler to work shop bench and presser tested very slow drop in presser at lest I no its not head gasket

Click image to enlarge

If you look insides top egr port with 1.2 bar presser applied to coolant side you can see white foam at ends tube

so now repayment cooler needed

16th Nov 2021 5:17pm

rallysteve

Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2200

2002 Defender 110 Td5 DCPU Keswick Green

Have you still got the EGR system connected up or have you blanked it? If you have got it blanked, I would be tempted to just bypass the cooler with the coolant pipes. I did start looking into it myself and was going to revert back to the 10p/eu2 coolant layout which didnt have the cooler but never actually got around to it.

Steve 02' 110 TD5 Double Cab Rebuild Thread
84' 90 3.9 V8 Caged Pickup Build Thread - Now For Sale

16th Nov 2021 5:41pm

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4406

Done precisely the above, EGR bypassed, cooler removed, hoses bypassed and all is good. Simpler and less to go wrong.

16th Nov 2021 6:15pm

rallysteve

Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2200

Geobloke, did you just link the coolant pipes which originally ran to/from the cooler or did you reroute from the oil cooler to the radiator like the EU2 setup?

Cheers,
Steve 02' 110 TD5 Double Cab Rebuild Thread
84' 90 3.9 V8 Caged Pickup Build Thread - Now For Sale

16th Nov 2021 6:24pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

EGR system connected up as it left LR in 2006

repayment cooler on its way, next think is removing the broken 6mm stainless steel bolt from exhaust manifold with out having to remover it

16th Nov 2021 6:29pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

geobloke wrote:
Done precisely the above, EGR bypassed, cooler removed, hoses bypassed and all is good. Simpler and less to go wrong.

did cross my mined but a lot of road side stop and DVSA inspect past one two days ago defender with EGR removed and tamper with and £1000 bill and DVSA spent good 1hr removing engine covers so give a miss thanks

16th Nov 2021 7:09pm

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4406

Blimey.

Do not blame you if the DVSA are that active near you. Nothing wrong with keeping the EGR kit installed, just keep it clean and working as it should.

16th Nov 2021 7:36pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

Its going to sound a bit like dentist tomorrow just found micro air grinder in work shop and at 6mm broken bolt will be out

16th Nov 2021 8:05pm

Anderzander

Member Since: 08 Feb 2011
Location: Lancashire
Posts: 999

I removed the EGR cooler - my coolant leak was from the front of the fuel cooler. If that’s leaking you’ll see pink inside the driver side engine mount. Simple enough fix too.

16th Nov 2021 10:56pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

Todays job too remover that 6mm snap bolt ended up removing exhaust manifold and drilling it out and re-taping so now down tools again awaiting parts but at lest exhaust manifold is good order

17th Nov 2021 3:42pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2251

dorsetsmith wrote:
geobloke wrote:
Done precisely the above, EGR bypassed, cooler removed, hoses bypassed and all is good. Simpler and less to go wrong.

did cross my mined but a lot of road side stop and DVSA inspect past one two days ago defender with EGR removed and tamper with and £1000 bill and DVSA spent good 1hr removing engine covers so give a miss thanks

DVSA are stopping private cars to check the emissions gear? And they spent "a good 1hr removing engine covers" What engine covers? The TD5 has one engine cover that can be removed in under two minutes.

lf the above is true, then anyone who has removed or bypassed the EGR system better fit it back on. Although ROW spec TD5's never had an EGR

20th Nov 2021 10:18am

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

now just wanting for post and manifold nuts

20th Nov 2021 10:48am

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

lightning wrote:
dorsetsmith wrote:
geobloke wrote:
Done precisely the above, EGR bypassed, cooler removed, hoses bypassed and all is good. Simpler and less to go wrong.

did cross my mined but a lot of road side stop and DVSA inspect past one two days ago defender with EGR removed and tamper with and £1000 bill and DVSA spent good 1hr removing engine covers so give a miss thanks

DVSA are stopping private cars to check the emissions gear? And they spent "a good 1hr removing engine covers" What engine covers? The TD5 has one engine cover that can be removed in under two minutes.

lf the above is true, then anyone who has removed or bypassed the EGR system better fit it back on. Although ROW spec TD5's never had an EGR

DVSA are stopping private cars to check the emissions gear? And they spent "a good 1hr removing engine covers" What engine covers? The TD5 has one engine cover that can be removed in under two minutes.

Seemed to be 1hr if your stuck in traffic just before dvas check not that i had anything not fitted or bypass and dipping fuel tanks for red dev

20th Nov 2021 10:57am

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2251

Yes you do get them checking for
red diesel round here, and l guess Defenders are more likely to be stopped for that as traditionally they are owned by farmers.

Plus with diesel being over £1.50 per litre, people might be tempted to use red diesel if they have access to it.

20th Nov 2021 11:55am

landy andy

Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5423

2006 Defender 110 Td5 USW Zermatt Silver

lightning wrote:
dorsetsmith wrote:
geobloke wrote:
Done precisely the above, EGR bypassed, cooler removed, hoses bypassed and all is good. Simpler and less to go wrong.

did cross my mined but a lot of road side stop and DVSA inspect past one two days ago defender with EGR removed and tamper with and £1000 bill and DVSA spent good 1hr removing engine covers so give a miss thanks

DVSA are stopping private cars to check the emissions gear? And they spent "a good 1hr removing engine covers" What engine covers? The TD5 has one engine cover that can be removed in under two minutes.

lf the above is true, then anyone who has removed or bypassed the EGR system better fit it back on. Although ROW spec TD5's never had an EGR

So refit the egr valve having removed the flap, and keep the blanking plate on exhaust end. All looks standard but not crappy egr.

20th Nov 2021 1:40pm

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