BennehBoy's D2 adventure

Bennehboy said:

Too late, already pushed the button, need to get this sorted ready for Saturday. Cheers for the offer though Aaron.

I reckon it's probably the o-rings between the exchanger and the housing...

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No worries, My fault, I didn't read all of the thread first :doh:

This isn't healthy... And it's not due to condensation...


Stripped some stuff out:


Hole where the oil cooler plugs in:


Back side of the cooler.


No immediately obvious signs of failure on the housing to exchanger front:



Removing the exchanger could be a different story unfolds though, o=-rings completely crushed and heavily coolant stained on one side, fingers crossed this is the issue!

Got a repair kit and new Genuine LR expansion tank cap coming tomorrow.

lol!

New bits arrived... anyone know why they've sent 2 sets of o-rings? The black ones were under the sealing bungs on the cooler, but there's also a set of skinnier green ones?

Hoping the fact it's ****part shouldn't worry me too much....

Decided to go with the green o-rings since they match what was on and are shown in all the promo shots for the unit.... assembled and fastened back on with new gasket:


Oil filter housing back on with new gasket:


I also fitted a new o-ring for the centrifugal housing. Will fit the centrifuge tomorrow after getting new filters, the new exhaust manifold makes the back bolt hard to put in so will fit the rotary filter with the whole lot off the vehicle.

Then it'll be back on with the turbo, white spirit flush of the hoses, IC and provent, replace the 'mushroom' with an elbow, new fluids and a 100 mile smash to see if sorted.

I wish I had known about the TD5 oil cooler as when rebuilding an oil to water cooler/heater (works both ways) equipped engine. I would have recommended changing.

MJI said:

I wish I had known about the TD5 oil cooler as when rebuilding an oil to water cooler/heater (works both ways) equipped engine. I would have recommended changing.

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I wish you'd known too

Bennehboy said:

I wish you'd known too

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I rebuilt a GM Y28SE a few years ago, I changed the oil cooler then. I just need to learn more about the TD5.

It's all back together now and have had a run over to Leeds, will have a quick check on everything when I get back

So, done 50 miles, and there's some slight gunk in the breather - fingers crossed it's residue from the oil remnants that were in the engine. Otherwise... cracked block? cracked head?

Will tear my hair out if it doesn't clear up :/

Only thing left to do is replace the PCV with an elbow - there's a PCV built into the provent casing (running without filter at the moment).

As a suggestion, run it for a few more days and if there is still a problem, strip out the pro-vent completely, then see if the problem persists.

Maaarrghk said:

As a suggestion, run it for a few more days and if there is still a problem, strip out the pro-vent completely, then see if the problem persists.

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Yeah that's the plan - to run it a few more days... but I go to France in it on Saturday! Any ideas why the provent, which is literally just a cylinder with an in and out on it, would cause mayo to appear?

Going to watch the coolant level like a hawk....

Just went round a friends and with the oil cap off there's vapour clearly visible on mine, but none on his even from cold start. His has 112K on the clock and no work has been done to the engine at all.

Feeling pretty gutted at the moment, if it needs a new head the old one is going through the window of the firm that pressure tested it.

Whipped off the cam cover to see if I could see obvious signs of coolant in the head...

Can't see a drop...

You will want 2k miles on that engine before rings/bores bedded in.my new citroen van drank oil till it had a few thou on the clock then never used a drop between services.

cambridgecockney said:

You will want 2k miles on that engine before rings/bores bedded in.my new citroen van drank oil till it had a few thou on the clock then never used a drop between services.

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Yup OK mate, oil level not really changing. Just trying to see if this coolant in the oil is remnants from the oil cooler failed o-rings, or something more serious.

It's had a 20 mile smash (thrashed the tits off it!) and the coolant level doesn't appear to be dropping Gave some tard in a Fiesta ST 500 a shock LOL

Performance has picked up, but I replaced all the hose clamps on the induction - think I know what the boost issue is, the input pipe on my Alive IC seems a bit crushed one side... Anyone got any ideas of how to make it nice and round again (preferably in situ)?

I like embarrasing other cars, I used to have a caravan and also a large petrol engined saloon.

A people carrier puts its foot down while I was passing, he lost!

Sat at Newhaven waiting for ferry, 70mph run down from Yorkshire, zero coolant loss so I'm a very happy bunny!

Deleted - being a tard