Fuel cooler seal - easy or not?!

toby_2009 · Mar 24, 2015

Hi,

The seal on the front end of the fuel cooler on my td5 is leaking,I've ordered the seal and some seal lubricant but having had another look/read about it, it looks like it's a difficult little space to work in and the clip which goes round it looks bloody difficult To get back on!

My mechanical skill/knowledge/experience is very limited but I'm pretty practical. Would you guys think I should attempt it? I'm just nervous about not being able to get the clamp thing back on and then not being able to get it to the nearest garage for them to sort it out!

Any input very much appreciated!

Thanks,

Toby

P38dseGAV · Mar 24, 2015

quite an easy job mate remove the retaining clip may need to bend some small locking flaps of metal then remove the end that leaks replace seal put back together i used a jubilee clip to hold it back in its place

cj_uk · Mar 24, 2015

Hi, I changed both of mine a couple of months ago, used the following instructions www.discovery2.co.uk - Leaking Fuel Cooler Fix which really helped

toby_2009 · Mar 24, 2015

cj_uk said:
Hi, I changed both of mine a couple of months ago, used the following instructions www.discovery2.co.uk - Leaking Fuel Cooler Fix which really helped

Thanks, was it difficult getting the clips back on?

cj_uk · Mar 24, 2015

I used a pair of pincers, the old type used for pulling nails etc, got the clips on then tightened them with the pincers. Difficult to describe really without having it in your hand. The one thing I did find is when I first refitted the cooler, both clips started to move to the edges of the cooler body, nearly falling off. So, I removed the cooler again and flared the edges of the cooler body out near the clips, there's only about 3 or 4 mm between the edge of the clip and the body, so now they don't move. Hope that helps

nadjila · Mar 25, 2015

cj_uk said:
Hi, I changed both of mine a couple of months ago, used the following instructions www.discovery2.co.uk - Leaking Fuel Cooler Fix which really helped

Very easy if you follow this link.
Did mine (front and back seal) almost a year ago and still leak free.
Don't fiddle with the old clips, jubilee clips is the way to go

toby_2009 · Mar 25, 2015

nadjila said:
Very easy if you follow this link.
Did mine (front and back seal) almost a year ago and still leak free.
Don't fiddle with the old clips, jubilee clips is the way to go

Hi, thanks for the reply! Just to check, are you referring to replacing the clips which go around the body of the cooler itself or those which hold the coolant pipe onto the end cap?

Thanks,

Toby

nadjila · Mar 25, 2015

The ones around the body.
Tried to re-use the old clips, but lost my patience getting them back on.
With jubilee clips it was a less than a minute job.

The one on the coolant pipe isn't difficult, use some pliers to squeeze it a little and the end cap goes off or on.

For info: could be overkill, but I put 2 o-rings on each side.

Headtester · Mar 25, 2015

Having wrestled with these type of clips when changing my thermostat I bought some hose clip pliers
Halfrauds aren't showing them on the website anymore but there are on Zamazon here

Well worth getting in my view, I think mine were about £12 - £14

Fuel cooler seal - easy or not?!

toby_2009

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P38dseGAV

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cj_uk

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nadjila

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nadjila

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Headtester

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