Mim said:

So...if a V8 is over/under-revving and generally acting up, one of the possible solutions might be to replace the coolant temperature sensor? Turns out that we ordered a sender rather than a sensor, but what the hell, replace it anyway, right?

Over-zealous boyfriend tightened the (as it turned out different sized) replacement sender to the point where it sheared off.

So, today he had-at the stump of the sender with a bolt remover (reverse thread-tap thing) with a similar amount of agression. The stump of the sender started to shift and then, CRACK goes the housing.

So now we have a '96 EFI Discovery with a big thread-tap thinger sticking out of where the coolant sender ought to be and a one inch crack running down to the body of the manifold. And it leaked a little coolant as you might expect. Could anyone suggest the next step please? I assume that it will need welding back up again and re-tapping for a new sender, but could we use epoxy or similar to keep it running in the meantime (without creating an exciting coolant fountain whilst on the M5). We seem to have borked our only mode of transport!

Any suggestions?

Mim.

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Mim said:

So...if a V8 is over/under-revving and generally acting up, one of the possible solutions might be to replace the coolant temperature sensor? Turns out that we ordered a sender rather than a sensor, but what the hell, replace it anyway, right?

Over-zealous boyfriend tightened the (as it turned out different sized) replacement sender to the point where it sheared off.

So, today he had-at the stump of the sender with a bolt remover (reverse thread-tap thing) with a similar amount of agression. The stump of the sender started to shift and then, CRACK goes the housing.

So now we have a '96 EFI Discovery with a big thread-tap thinger sticking out of where the coolant sender ought to be and a one inch crack running down to the body of the manifold. And it leaked a little coolant as you might expect. Could anyone suggest the next step please? I assume that it will need welding back up again and re-tapping for a new sender, but could we use epoxy or similar to keep it running in the meantime (without creating an exciting coolant fountain whilst on the M5). We seem to have borked our only mode of transport!

Any suggestions?

Mim.

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fett said:

if you were local I could bodge it for you with some specail epoxy but the time it would last would be guesswork. it would bebest to take it off to weld it as cast ally it a bastid to weld so you may as well fit a used one, I expect there are a million out there.

I would look on ebay for somone breaking a range rover of the same spec and age.

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joe1972 said:

Step 5, Get another boyfriend!

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Mim said:

An update...

Boyfriend returned with steel epoxy gubbins which we've now used to fill the crack and hole for the sender. I've tracked down an undrilled replacement manifold - figure I can sort the drilling/tapping for LPG injectors later.

We waited until the epoxy had cured, then it started raining. Got bored of waiting for it to stop, so armed with an umbrella and a number of rags we replaced hoses, dizzy cap, plug leads, and refilled the coolant.

Screwed the radiator cap back in, then when I tightened it (gently - I swear!) the top of the cursed, hateful thing came off in my bloody hand.

We then stepped back inside before one of us could push the damn car down the hill into the sea (mud). The remainder of the cap has been pried out and epoxy is once more curing as I type...

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Mim said:

I'd say that; :doh: describes it all so much more elegantly than I ever could

Scary thing is, I'm actually really enjoying myself...

He's been out for a run, and the bodges seem to be holding. I'll be taking a big bottle of water, the rest of the epoxy filler, plus the toolbox with me to work tomorrow.

Imagine I'll be back soon with noob questions about refitting inlet manifolds. Wish me luck!

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Mim said:

I think that this thread needs a new title...

Disco drove beautifully over to Bristol this morning. Approx half a mile away from work I noticed the tiniest wobble in the power, and switched it from gas to petrol to see if there was any difference just before getting off the motorway. It didn't seem any different, but after stopping at lights and going again I couldn't notice anything wrong any more, only problem was that it didn't want to switch back to gas.

As I pulled into the car park I noticed a small amount of steam escaping briefly from under the bonnet on the same side as the radiator cap. I parked up, opened the bonnet and as expected, our fix on the cap had failed and the radiator had leaked through the hole in the cap. There was no more steam, so I assumed all was ok - I just needed to fix or replace the cap and replace any fluid lost.

Spent the day (in between working) unsuccesfully trying to source a new cap - I ended up sneakily mixing up epoxy resin in the kitchen at work and re-glueing the cap back together.

So work ends, I top up the coolant with (quite a lot of) water and replace the cap. Then when I turn the ignition, the fuel pump doesn't prime and the engine cranks, catches very briefly, then dies.

Over the next hour and a half we tried starting it on gas (nearly, but not quite first time, then nothing), putting it in gear and cranking (nothing), swearing at it (nada) and, standing over the other side of the car park glaring at it whilst smoking cigarettes.

We have abandoned the rotten thing in Bristol having borrowed OH's brother's car. We're heading back with a multimeter and jump pack tomorrow to try jumping the fuel pump directly. I've told the guys at work that if they need me, I'll be in the car park...

Is there any way that the rad leak could cause the fuel pump to fail? Or is this just not my week?

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fanatic said:

If you get really stuck pm me

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