Coolant loss on 2.2tdci - EGR / head gasket?

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Psychosomatic

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Anglesey
I'm new here, and would welcome any advice that you can give.

Defender 110 hardtop 2.2tdci, bought it at 18K miles from a reputable non-main-dealer, and now at 62K miles. Trouble-free between 18K and 57K, six months ago. Only odd thing noticed was that the heater sometimes heated a lot and sometimes rather less, and seemed rather responsive to how hard the engine was working - but I presume that's normal for a Defender? Mainly worked (sorry!) on motorways, with long journeys at 50-80mph, occasionally towing.

Then at 57K, the engine went into 'limp' mode heading up a hill, and became clear that the coolant level was very low. Topped up; fine. No apparent problem, except that every journey (no matter how long!) the coolant level had dropped by 1-2cm in the expansion tank. So, topped up, and up. Checked by LR specialist garage, who said oil was clear and pressure test of coolant system was fine. The loss seemed to be much less of a problem through the Winter.

In the last month, things have got much much worse, ... I wondered if the coolant loss had accelerated again, and so was checking more often. Stupid me left the tank cap off before a journey down the dual carriageway. Heating went off, engine overheated and pulled over, opened bonnet to find hissing and err no tank cap. Filled up, by me; and then seen briefly by very busy LR specialist garage, who found the cooling system was 'pressurised', drained and refilled the coolant, and wondered about the EGR.

After each journey, the expansion tank level seems HIGH - close to the top of the tank. Is that normal? I leave the cap loose, and it then settles down to way below normal. That said, I now have an approach which seems to work ... leave cap loose when back from a trip; fill up with coolant (well, water) before next journey and put cap back on! It is needing typically 700ml (yes, 700ml) each trip.

I can't be sure that the engine doesn't have less power - does it sound different and respond differently to normal? I think so, but then I am running it softly, and barely touch the accelerator in case I don't get home.

Garage is planning to replace EGR (valve?), which apparently also needs the gearbox removing to get at it.

But will that cure it, or should I also be getting them to check the head??

Should I get a BAS remap, and /or take out the EGR?!

Advice / tips appreciated. Thanks!
 
Have a look at these attachments. Garage is probably suggesting the EGR cooler is replaced. Awkward to get at, but the gearbox does not need removing to do the job. Find another garage. If you remove the EGR system, and the MOT tester spots it has been removed, your car will fail its MOT.
If your heater is erratic I would suspect the problem lies there so investigate it for leaks.
 

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One attachment missed in the first response, and a couple more for info.
 

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  • Defender MY12 Workshop Manual (dragged) 9.pdf
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Thanks VERY much for your comments and invaluable workshop manual pages. I'll talk this through with the garage.
I'm really hoping that the EGR cooler is the problem, and that I can move forward then with a trouble-free Defender. At the moment, I have "learned helplessness" - progress seems futile and every step forward leads to a step back!
I'll update here in due course.
Thanks again.
 
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