Disco 2 Diesel Fuel Cooler Removal (To Fix Properly)

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Intestinalworm

Well-Known Member
Posts
712
Location
Australia
2003 Disco 2 Td5 with the older-style shell/tubes HEX diesel fuel cooler with the plastic end caps, o-rings and strange clamps!

Now, fixed leak significant leak at the front end of the cooler around a year ago, but now I have a small leak at the back end (the hard to access end!).

To make it easier this time around, I wanted to completely remove the fuel cooler (think 4 x 10mm nuts) and put a new o-ring on at the back and a new slimline worm-drive clamp. Will obviously need to disconnect the fuel lines as well.

Has anyone removed the fuel cooler from the top successfully (leaning over the driver's side fender), or will I have to get the overalls on and get underneath and extend my orangutan arms up into the engine to undo the two lower 10mm nuts!?:(
 
I did, (without disconnecting the fuel lines) to get better access for inlet manifold removal. it is not difficult to remove the nuts but was f..in difficult to put back the bottom ones :)
(note. my car is LHD so might be different)
 
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