Disco 2 fuel cooler leak

berg450 · Jan 18, 2022

Hi All
Hope you are doing fine!
I have found my fuel cooler leaking for a few days and seems that it is only the front end.
Even it is very minor leak but the car slowly loosing coolant from the system so it is time to repair.
I have already ordered Viton BS225 O rings.
Has anyone of you have experience with do it in situ? Do I need to release coolant from the whole system? I have read on www.discovery2.co.uk that the coolant loss is very minor when you disconnect the cooler.
or, just to be on the safe side, better do it on both sides, remove the cooler and do it on bench?
Any other advice?
Thanks

Spong · Jan 20, 2022

@berg450 Mine was weeping from one end, but i took it out and did both sides.
You need a fuel hose clip remover and If you still have the original water pipe clamps then one of those remote spring clip removers pay for themselves. I did a thread on mine, but I followed the Discovery 2 site as well as watching a video or two on YouTube.
https://www.landyzone.co.uk/land-rover/fuel-cooler-leak.367639/
The hardest bit was getting to the bolts underneath the cooler, as there was always something in the way to stop you turning the ratchet , but in the end I found a 10mm (I think) impact socket was just the right length.

berg450 · Jan 21, 2022

I did the job 2 days ago on situ. Changed only the leaking front end. Was very easy took only an hour. No need to drain the cooling system as only very minor coolant looses when you remove the front hose. I used standard 9mm wide clamps by grinding it to 7mm on the 4 places where the plastic legs are located. No leak so far.

Spong · Jan 21, 2022

berg450 said:
I did the job 2 days ago on situ. Changed only the leaking front end. Was very easy took only an hour. No need to drain the cooling system as only very minor coolant looses when you remove the front hose. I used standard 9mm wide clips by grinding it to 7mm on the 4 places where the plastic legs are located. No leak so far.

Nice one. I did think about just doing the front, but I knew that the other end would start after that! Hopefully yours is good for a while.

berg450 · Jan 22, 2022

Spong said:
Nice one. I did think about just doing the front, but I knew that the other end would start after that! Hopefully yours is good for a while.

If the other end will start leaking then i will remove the whole unit or maybe do also in situ. Will be more difficult but as i have LHD car i have more room there.

Landmark2 · Jan 22, 2022

Berg,
Out of interest did you use 1 or 2 O rings at the end. Read somewhere that there are 2 grooves each end?
Regards,
Griff

berg450 · Jan 22, 2022

Just one. I think the 2nd groove designed for something else as seems to be different in width, and seems that the cooler housing is also wider in that area.

Landmark2 · Jan 23, 2022

Thanks.
Griff

Disco 2 fuel cooler leak

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