Defender TD5 Radiator swap problems

Hi,
I found a hole the size of a golf ball in my rad so ordered a new one, I removed the old one and there is a hose at the bottom on the left (as you stand facing the windscreen) but there is no connector on the new radiator? I think it maybe the fuel cooler?
Anyone got any ideas what I can do? Did I get the wrong rad? There was only 1 I could find for all TD5 defenders 99 onwards.
Any help appreciated.

James

eethon said:

Hi,
I found a hole the size of a golf ball in my rad so ordered a new one, I removed the old one and there is a hose at the bottom on the left (as you stand facing the windscreen) but there is no connector on the new radiator? I think it maybe the fuel cooler?
Anyone got any ideas what I can do? Did I get the wrong rad? There was only 1 I could find for all TD5 defenders 99 onwards.
Any help appreciated.

James

Click to expand...

there are 2 types. one for 1999 to I think 2001 and one for 2001 onwards. The early ones had the seperate 4 bars for the fuel cooler. The fuel cooler is a 3 connector cylinder type one. The later ones are all in one rads with an extra spur off the bottom hose that then goes to the egr cooler and then the fuel cooler which is a square type one with only 2 hose connections.

so can i get away with putting a spur on the bottom hose? I really need to get it fixed tomorrow and cant wait for a new Rad also I cant return the one I have!

eethon said:

so can i get away with putting a spur on the bottom hose? I really need to get it fixed tomorrow and cant wait for a new Rad also I cant return the one I have!

Click to expand...

I can't see why not providing that the mountings are the same. You will need to sort out how to blank one of the connectors on the fuel cooler though. You need a coolant diagram of the later type system to work out how to route your plumbing though. There is a guy on ebay selling the later square type fuel coolers for about £15 to make it a more permanent fix. Either that or ebay the new rad to pay for the correct one.

You may even be able to join the existing pipes as a temp fix. As long as the tank is full of fuel it 'should' be ok

its really strange that there is only 1 pipe missing a connector. you would think it wold be 2 an in and an out? ill have a better look tomorrow....

eethon said:

its really strange that there is only 1 pipe missing a connector. you would think it wold be 2 an in and an out? ill have a better look tomorrow....

Click to expand...

If you mean connector on the radiator, the other one is on the front of the radiator hidden behind the grille on the drivers side opposite the other one.

If you mean actual coolant pipe. Your current bottom hose is a single pipe which curves downwards from the bottom of the thermostat to the bottom of the radiator with a drain/bleed screw in the bottom of it. The new style pipe is the same but has a plastic T-piece in it with the additional spur coming off that. The earlier fuel cooler has the extra connector on it which is not on the newer version. I suspect that the pipe to this connector is the second pipe that you are on about.

Hi, Its all in now and running ok. In the end I made a bung for the coolant hose that did not have a connector on the radiator, this is until I can find a better solution.

The coolant hose that bends around the back of the rad is present and connected, The radiator connector that is missing is the on the other side of the Rad to the one that bends around, It is the same size hose just no connector on he Rad. And this is the one I made a bung for the hose, this is at best temporary as I`m sure ill need the fuel cooler in the summer! I might have to create a Connector for it in some way. Im just happy its running and I have heating again!

Thanks for you help, still open to suggestions on what I can do for a permanent fix.

obviously the right Radiator is the right way to do it, but now the new one is in I dont want to take it out! So need a work around. Might join it to a coolant hose that does connect to the rad. depending on if its an In or an out hose

Join it to the small hose that runs to the front of the rad.
Thats what I did and its been absolutely fine since March this year.
I used 15mm copper plumbing fittings and made a T piece.
There is just enough room to joint the pipes at the side of the engine before they curve forward to the rad.
If I can I'll take some pics 2moro.

Here you go.
Took 5 minutes to make and another 5 minutes to fit.
Cut both pipes carefully and join together taking the single one to the fitting on the front of the rad.

Thats great thank you! Ill give it a try. Really appreciate your help guys.