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BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

2004 Defender 90 Td5 CSW Santorini Black

Just my Luck . . .

Months ago I booked three weeks annual leave to drive down to Morocco and back. I finally set off on Saturday morning and made it to Bordeaux. On Sunday I was nearing Lamego, Portugal (I fancied a detour for the day) and the 2.2 started to overheat. Brilliant . . .

Anyways, I limped the last two miles to the campsite and found several litres of coolant had been sprayed over the engine bay and also just vanished.

Yesterday morning I set off, after filling the cooling system again. To be almost immediately met with clouds of white steam from the exhaust and the reek of coolant again. End ex, I thought . . . But not yet.

One thing Instagram has given me is a network, and fortunately the Portuguese know a thing or two about a Land Rover. The 110 was in the Offroad Projects workshop by this time yesterday, after they arranged recovery (arrived in about 10mins!!!). They’ve identified the EGR cooler had catastrophically failed, dumping enough coolant into the inlet to cause overheating and a head gasket failure.

Major stuff, but repairs are underway. Maybe Morocco will still be possible. We shall see.

Click image to enlarge

Click image to enlarge Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

26th Sep 2023 12:19pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2420

2007 Defender 110 Puma 2.4 SW Chawton White

Really bad!

were you using the specified coolant/changed according to recommendations? Puma 110" SW

.............................................................
Earth first. Other planets later

26th Sep 2023 1:06pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

Yes, correct spec coolant.

I know the EGR cooler is a common point of failure.

I expect it was a combination of high EGTs on the steep Portuguese motorways and an 11 year old EGR cooler. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

26th Sep 2023 1:12pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2420

Ok but another major point of unreliability. Lucky you were not in the middle of Australia or Turkmenistan. Another point for the Troopy. Puma 110" SW

.............................................................
Earth first. Other planets later

26th Sep 2023 1:16pm

Ianh

Member Since: 17 Sep 2018
Location: Essex
Posts: 2027

Ian at IRB developments ( porny on here and site sponsor) has highlighted the issue with the 2.2 EGR cooler leaking

See link

https://www.facebook.com/IRBdevelopments/v...591089960/

It’s the first failure I’ve read of on this forum though and seams to have quite significant consequences re head gasket.

Hope all gets fixed ok and you get to recommence your holiday.

26th Sep 2023 1:25pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

MK wrote:
Ok but another major point of unreliability. Lucky you were not in the middle of Australia or Turkmenistan. Another point for the Troopy.

Yes, I was lucky I was still in Europe. It wouldn’t have been fun to have this happen in the Sahara . . . Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

26th Sep 2023 1:28pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

Ianh wrote:
Ian at IRB developments ( porny on here and site sponsor) has highlighted the issue with the 2.2 EGR cooler leaking

See link

https://www.facebook.com/IRBdevelopments/v...591089960/

It’s the first failure I’ve read of on this forum though and seams to have quite significant consequences re head gasket.

Hope all gets fixed ok and you get to recommence your holiday.

I’ve been messaging Chris at Venture 4x4, as my regular go-to when in the UK, and he suggested the EGR cooler straight away. Looking online, it seems quite a well known weakness of the TDCi engine in all applications (LR/Ford).

It certainly adds weight to the argument for deactivating the EGR and bypassing the cooler.

Thanks! Hopefully I’ll be wheels rolling tomorrow or the day after. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

26th Sep 2023 1:32pm

Dinnu

Member Since: 24 Dec 2019
Location: Lija
Posts: 3419

2012 Defender 90 Puma 2.2 CSW Santorini Black

As I understand, for a 2.2 you need to get a DPF and EGR delete at the same time. You cannot do an EGR delete only. But I stand to be corrected. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black

26th Sep 2023 1:49pm

andy63

Member Since: 30 Jun 2023
Location: north east
Posts: 529

I think when I spoke to bells in York I was told that if you disable the dpf function you effectively disable the egr from it's normal working but still have to leave it electrically connected as it still does some sort of purge at shutdown.. May be getting it wrong but I remember on my mk 7 transit you could hear a sawing noise when tou shut down sometimes.. I was told that was the egr valve cycling..

26th Sep 2023 2:24pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

Yes, that noise on shutdown is the EGR. The TDCi in Defender form does the same cycle. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

26th Sep 2023 2:32pm

TexasRover

Member Since: 24 Nov 2022
Location: Paris
Posts: 1079

2002 Defender 110 Td5 DCPU Chawton White

Unfortunately all these emission control system are a high point of failure on a lot of modern cars, but without it nowadays you cannot drive around a bunch of cities. Pros and cons.

Shop looks nice! I would not call it luck you found them. You knew were to look for them and you are obviously well prepared to deal with set backs.

Makes for a good story later in the pub no?

26th Sep 2023 2:42pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2420

Time to bypass it on my 2.4 I guess Puma 110" SW

.............................................................
Earth first. Other planets later

26th Sep 2023 3:23pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

TexasRover wrote:
Unfortunately all these emission control system are a high point of failure on a lot of modern cars, but without it nowadays you cannot drive around a bunch of cities. Pros and cons.

Shop looks nice! I would not call it luck you found them. You knew were to look for them and you are obviously well prepared to deal with set backs.

Makes for a good story later in the pub no?

Makes me glad I’ve removed it on the Td5.

Fortunately I have a bit of a Portuguese contact, who was a total hero yesterday.

That is very true! These things are sent to test us. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

26th Sep 2023 3:27pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

MK wrote:
Time to bypass it on my 2.4 I guess

I would seriously consider that! Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

26th Sep 2023 3:28pm

Race.it

Member Since: 27 Aug 2019
Location: Algeciras
Posts: 823

2010 Defender 110 Puma 2.4 SW Alaska White

Not defender related but the wife’s daily egr cooler (BMW) let go the other day limped it 200km hole with frequent coolant refills, just waiting for the replacement to arrive from Germany so it can be repaired. Searching for my first Defender...and started just as Covid hit, so talk about timing.

5 months after starting the search I found it, and here is the details

26th Sep 2023 4:38pm

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