I've been trawling through old posts but can't quite find what I'm looking.
I'm currently losing a bit of coolant - not loads but I'm topping up about half a litre a fortnight. When I'm starting the car from cold I'm getting lots of white smoke for the first mile or two. This will then clear and the car drives well. It isn't injectors or glow plugs by the way. No relevant error codes. Starts easily even at -10.
My egr valves are blanked and the pipework to the air box is removed.
My suspicion is that one or both of the egr coolers are leaking coolant into the exhaust system causing lots of white smoke on start up until it evaporates.
I'd like to remove the entire coolant circuit to the EGR coolers. I have read somewhere the Disco Mikey has done this but I can't see any advice on how to do this.
I can see most of the pipework but I'd appreciate advice on how people have done this.
2nd May 2017 10:19 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20731
I was going to do it, but never got round to it, as there will be a TDV8 replacing the current V6 My D3 Build Thread
Member Since: 22 Dec 2009
Location: Maidstone
Posts: 7274
I was looking at this the other day and came to the return pipe whish seemed to have the temp sensor in it, I did not get to look any more as ran out of time so if you do get around to doing it post up a thread as I bet a few people would be interested in it
3rd May 2017 6:50 am
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20731
You need an EU4 top hose, as it contains the ECT in the plastic housing
The Small coolant hose from the plastic coolant housing goes to the FBH
Can't remember where the 3rd hose goes My D3 Build Thread
Member Since: 23 Oct 2016
Location: Penrith
Posts: 143
Many thanks for the replies.
I saw that the current ECT location will be lost if the pipe work is removed. I have a spare set of hoses from an EU4 so I can sort that bit no problem.
MY FBH is currently removed from the coolant circuit - pipes were removed by previous owner. I'd like to reinstate it.
I think I'll need to take some photos of this and report back. Might be a few days.
Thanks again.
3rd May 2017 9:04 am
Ceekay
Member Since: 17 May 2009
Location: Bury
Posts: 2057
I had the same problem a few years back but cant quite remember the detail although it wasnt that difficult. My coolers eventually completely give in and it was impossible for anyone onthe road to see anything for the white smoke.
I remember i got some silicone water hose and just removed the cooler hoses and linked both sides from the back of the engine back around to the sensor at the front and then just blanked of the original cooler outlets.
I will have to get under the bonnet and take the cover off to refresh my fading old brain though.D4 HSE Lux MY16 Club Waitomo
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3rd May 2017 10:48 am
gilesharrison
Member Since: 23 Oct 2016
Location: Penrith
Posts: 143
CeeKay,
Thanks for that. Good to know this has been done successfully. Do my problems sound like yours? Lots of white smoke on first start of the day.
If you were able to take some photos then that would be really useful- I'd like to know what you did at the plastic water distributor in the 'V' of the engine.
Thank you all for taking the time to help.
3rd May 2017 6:26 pm
Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10363
I looked at doing it, but was worried there would be no flow past the coolant sensor.
But as this is only to prove a point, (that it stops the white smoke) just disconnect them at the front and put a loop in, or block the pipes somehow.
Just note the gauge and ecu temp may read low and cause other issues!
3rd May 2017 6:59 pm
defector
Member Since: 23 Feb 2009
Location: Greater Manchester
Posts: 1420
I have done this on my EU4 D3.
I removed both EGR coolers and the metal coolant pipe at the top rear of the engine.
I put a 15mm copper stop-end with jubilee clips to the coolant pipes that used to go to the coolers.
I tried to loop the pipes between the coolers but the engine started to run cool according to temperature gauge (checked with IR thermometer as well), which increases fuel consumption as well.
I found out that the EU4 EGR coolers have inbuilt mini thermostats in them whereas the other D3's don't.
There are a couple of coolant flow diagrams on the forum but i cannot find them at the moment.
3rd May 2017 7:41 pm
gilesharrison
Member Since: 23 Oct 2016
Location: Penrith
Posts: 143
Defector,
That's great. Thanks for that. What sort of end-stops did you use? Was it the plastic push fit type ones like this?
I'll try and get this done at the weekend - I'll take some photos and post them up.
3rd May 2017 10:35 pm
defector
Member Since: 23 Feb 2009
Location: Greater Manchester
Posts: 1420
Those end stops will be fine.
I made mine using a 1.5 inch length of 15mm copper pipe and soldered two copper end caps (used yorkshire fittings - come with solder built in all you need to do is heat up after applying a bit of flux).
I used the yorkshire fittings because they come with a groove built in which act as a natural stop to place the jubilee clip.
Might seem over the top but i had the materials available to hand.
3rd May 2017 11:54 pm
defector
Member Since: 23 Feb 2009
Location: Greater Manchester
Posts: 1420
Thanks to Robbie on a previous thread.
This is for EU3 engines.
4th May 2017 12:17 am
KostasA
Member Since: 23 Aug 2015
Location: nairobi
Posts: 286
i was thinking to buy two thermostats (you can find them cheap enough 3-4 pounds) and make two aluminum/copper pipes similar to the ones on the EGR cooler. so then you bypass the two coolers with those pipes with the thermostats (inserted in) and you have the whole EGR kit out of the equation.
4th May 2017 9:36 am
Steinar
Member Since: 31 Jan 2008
Location: Aalesund
Posts: 3
From the drawing it looks like all the EGRs can be removed, block one of the browm, and install a thermostat between the second brown and the pink tube.
Then it will be less tubes, and the EGRs will be completely out.
6th May 2017 8:22 am
philm
Member Since: 02 Oct 2016
Location: Manchester
Posts: 732
I have never seen an EGR valve off the car but would have thought if they had thermostats in, then they must be bypass stats or when first one closed no heat would get to car heater or second EGR.L633 Defender
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