110WestCape Posted April 12, 2010 Share Posted April 12, 2010 Hi folks, A fuel cooler on a TD5 has 2 x stub pipes attached to the fuel cooler body which allows for fuel return from the injectors to pass through the cooler and exit the cooler through the second stub back to the filter / tank etc. The fuel cooler is made of stainless steel, it seems. I am about to repair a crack where the stub pipe is attached to the fuel cooler cannister. Would silver soldering be the correct way ? Would a silver soldered repair be able to withstand the pressure in the fuel cooler (4 bar)? Appreciate your thoughts on this. Regards Wikus Quote Link to comment Share on other sites More sharing options...
FridgeFreezer Posted April 12, 2010 Share Posted April 12, 2010 If it's on the return line, is it really under 4bar pressure or just an open vent back to the tank? Quote Link to comment Share on other sites More sharing options...
110WestCape Posted April 12, 2010 Author Share Posted April 12, 2010 Thinking about it, probably not at 4 bar. One would probably have to test the system at that point to determine the pressure. Fuel pressure would normally be tested at the point where it enters the fuel pressure regulator (HP side), it should be the quoted 4 bar (as per Rave). The injectors pressurise the fuel to approx 1500 bar and excessive fuel from the common rail not taken into the injectors then exits back through the pressure regulator to the cooler and back to the filter and tank. Sooo ... to answer my own question , it cannot be at 4 bar as it is at the point where the pressure drops from 4 bar to the LP stage. Conclusion .... lower than 4 bar .... how much pressure ? ..... would need to be tested. Silver soldering ? Will give it a try ... unless the more knowledeable people here can show me the way. Quote Link to comment Share on other sites More sharing options...
FridgeFreezer Posted April 12, 2010 Share Posted April 12, 2010 On petrol EFI the return line is basically unpressurised, I can see no real reason the diesel system wouldn't be the same. I'm not 100% on the metallurgy but there is plenty on google about that sort of thing. Quote Link to comment Share on other sites More sharing options...
nickwilliams Posted April 12, 2010 Share Posted April 12, 2010 TIG welding would be the 'correct' way but silver solder will do it if you don't have a significant gap to fill. Silver solder fluxes are usually pretty corrosive, so make sure you clean it up well. But you probably knew that already! Nick. Quote Link to comment Share on other sites More sharing options...
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