I took my car in and was told after pressure test I need new Egr cooler and a hose as it was slightly leaking(the hose) the Egr cooler plastic housing had cracked. 

I collect car and had a eml and hill assist error and I stated that wasn’t there when I took it in the exhaust also sounded weird. 
 

He then uses a computer and plugs it in and opens the bonnet and manually turns this little metal valve thing and said that you now the other guy never put the bits back properly( was a bit sketchy)

I start car up all errors gone drove around 8 miles and now I have a new leak that’s worse than the cooler leak and in a new place in the bay the Egr cooler leak was front top end engine under big pipe but new leak is from right side of engine around 2 large rubber pipes that if I’m correct has the thermostat housing below

im not sure if they have done a bad job and should take it for them to correct or if maybe a new leak has happened after fixing the first issue .

14 minutes ago, Mick93x said:

I took my car in and was told after pressure test I need new Egr cooler and a hose as it was slightly leaking(the hose) the Egr cooler plastic housing had cracked. 

I collect car and had a eml and hill assist error and I stated that wasn’t there when I took it in the exhaust also sounded weird. 
 

He then uses a computer and plugs it in and opens the bonnet and manually turns this little metal valve thing and said that you now the other guy never put the bits back properly( was a bit sketchy)

I start car up all errors gone drove around 8 miles and now I have a new leak that’s worse than the cooler leak and in a new place in the bay the Egr cooler leak was front top end engine under big pipe but new leak is from right side of engine around 2 large rubber pipes that if I’m correct has the thermostat housing below

im not sure if they have done a bad job and should take it for them to correct or if maybe a new leak has happened after fixing the first issue .

You've been had ! The leak you have now was the original id bet. NEVER trust any garage, mostly they are scumbags out to fleece you. They will fire the "parts cannon" at it just to see if it works. Who pays for that ? YOU ! Thats MY experience anyway, and thats why i do it myself, if any repairs are required. Im grumpy today lol.

My concern is there’s a bigger problem not diagnosed as I know for a fact there was no leak over the right side of the engine and I seen the cracked cooler after removal, I was thinking they have not tightened a hose or possibly something else has caused the next part to brake then I fix that and another part brakes it seems to me like the coolant is trying to find its next easiest/weakest point to escape but I could just be making this up in my head haha 

4 hours ago, Mick93x said:

My concern is there’s a bigger problem not diagnosed as I know for a fact there was no leak over the right side of the engine and I seen the cracked cooler after removal, I was thinking they have not tightened a hose or possibly something else has caused the next part to brake then I fix that and another part brakes it seems to me like the coolant is trying to find its next easiest/weakest point to escape but I could just be making this up in my head haha 

The coolant system is pressurised, so it will keep finding the next weakest point until you fix all the leaks.  Then the weakest point 'should' be the reservoir cap that allows excess pressure out.

Sadly I don't think we can diagnose this fault without a picture of the new leak area at the very least.

I was doing a better look earlier it’s the thermostat housing I took the air box out and can see the leak not sure if I’ll need a new unit or if it’s able to be fixed/repaired seal etc 

my concern now is or even my question is how was there no signs of a new leak when I left the garage after the Egr cooler replacement l I mean it’s all over my driveway but the drive to the shop/grocery store after leaving the garage yesterday was fine,I literally drove no more than 12 miles all in and I can imagine the mechanic was not near the right of the engine as the cooler is mid/top front.

or let’s say I replace thermostat housing and do a presssure test post repair and have zero leaks then after a short drive another coolant part fails,what would someone’s hunch be as to why for the sole purpose of avoiding further damage.

Without a picture we can't say whether the housing is cracked and will need replacing or whether it's just a seal failed or even a loose hose clamp.

If there is a lot of pressure building up in the coolant, and it's not just a faulty reservoir cap, then that usually means exhaust is getting into the cooling system.  There are two ways for that to happen:

1. The EGR cooler

2.The head gasket

Fortunately there is a very easy test for this.  Now called a CO2 leak tester or even a headgasket tester but if you're dealing with an old-school mechanic they'll probably still call it a sniff test.  (Unless that's just me...)

Well I’ll go take some pictures today and report back, 

also in order of what I’ve done on the last 2 weeks 

replaced coolant expansion tank and cap as when I opened it the lid thread was stuck inside the tank couldn’t extract so just opted to replace.

2 days later erg cooler leaked or possibly was already leaking but was missed and just got worse so replaced cooler and Egr hose that was slightly leaking too,

drive car 12 miles now thermostat is leaking or possibly was already leaking and got worse. 
 

unless it’s all due to high thermal stress and on this case I’ll perform a sniff test tomorrow.

 

Was thermostat I forgot to pics but cars back to normal so all in new coolant cap, new expansion tank,new Egr cooler,new thermostat plus a hose them a few coolant flush’s. I also got the cap pressure tested and released the psi as and when it should so I’m happy now temps are good no leaks 🥳

Adding my post to my previous post as it’s related 

 

 

so if you read above back in April I replaced my thermostat housing,Egr cooler(only) not full housing and a new expansion tank(only done the tank just to be safe and why not really) 

 

yesterday all coolant gone again done a pressure test and what do you know the Egr coolers got a hairline crack in the plastic housing

 

I’ve decided this time bite the bullet and replace full erg and housing this time as maybe I should have just done that to begin with rather than the cooler 

 

my question is for you enthusiasts on here: would you agree that it’s only gave in as the whole housing wasn’t replaced or would you think there’s a bigger issue that’s causing this as I mentioned back in April. In other words I’ll be pretty ***** if the new replacement does this again and it happens a Third time.

I’ll also mention as embarrassed as I am to say I bought the cheap £90 cooler and gasket the first time this time I’ve opted for a mahle brand that has good reviews and at a much higher cost.

mileage, service history, vehicle condition

we are flying 100% blind - how can we advise when we have nothing to go on

 

 

so the mileage is just over 75k it’s had every service on the book on time every time even the oil changes and filter etc I’ve always done what’s needed of the car asks for oil service it gets it within 100 miles of the indication I only use shell premium diesel(don’t think that matters but hey I’m throwing it in there)

the only thing that’s happened to the car out with it’s servicing requirements is a front o/s bearing and new alloy I got as I put a pot hole and it dented making me loose air gradually threw time but was annoying and not safe so I got a new alloy rather than repair,

the only reason I got the cooler before hand and not a full unit is because as much as I’m not poor im not rich Eaither and it was 5x more expensive to source locally and I needed the car back quick 

I’ve now ordered the whole unit and it will arrive by Tuesday, before I was busy just had a child and just paid the mechanic but I am mechanically minded and this time I’m doing it myself I’ve even arranged to get paid leave wed thirs and Friday next week just to be safe I reckon I’ll do it same day but I like to have the buffer time before needing to rely on having the car to get to work so that gives me 5 days 

I’m just worried there’s something more sinister going on that I haven’t caught/diagnosed and that I have the same thing happen to the whole unit again costing more money 

12 hours ago, Mick93x said:

I’m just worried there’s something more sinister going on that I haven’t caught/diagnosed and that I have the same thing happen to the whole unit again costing more money 

Unfortunately you won't be able to test for a headgasket leak until the EGR cooler is sealed again.  But I would be testing for that and coolant pressure when hot after the repair.  If it passes sniff test and pressure isn't excessive (should be around 1.4 bar) then there shouldn't be any other coolant system faults at this time.

I forgot to say I ended up doing it myself I took pictures and do t mock my coloured tape it’s the only think I could think of to help remember where they all went back haha I’ve changed it and done a sniff test everything’s looking good for now I’ll put it down to the fact on April I replaced the cooler only in the mechanic shop keeping in mind I was wanting to avoid the cost so I was quoted 910 and I got a full housing with cooler this time mahle brand new gaskets etc for 250 coolant 20  saving myself 640 quid keeping in mind I’ve only ever done brake pads,discs,exhaust flex and suspension before on various cars over the years so I’m really happy I went into the bay and succeeded 😝