300 tdi advice please ???

Elo all , new to discos but already impressed . Im tryin to get to the bottom of my coolant system probs , had a few leaks which stop wen i loosen filler cap and release pressure , ive been drivin with cap loosened and all been fine temp wise . After a weekend investigation i found 2 core plugs leaking , after removing manifolds and starter motor i now have access to remove and refit , straight forward im hopin . I was surprised at the amount of oily gunk in pipework ,turbo, and inlet manifold so ive decided to remove and blank egr and de cat at the same time .
Question 1 - i will degrease pipes and inlet manifold with petrol but should i be doin the turbo itself ???

Question 2 - i will b making my own blankin plate from 4mm steel and replacing inlet hose . Is this ok ??? And wondering wot to do with vacuum hose and electrical connections


also i have had a annoying tappin from manifold side of engine
discovered a stud missin frm far top right of exhaust manifold its been blowin frm ther ,u can see the soot . Could this b the tappin ?? Gasket looks in good nick does it need replacing or is it reuseable , thanks all in advance

Just to add this disco has been stood 2 years before i repaired it and put thru mot . It had head gasket done at craddocks in cannock 2008 a month b4 it was taken off the road , i thought they had a good rep ?? So far theres a stud missin FRM EXHAUST MANIFOLD . And bolt missin frm starter missin no rocker gasket and a 13 mm socket rattlin around under rocker cover !! As they wer last people to touch it , im not very impressed .

egr- you can pull them out of the way not needed at all mine are still there just tucked behind the air box i think

yes a blowing manifold can give a tapping noise

any advice as to hw to clean crap frm turbo ~????

in or around turbo? i use brake cleaner for everything!

well as far as i can see the inside of the turbo is full of the same crapy gunk as the rest of the system . assuming this will effect permfance in some way ?

i have never had to clean the inside of a turbo before they normally stay quite clean, its worth cleaning out the inlet manifold and intercooler there are threads about it on here somewhere

Re the tapping noise - if it is coming from the drivers side of the engine and somewhere near the oil filter housing it could be the vacuum pump on it's way out.

Re cleaning turbo, I would not use any solvent in that area at all asthe turbo runs on a film of engine oil and disturbing that would not be good.

Can't remember if you said you had cleaned the intercooler, but if you haven't may I advise you to do it so you will get the best benefit from it.

the tapping noise was coming frm manifold side , that wer i found a stud missin frm top right ex manifold with signs of it blowin frm ther , i have cleaned out all components except turbo unit itself ,

problem now - ive vdone away with egr , got a non cat dwn pipe but realy cant fit it in place no matter wot i try . is ther a way to get it in ???
the old one was tight coming out but it had the flexi part on .
im loosin patients with dwnpipe nw ,cheers

midnite moocha said:

the tapping noise was coming frm manifold side , that wer i found a stud missin frm top right ex manifold with signs of it blowin frm ther , i have cleaned out all components except turbo unit itself ,

problem now - ive vdone away with egr , got a non cat dwn pipe but realy cant fit it in place no matter wot i try . is ther a way to get it in ???
the old one was tight coming out but it had the flexi part on .
im loosin patients with dwnpipe nw ,cheers

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HI MM, the trick to doing a new exhaust downpipe on a TDi is to jack up the CHASSIS at the front end, to give more working room between the engine and the front axle.

Once you've done that it should be a piece of cake.

Cheers
Dave

thanks for reply , i will try the jacking method shortly , had to come in for a cup of tea before dwn pipe ended up launched over fence , cheers

ive nw managed to fit dwn pipe , by jackin chassis , fits gr8m
ive now reassembled air system after cleanin and removing egr , alot of the oily gunk seems to have come via the rocker breather that goes into air pipe before turbo , seperator looks ok , im wondering if ther would be any mileage in doin away with the breather , wot i mean is fitting a small breather filter to exit on seperator and blocking off hole in air pipe , just a thought but this would keep all the crap out the intake ?????
any opinions please guys ?????

midnite moocha said:

And wondering wot to do with vacuum hose and electrical connections

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Tie up the electrical connector and blank off the vacuum pipe

Allan

one of my mates has his breather running down the side of the engine instead of in the intake pipe and blocked the hole up in the intake pipe, he says it runs better like that, but i dont think it will be very good if you got green laning or off road

why not off road ? in case water or crap out in ? i was thinkin of mounting a small breather /filter right onto cyclone seperator thing , so should be out the way? if water got that high i may be in trouble lol
ive driven for 1st time today after de cat and egr removal , seems more responsive ,running better , done 100mile on motorway and fuel economy seems bit better . money well spent id say , well i got 55 quid for the cat at scrapyard so that payed for parts and a few extras .

yeah it wont be any good for me as i have been in water over the bonnet a couple of times now and you really dont want water in your oil