Discovery 3 Engine re-build

Sorry pressed wrong key fuel belt fitted, no timing needed on the 2.7 re used the tensioner you can reset them, air con, power steering, front pulleys, egr valve, crank stop blank is under air con bracket hoping to finish tomorrow and fit gearbox on Monday

Why would you re-use the belt tensioner? the bearing has done more work than any other bearing / bushing the belt runs on and they're not exactly expensive for a decent quality one. Yes, I know 'in theory' it won't do much damage if it fails - it just seems to be saving money on the wrong things to me.

Its

Sorry dog tread on phone again its brand new only been fitted run for 5mins and then removed for the head work

Ah, well that makes sense!

Spot on about tensioners most belt failure is probably due to tensioner failure, belt may last to service period not sure tensioners do well that's what I've always thought, even the tensioners on my merc are part plastic or nylon, next project is a 3.0 xf with belt failure no tensioner but lots of telltale debris will put pic on when I get it in

Most Mercs have chains, it's only the Renault engined ones that are likely to have belts, that said, I've changed more worn chains than I have failing / failed tensioners.... Most problems are due to people thinking they know better than the torque setting for the tensioner bolt, causing fractures in the mounting.

Engine back together well almost turbo and its piping to do, wiring on, note no knock sensors on 09 is also another difference in wiring loom few other odds and sods to do, alternator, and right hand engine mount left off at this point, gives a bit more room when refitting motor, saves disturbing steering, will lift it off the stand and set it down to fit the gearbox over next day or so, have to fit new calipers on my D3 at some point, hopefully fit the motor at the weekend also in pic differences between pre and post 07 egr valves post 07 have a larger water jacket and egrs have a thermostat, my son wants to do a YouTube video of me putting in the engine/box back in for part of his A level assignment will let you know maybe

Finally back in workshop fitted turbo pic of tool for getting to the top two nuts, six sided spanner welded to a socket useful to remove turbo, body on, and the top two bolts on the transfer box. Waiting for mainshaft/ torque converter seal forgot to be honest. Still cleaning other parts for next 2.7, pistons soaked in berrymans then cleaned the grooves out with a bit of old ring and a re soak and final wipe over one or two hardly visible vertical scoring unbelievably good condition, five of the rods check out apart from number four , see pic light marking scratching will replace this no other visible Mark's any where on any parts, also pic of wear patterns on big end bearings all being replaced by king's supplied and recommended by my machine shop who checked out the block and honed for me they also crack tested and polished the crank

Turbo all primed and piped up, auto box cooler pipe fitted, I put coolent pipes on to familiarize their routes might try leaving them on, arrows show bypass on 07 on just have to fit torque converter and box then ready to go in waiting for gearbox seal hopefully fit next weekend going to check out front to rear brake lines and change if needed easier at this stage will also get discs/pads/shows before mot

Still waiting for a seal to turn up so started doing a few odd jobs on my 07 pulled the suspension fuse last night fronts dropped 40mm rears about 5mm, removed compressor cover did the fairy liquid thing no leaks on any height setting nor on front strut connectors, have ordered a front valve block/fittings going to change at the same time as struts, just because I'll be under the wheel arch, going to double check the dryer for moisture tomorrow was repacked last August.
Also looking for these 8mm double fuel pipe clips seem quite hard to source have found a couple of places but will only sell to trade if anyone could give me a heads up it would be most appreciated maybe a ford part? Also another quick question can anyone recommend a rust treatment cills not too bad for a 07 going to treat and chassis black as I work through it, may actually keep this one it's chipped and has more boost goes like stink still haven't gotten over the novelty yet although this may wain if it blows up don't have details on the chipping as it was commissioned by the previous owner. Quick message to @gstuart wife was being generous and has allowed me a better budget on the diagnostic you kindly recommend have left you a message in conversation sorry mate just want to pick your brain a little bit more many thanks

tyregeezer said:

Still waiting for a seal to turn up so started doing a few odd jobs on my 07 pulled the suspension fuse last night fronts dropped 40mm rears about 5mm, removed compressor cover did the fairy liquid thing no leaks on any height setting nor on front strut connectors, have ordered a front valve block/fittings going to change at the same time as struts, just because I'll be under the wheel arch, going to double check the dryer for moisture tomorrow was repacked last August.
Also looking for these 8mm double fuel pipe clips seem quite hard to source have found a couple of places but will only sell to trade if anyone could give me a heads up it would be most appreciated maybe a ford part? Also another quick question can anyone recommend a rust treatment cills not too bad for a 07 going to treat and chassis black as I work through it, may actually keep this one it's chipped and has more boost goes like stink still haven't gotten over the novelty yet although this may wain if it blows up don't have details on the chipping as it was commissioned by the previous owner. Quick message to @gstuart wife was being generous and has allowed me a better budget on the diagnostic you kindly recommend have left you a message in conversation sorry mate just want to pick your brain a little bit more many thanks

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These any good?

Thanks mate might just do the trick

tyregeezer said:

Still waiting for a seal to turn up so started doing a few odd jobs on my 07 pulled the suspension fuse last night fronts dropped 40mm rears about 5mm, removed compressor cover did the fairy liquid thing no leaks on any height setting nor on front strut connectors, have ordered a front valve block/fittings going to change at the same time as struts, just because I'll be under the wheel arch, going to double check the dryer for moisture tomorrow was repacked last August.
Also looking for these 8mm double fuel pipe clips seem quite hard to source have found a couple of places but will only sell to trade if anyone could give me a heads up it would be most appreciated maybe a ford part? Also another quick question can anyone recommend a rust treatment cills not too bad for a 07 going to treat and chassis black as I work through it, may actually keep this one it's chipped and has more boost goes like stink still haven't gotten over the novelty yet although this may wain if it blows up don't have details on the chipping as it was commissioned by the previous owner. Quick message to @gstuart wife was being generous and has allowed me a better budget on the diagnostic you kindly recommend have left you a message in conversation sorry mate just want to pick your brain a little bit more many thanks

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Hi mate

Have replied to u my friend via pm

Ref rust I’ve used fertan on the old rock sliders I restored then i used dinitrol after for the inside and outside , was also used on my chassis and very impressed with it, know there are other makes that others have used

Often wonder if the sills rust if there’s side steps fitted in where they become water traps

When I done the rock sliders I drilled several holes in the bottom on each one to allow any water to drain and not sit inside them

Ref suspension as I first rebuilt my valve blocks then vacuum tested them and they still failed , alas was due to the white silica dust going round the system, after removing the compressor and blowing out all the lines I had to replace the compressor, air tank, all 3 x valve blocks and front struts , alas was also down to previous owners neglecting the air suspension allowing it to get so bad , was like night and day after I rebuilt the entire suspension system and was such a dream to drive and also amazed how well it drove on the motorways and through lanes etc, of course I doubt u would have to go that far

Still can’t get over that new Voss connectors are around £14 each , another reason I converted all of mine to the brass push fits which were only around £4.00 each along with making life a lot easier in not having to struggle trying to do the nut up on the Voss fittings

Ref the brake fluid I used the class 6

Hope u get on ok mate

Thanks mate seen no evidence so far of powder when I changed the balls in August they were damp but not powder, changed the tank then too and centre valve block but only because it had a cross threaded pipe fitting, checked all pipe work, with fairy liquid including tops of front shocks nothing, did in both heights, normal height rears are 505mm. fronts l/h 460mm drops to 425mm overnight. r/h 440mm drops to 400mm overnight, rears drop less than 5mm suspect airbags as can't find any other leaks haven't checked front valve block yet did in August no leaks but it's old and wheel off I thought I may as well, no fault codes no dash warnings rises quickly, I'm thinking airbags and calibration (many thanks) are the way to go?

tyregeezer said:

Thanks mate seen no evidence so far of powder when I changed the balls in August they were damp but not powder, changed the tank then too and centre valve block but only because it had a cross threaded pipe fitting, checked all pipe work, with fairy liquid including tops of front shocks nothing, did in both heights, normal height rears are 505mm. fronts l/h 460mm drops to 425mm overnight. r/h 440mm drops to 400mm overnight, rears drop less than 5mm suspect airbags as can't find any other leaks haven't checked front valve block yet did in August no leaks but it's old and wheel off I thought I may as well, no fault codes no dash warnings rises quickly, I'm thinking airbags and calibration (many thanks) are the way to go?

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That’s great there’s no dust , funny enough my front struts only leaked on access height with the rubber showing the most at that height , redone the test after removing them

Indeed might be a pipe leaking or fitting, had similar where it would keep dropping so isolated sections and using a pressure gauge , tested each circuit one by one after putting it onto axle stands to prevent it dropping to access mode

Took a lot of searching as there were leaks all over the place so just took time in testing all the lines etc

Fingers crossed after u fit new front struts and valve blocks then calibration it will be fine

Yes went through the stages when I bought it was rising slowly on dash, filter as you said compressor dryer, then three separate leaks one being the tank, faulty height sensor tripped a few times, didn't like the caravan but did 1300 miles across france now all sorted and at least I now have no fear of well at least the pneumatic side at least think I have same problem as you had airbags was going to wait for bottom arms and do it all together also doing rust prevention along the way as parts are removed. . My 09 project needs discs and pads considering fitting brembos on mine from a supercharged and using my new discs and calipers on my project but will also need 20in wheels many thanks will let you know how I get on

Diagnostic arrived yesterday, thanks @gstuart for recommendation and help,looking at suspension yesterday quickly before work, fault code u0416-86 appeared not picked up by icarsoft, also have low gallery pressure 65psi at normal height, rear right height sensor had varying voltage moving up and down by 0.2v constantly, reset code suspension back to normal but on way home back to stiff, no lights or gongs, plan of action have spare compressor (was the original) cleaned and had new dryer crystals going to fit this over weekend, ordered repair plugs for rear sensors see if that cures sensor fluctuation will then go from there, just have to work out how to use calibrate Lol, thanks also to @Stanleysteamer for recommending pipe clips while searching for them I actually stumbled into the correct ones (been looking everywhere) part number esr1373 listed as usual as many different applications, gearbox seal arrived so can continue with 09 engine installation hopefully next week have a good weekend all. p.s all advice with suspension gratefully recieved

tyregeezer said:

Diagnostic arrived yesterday, thanks @gstuart for recommendation and help,looking at suspension yesterday quickly before work, fault code u0416-86 appeared not picked up by icarsoft, also have low gallery pressure 65psi at normal height, rear right height sensor had varying voltage moving up and down by 0.2v constantly, reset code suspension back to normal but on way home back to stiff, no lights or gongs, plan of action have spare compressor (was the original) cleaned and had new dryer crystals going to fit this over weekend, ordered repair plugs for rear sensors see if that cures sensor fluctuation will then go from there, just have to work out how to use calibrate Lol, thanks also to @Stanleysteamer for recommending pipe clips while searching for them I actually stumbled into the correct ones (been looking everywhere) part number esr1373 listed as usual as many different applications, gearbox seal arrived so can continue with 09 engine installation hopefully next week have a good weekend all. p.s all advice with suspension gratefully recieved

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You are welcome and good on you for your progress!

tyregeezer said:

Diagnostic arrived yesterday, thanks @gstuart for recommendation and help,looking at suspension yesterday quickly before work, fault code u0416-86 appeared not picked up by icarsoft, also have low gallery pressure 65psi at normal height, rear right height sensor had varying voltage moving up and down by 0.2v constantly, reset code suspension back to normal but on way home back to stiff, no lights or gongs, plan of action have spare compressor (was the original) cleaned and had new dryer crystals going to fit this over weekend, ordered repair plugs for rear sensors see if that cures sensor fluctuation will then go from there, just have to work out how to use calibrate Lol, thanks also to @Stanleysteamer for recommending pipe clips while searching for them I actually stumbled into the correct ones (been looking everywhere) part number esr1373 listed as usual as many different applications, gearbox seal arrived so can continue with 09 engine installation hopefully next week have a good weekend all. p.s all advice with suspension gratefully recieved

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Ur so welcome my friend and that it helped

Indeed compressor should be around 250 psi and then after turning the engine off the gallery pressure reduces to roughly 47psi

If u don’t mind me adding using a small piece of timber on a trolley jack makes life easier when taking the old compressor out and fitting the new one , personally used all new stainless steel nuts and bolts , along with new chassis mounting clips

Good to hear u now have the ap200 and likewise is brilliant to keep it in ur glovebox for when ur out and about

Plse let us know how u get on