300 Tdi Rebuild

Cheers, James. I think it's smoking a bit less at start up too so my fingers are crossed on that one. I'll see what another two or three thousand miles does to it.
Can I ask a question about brake servos? I've just changed mine tonight. The brakes were a bit numb, but the vac pipe sticks to your finger. Also, when I pumped the brake pedal hard, held it down and started her up there was no movement on the pedal. Anyway, changed the servo and brakes seem a lot better. Had Mrs test it too and she says they are a lot better. However! When I do the start the engine test with my foot on the pedal, there's still no pedal movement. Is this test 100% reliable? Cheers.

generally yes you should feel a little pedal sink feel

jamesmartin said:

generally yes you should feel a little pedal sink feel

Click to expand...

Hmm, ok. I'll see what it's like tomorrow. I put a smear of grease around vacuum pipe before I pushed it in to the servo. I can't see that causing a problem. I'll keep an eye on it. Cheers.

The new servo is working fine.
Took the vacuum pipe off it and tried it down the street. Seemed fine Reversed up the street and drove on to the drive and suddenly I was having to stand up off the seat to stop from hitting the garage doors. The servo obviously holds vacuum for quite a while! Put the vac pipe back on and tried it down the street again. Great! Back on the drive and tried the hold the pedal down and started it up test. I could feel the pedal, very slowly, moving down. Couldn't feel that before! Don't know if taking the vac pipe off and on made a difference, or if I just couldn't sense the pedal moving before. Anyway, all seems good.

I've turned my attention to the aux belt noise I mentioned a while back. It's canny loud Bit of clickety clackety sound among it too. I was a bit concerned that something was loose in the engine, so I took the belt off and ran it. Very quiet and smooth engine sound greeted me
Put the belt back on and did the water spray test again. (Did it a few weeks ago)

This is the powdered rubber build up on the power steering pump.

I tried the penny trick and it sound the same if not worse! So, for starters, I've ordered a new OEM tensioner.

New tensioner, Dayco OEM arrived and put it on tonight.

Still making a noise , but a slightly different sound
Staring at the situation I noticed a ridge in the belt which I'd never seen before.
It was here.

You can't see it because I had already removed the issue when I took this picture.
This was the problem.

A section of one of the V's in the fan pulley was full of rubber.
There was some stuck in the water pump pulley anorl.

I pulled the rubber out and then wire brushed the pulleys.
I then took the water pump and power steering pump pulleys off, just to check for play and that they were seated flat and true.
The power steering pulley is pretty shiny, which must indicate that the belt is being pulled across it?

With this picture I was trying to show the rubber dust that had collected behind the pulley. Which you can clearly see. I was also trying to show the shine on the pulley, but you can't see it That pulley is actually silver in appearance other than a few millimetres at each side of the pulley. Should the pulley surface be that shiny?
The Mrs is going to pick up another belt on the way home from work tomorrow. (current one, Dayco, has only done 2700 miles)
Any thoughts as to the culprit? (Assuming the new belt still makes a noise)

pulley will be shiney its doing some work,something must be out of line to pull a rib of the belt

jamesmartin said:

pulley will be shiney its doing some work,something must be out of line to pull a rib of the belt

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It's so frustrating, James. What would you try next? Fan pulley bearing?

with the fan off watch a new belt as it runs on each pulley

jamesmartin said:

with the fan off watch a new belt as it runs on each pulley

Click to expand...

Oki doki, will do tomorrow when I get a new belt.
In the video I tried to focus in on what looked like some belt movement on the power PAS pulley. Could you see that?

vid was unavailable

jamesmartin said:

vid was unavailable

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Damn. I can see it. Uploaded it from Youtube.
I'll report back after the new belt/ no fan test tomorrow. Cheers.

I have had a belt shred itself in double quick time. I had to buy a 'fix kit' which realigned tensioners etc. Belt turned to candy floss in approx 2000miles.

vec150 said:

I have had a belt shred itself in double quick time. I had to buy a 'fix kit' which realigned tensioners etc. Belt turned to candy floss in approx 2000miles.

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What's a fix kit?

@jamesmartin could you confirm which belt I should have? ERR3287 or ERR5911 My Defender is a 1996 P reg. Cheers

Al2O3 said:

What's a fix kit?

@jamesmartin could you confirm which belt I should have? ERR3287 or ERR5911 My Defender is a 1996 P reg. Cheers

Click to expand...

depends on alt pulley size, id have gone for err3287

jamesmartin said:

depends on alt pulley size, id have gone for err3287

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Cheers, James. Would I get the symptoms I've got if I had the wrong belt on?
I'll measure the Alt pulley.

no ,early belt is very slightly longer thats all, both will fit either but it would either be tight to fit or quite easy to fit

jamesmartin said:

no ,early belt is very slightly longer thats all, both will fit either but it would either be tight to fit or quite easy to fit

Click to expand...

Damn, was hoping that would be an easy fix.

The Alt pulley is 50mm diameter

What have you changed ? Assuming it all ran fine before the engine rebuild. Then Is it worth looking at what if anything you changed to see if it is slightly out of line ?

Cheers

neilly said:

What have you changed ? Assuming it all ran fine before the engine rebuild. Then Is it worth looking at what if anything you changed to see if it is slightly out of line ?

Cheers

Click to expand...

The only thing that is new to the belt is the water pump.
Same alternator, PAS pump, etc.
Old belt wasn't in great nick to be honest, so might have had an issue before which is now getting worse. I put a new belt on when I did the engine.

Al2O3 said:

Damn, was hoping that would be an easy fix.

The Alt pulley is 50mm diameter

Click to expand...

Actually it'll be 49mm if you happen to need to reference by size but thats the later smaller one that you should have on a 96 truck. You want the 1580mm belt.

Is there a penny behind the tensioner? If so get a new tensioner and chuck the penny away. What happens is that the tensioner wears and the wheel gets pushed off to the side, moving the belt away from the block so it then rides up and shreds on the waterpump pulley. People stick the penny in so the tensioner is now in the right position but skewed across the belt and the belt whines and squeals like you woulnt beleive....