Disco 1 300tdi Auto - what to swap for expedition..

I've a 300TDi auto. 1996, been set up as a bit of a mud plugger. Bought off a mate. Unsure on the history, but he isnt the sort to skip on servicing when needed. 150k miles on it though...

Fundamentally, it's OK. I'm due to go on a trip to Romania at the end of the month, and I've prepping out what I need to do to make it as reliable as reasonably possible. So I'm after pointers from people as to what I've missed...

So far I've swapped...

Front wheel bearings, swivels, swivel bearings obviously. Halfshafts and diff checked. All looks OK. No leaks.
Rear wheel bearings checked, all OK, repacked. Diff checked, no leaks.

Less than 5k ago it got a 2" lift on terrafirma springs, so it's new shocks as well.
Brakes checked, all looks good. No sticky calipers etc. Has new discs.

Sadly last weekend, on road testing it spat it's steering pump out. Halfway up Pindale rake no less.

So I have the following goodies to fit this week....

Steering pump.
Steering box (was leaking before it got collapsed bearing bits in it! its well stuffed now)
Waterpump (nothing wrong with it, but cheap to get a new one...)
Range rover coolant cap for coolant level sensing.
Top and bottom radiator hoses.
Thermostat
Brass plugs for stat housing.

Questions that I can think of...

1. Do I need to swap the P gasket? Its not leaking - should I leave well alone or is it worth a new one with waterpump etc coming off?
2. Alternator. It's original as far as I know. Bearing life? Should I take a regulator pack and brushes with me to swap in the field if needed?
3. Starter motor - brushes for this?
4. what to look for on the engine? I need to check if the cambelt mods have been done, then ordering the cambelt and tensioners. I suspect it has been done, as the fan pulley feels so smooth I cant think it would be original... Is it worth a strip and check of the rocker shaft? I'll be doing the tappet clearances before I go.

Chassis is sound, no rot at all. I've got some bits on the wheel arch to finish off, but the body is stunningly good for a 96 Disco - previous owner used to spray waxoyl everywhere....

What spares as well to take? I'm going to take the waterpump I remove since it's good, plus thermostat, oil temp sensors. Worth ordering a couple of pushrods and rockers? Drive flanges? Can't think of anything else I'd be happy swapping in the field.

Lot of questions I know, thanks in advance for reading this far!

all the fluids

Already done that - the stuff that was in wasnt too bad. I put some cheap stuff in to just flush the diffs and transfer case out and will drain and put some decent stuff in before we leave.

Is there a filter in the autobox to swap? It's had a 5 litre swap already was planning on another one before I go.

theres is a gauze filter you can wash out or replace, but if oils clean it will be atf is very detergent

if its well serviced and rad and hoses is in very good condition full wallet should take care of any breakdowns you cant carry everything that could fail,

OK cheers. We are going with another 4x4 so if we get stuck there wont be a long walk out (and we have HF radio anyway...). Ultimately it'll be the RAC who dig us out with a recovery back home I expect!

Best get on undoing some pumps then......

Does the head gasket go like on a 200? On those it's 150k like clockwork.

Vinlander said:

Does the head gasket go like on a 200? On those it's 150k like clockwork.

Click to expand...

more commonly

Well I got waterpump and PAS pump off with no trouble.

The crank pulley looks a prize pain to do. Bolts off - just got to draw the pulley off now...

OK I've finally pulled off everything I need to. I can start actually fitting new stuff now.. and it's like everything...

I think the previous owner bathed it in clay and left it. No wading plugs used. The timing case is full of solid dirt stuck on all the walls inside. Half inch deep. Every bearing is shot and full of crud, alternator stripped out, bearings regreased. waterpump. PAS, tensioners, everything. It's almost never ending. There's clay stuck behind the bonnet liner and a nice terracotta baked cast of the head I found lurking under the rubber timing case.

Cam timing was a whole tooth out although fuelling was spot on. That hopefully will improve the fuel emissions, as well as knocking down the valve clearances from 0.6mm *sigh*

And Paddocks quality aftermarket timing kit has britpart tensioners in it - no name bearings I wouldn't trust on a rollerskate. Why sell a Dayco belt with crappy bearings? time to order some decent ones...

I had a 300tdi 96 auto back a few years ago a spare fuel lift pump agood thing to have and I do remember having a slight issue with gear box temp warning think it was a sensor on gear box or something kept losing power until it cooled down after sensor change it was fine

Ok I just screwed something up big time. I pushed the timing pin in and forget it was there, tried to turn the crank to settle the timing belt and the nose of the pump hosing broke and piddled diesel everywhere.

How easy to swap an injection pump? I'm aware it's a lot of money....

easy job,just ensure your new one has the flange fitted ,you should get a used one for 100 -150 quid

not worth getting a rebuilt one? also how do I identify what I need - looking at it this is an auto so presumably some EDC style one but there appears to be loads of different ones listed..

have you a pic of yours ?

Some pictures in here.... https://www.dropbox.com/sh/tv0zw2tkpnc5bgq/AADeP9Zluye7wNc03subpIKSa?dl=0

looks like just the nose smashed but it spews fuel everywhere so obviously something sealing and important isnt anymore....

It's a 1996 autobox with cruisecontrol and an EGR (deleted) if that make any difference.

Thanks to all. I'm going to have a beer and sulk now!

yes its edc but i dont think you can just swap them, you may well need a non edc pump

Thats what I wsa afraid of, presumably the pump is coded to the engine management somehow?

you could by another and get someone to swap the housing

OK, I bit the bullet and bought a new pump. Assuming that the old one was probably getting on and would be needing overhaul before too long anyway it's not that bad I suppose....
I should apparently be able to just do a straight swap since all the immobiliser coding is talking to the ECU. So it arravies tomorrow and fingers crossed it'll be an easy swap. I'll take photos for a writeup if people think it would be useful....

Thanks to everyone for their help so far, especially jamesmartin but there are many people on here willing to help. Glad I found you all.