300 Tdi Rebuild

Al2O3 · May 27, 2017

raywin said:
Yes I agree in this application the seal would probably work fine either way.
You need to account for a Landy sometimes taking a dip but of course you won't expect it to be submerged for long periods.

Don't know about it going for a dip

I'm more likely to take the bloody thing to bed after all this.

ifloochies · May 28, 2017

Al2O3 said:
Don't know about it going for a dip
I'm more likely to take the bloody thing to bed after all this.

I would too....she's certainly a looker now with all that red paint and shiny clean metal under the knickers

Al2O3 · May 28, 2017

ifloochies said:
I would too....she's certainly a looker now with all that red paint and shiny clean metal under the knickers

She's certainly worth looking after.

Started this morning fitting the timing case seal.

Then I set the tappets.

When I finished I went though them again. I kept a pencil tick record next to the sequence in my LR manual, so I didn't get lost off. Second time around 4 of them needed a slight adjustment.
Put the new rocker cover seal in and fitted it followed by the breather pipes

Cleaned the shaft up on the crank pulley and fitted the newly painted flinger. Tapped in on with a block of wood. It's nice and tight.

Put more copperslip on the crankshaft as per @Saint.V8 's recommendation in his sticky how to. I didn't put quite as much as as you though, mate.
Put some threadlock on the crank pulley bolt and set up @aaronmorris 's pulley tool. Cheers mate. It'll be on it's way home soon.

Torqued it to 80N.m EASY!

Got the Mrs to watch the angle gauge.

While I stood on the bumper and front chassis cross member with a three foot breaker bar

Took some pulling. Here's the 'after event' picture.

Connected all the pulleys with a little threadlock on the bolts.

Fitted the new belt.

Then I fitted the airbox/filter and pipes around to the turbo.

Fitted the radiator surround, radiator, intercooler and pipework.

New pipework with EGR removed.

Used the blank that came with the EGR kit on the controller. I need to go through back pictures though to check I have the pipes and blank in the right places. Meant to do that but got carried away with the thought of starting her up.

This is the arrangement at the moment.

Filled her up with oil and then with antifreeze and water.
The final slow and repetitive top up via the top of the thermostat housing.

Measured the coolant and got a good eleven and a half litres in.
Topped up the power steering with ATF and did another check on the clutch fluid.
Removed the turbo return oil pipe and stuck it in a milk carton.

I was feeling a bit tense at this stage and was actually developing a bad head!

Connected up the battery and, with the stop solenoid disconnected. Turned it over!
This amount of oil came out of the turbo.

It was then I realised I had no idea how much oil to expect

I thought at least there is oil coming through. I'll connect the stop solenoid and try starting it with the pipe disconnected and see what happens

It took a bit of turning over, but I had replaced the fuel filter and so this was to be expected.
It started catching and then fired up. The Mrs was videoing so I'll post that soon.
It sounded SUPERB

It was so smooth and quiet!

I stopped it after a few seconds.
This is how much oil had come through the turbo in a very short space of time.

Refitted the oil return pipe and took it for a 12 mile blast.
Quiet, smooth and pulled really well. Left the 30mph zone of the village and pulled quickly up to 60mph

Feels great!

I'll upload some video to youtube.

jamesmartin · May 28, 2017

Al2O3 said:
She's certainly worth looking after.

Started this morning fitting the timing case seal.
View attachment 124519
Then I set the tappets.
View attachment 124520
When I finished I went though them again. I kept a pencil tick record next to the sequence in my LR manual, so I didn't get lost off. Second time around 4 of them needed a slight adjustment.
Put the new rocker cover seal in and fitted it followed by the breather pipesView attachment 124521
Cleaned the shaft up on the crank pulley and fitted the newly painted flinger. Tapped in on with a block of wood. It's nice and tight.
View attachment 124522
Put more copperslip on the crankshaft as per @Saint.V8 's recommendation in his sticky how to. I didn't put quite as much as as you though, mate.
Put some threadlock on the crank pulley bolt and set up @aaronmorris 's pulley tool. Cheers mate. It'll be on it's way home soon.
View attachment 124523
View attachment 124524
Torqued it to 80N.m EASY!
View attachment 124525
Got the Mrs to watch the angle gauge.
View attachment 124526
While I stood on the bumper and front chassis cross member with a three foot breaker bar
Took some pulling. Here's the 'after event' picture.
View attachment 124527
Connected all the pulleys with a little threadlock on the bolts.
View attachment 124528
Fitted the new belt.
View attachment 124529

Then I fitted the airbox/filter and pipes around to the turbo.
View attachment 124530
View attachment 124531
Fitted the radiator surround, radiator, intercooler and pipework.
View attachment 124532
New pipework with EGR removed.
View attachment 124533
Used the blank that came with the EGR kit on the controller. I need to go through back pictures though to check I have the pipes and blank in the right places. Meant to do that but got carried away with the thought of starting her up.
This is the arrangement at the moment.
View attachment 124534
Filled her up with oil and then with antifreeze and water.
The final slow and repetitive top up via the top of the thermostat housing.
View attachment 124536
Measured the coolant and got a good eleven and a half litres in.
Topped up the power steering with ATF and did another check on the clutch fluid.
Removed the turbo return oil pipe and stuck it in a milk carton.
View attachment 124537
I was feeling a bit tense at this stage and was actually developing a bad head!
Connected up the battery and, with the stop solenoid disconnected. Turned it over!
This amount of oil came out of the turbo.
View attachment 124538
It was then I realised I had no idea how much oil to expect
I thought at least there is oil coming through. I'll connect the stop solenoid and try starting it with the pipe disconnected and see what happens
It took a bit of turning over, but I had replaced the fuel filter and so this was to be expected.
It started catching and then fired up. The Mrs was videoing so I'll post that soon.
It sounded SUPERB It was so smooth and quiet! I stopped it after a few seconds.
This is how much oil had come through the turbo in a very short space of time.
View attachment 124539
Refitted the oil return pipe and took it for a 12 mile blast.
Quiet, smooth and pulled really well. Left the 30mph zone of the village and pulled quickly up to 60mph Feels great!
I'll upload some video to youtube.

when your happy its running sweet and no leaks etc it need some very hard work to run the rings/bores in

raywin · May 28, 2017

Yahoo
Bet you feel on top of the world, glad to hear it's running so smooth.

neilly · May 28, 2017

Very nice.

Cheers

Al2O3 · May 28, 2017

I turned it over quite a bit with the stop solenoid disconnected. I've got a video of that but nothing much happens

This is the first start attempt.

Reconnected the turbo return pipe and started it again.

Then took it out for a spin.

jamesmartin said:
when your happy its running sweet and no leaks etc it need some very hard work to run the rings/bores in

What do you have in mind when you say that, James? Long fast run, pushing her hard up hills, running her hard in fourth? I've really no idea.
The run we did was country B roads really. Pretty fast though, had her up to 70 for a while and 60 for three or four miles. One very steep hill.

Al2O3 · May 28, 2017

Forgot to say, I noticed the air box is wandering a bit. I need to check I've properly connected the bottom support bar.

jamesmartin · May 28, 2017

Al2O3 said:
I turned it over quite a bit with the stop solenoid disconnected. I've got a video of that but nothing much happens
This is the first start attempt.

Reconnected the turbo return pipe and started it again.

Then took it out for a spin.

What do you have in mind when you say that, James? Long fast run, pushing her hard up hills, running her hard in fourth? I've really no idea.
The run we did was country B roads really. Pretty fast though, had her up to 70 for a while and 60 for three or four miles. One very steep hill.

have you anything to tow

neilly · May 28, 2017

Hi @Al2O3

I bet during that 1st video your sphincter was twitching like a rabbits nose. Very nice job.
Just one thing, not sure posting a vid of you speeding ( at least that is what it looks like ) is a good idea, you never know who wil make an issue of it,, Blimey I must be getting old....LOL

One final thing, what took you so long?????? ...........................

Cheers

Al2O3 · May 28, 2017

jamesmartin said:
have you anything to tow

Hells teeth, you're going for it big style here!

I have a small Erde trailer, but nothing heavy to put in it.

jamesmartin · May 28, 2017

Al2O3 said:
Hells teeth, you're going for it big style here!
I have a small Erde trailer, but nothing heavy to put in it.

perhaps not then but the best thing you ca do is load engine ie revs are bought down as happens on a dyno or towing uphill etc

Al2O3 · May 28, 2017

neilly said:
Hi @Al2O3

I bet during that 1st video your sphincter was twitching like a rabbits nose. Very nice job.
Just one thing, not sure posting a vid of you speeding ( at least that is what it looks like ) is a good idea, you never know who wil make an issue of it,, Blimey I must be getting old....LOL

One final thing, what took you so long?????? ...........................

Cheers

Hadn't thought of that. Did touch 70 for a wee while

It might sound daft, but as I was topping the fluids up I started getting quite nervous and did start to get a bit of a bad head. I was definitely stressed or nervous or excited or all of those things. But, mostly stressed I think

What took me so long

Do you mean today or altogether? Sunday's are a bit tricky to get stuff done. My mate down the street calls in for a coffee and a chat for an hour and then the mother in law comes around for her Sunday lunch. It's great and I wouldn't have it any other way as I love to see them both. Stops work for about three hours all told.
Generally, I think I'm a cautious worker when it comes to this sort of stuff. Always stopping to research on the internet, LZ, post on LZ to you lot, worry about stuff, this all takes time. Plus, these things take a hell of a lot more time than you think.

That's my excuse anyway

neilly · May 28, 2017

Al2O3 said:
Plus, these things take a hell of a lot more time than you think. That's my excuse anyway

Forgive me @Al2O3

I was taking the mickey,.......

........ you have done a great job.

I was thinking as this is now done when is a good time to drop mine around? needs a bit of a refresher if you do not mind.......LOL.

Cheers

Al2O3 · May 28, 2017

jamesmartin said:
perhaps not then but the best thing you ca do is load engine ie revs are bought down as happens on a dyno or towing uphill etc

Next best thing has to be high gear, up hill then?
The last mile and a bit back to the village is up hill. The Mrs was driving at this point cos we'd swapped half way around. I wanted her opinion of it as it's her daily drive to work and she knows it extremely well. 'It's just pulling up the hill in 5th!!!', she said.

Al2O3 · May 28, 2017

neilly said:
Forgive me @Al2O3

I was taking the mickey,............... you have done a great job.

I was thinking as this is now done when is a good time to drop mine around? needs a bit of a refresher if you do not mind.......LOL.

Cheers

Seriously, neilly it has taken me far longer than I would have liked. (I did put a smiley in my last post and in no way was worried about what you said

)
Looking back on it though, I don't think I could have done it faster for a first time around. Like the chassis and body rebuild it would be a lot faster second time.
I fancy going back out for a spin, but I've had half a bottle of celebratory shiraz and a can of Guinness to dilute it.

I'll be up sharp in the morning though!
I still can't believe how much quieter and smoother it is.

neilly · May 28, 2017

So how many miles before you do an oil change?

Cheers

Al2O3 · May 28, 2017

neilly said:
So how many miles before you do an oil change?

Cheers

Good question. What would you go for? 500, 1000? I'm not sure.

neilly · May 28, 2017

Al2O3 said:
Good question. What would you go for? 500, 1000? I'm not sure.

I would probably go overkill, change it and filters at 500 miles, then again after another 1000 miles, then go onto the normal 6000 miles routine.

But, I enjoy doing oil changes,......LOL

Cheers

jamesmartin · May 28, 2017

Al2O3 said:
Good question. What would you go for? 500, 1000? I'm not sure.

200, you want it flushed as soon as

300 Tdi Rebuild

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