Shoot me I've purchased a lemon!! DOH!!

[VonSwirl]

Hey All,

Having some sad times at the moment and would be really gratefully for any help and advise.

Will try and keep short...bought a 96 300tdi 290K...2 weeks ago to travel oz in. Looked sounded an felt fine on test drive but the gears where clunky but careful slow changes seemed to help so I bought it....

Since then this is what has happened... :(

Head Gasket failed forcing compression in to coolant. Overheating and then coolant streaming out of cap

Battery dead

Aircon compressor bearing REALLY loud!

Lights intermittent brakes sides etc.

Oil leak at the gearbox side off transfer case

Power steering sqeaks slightly

Gears really gudder and clunk if I'm not careful with the clutch and the peddle seems to judder when depressed.

.............Ok so theses are the problems and this is what I've done.

Lights fix

Battery replaced

Rinsed and shook radiator, flushed and back flushed all pipes, block and matrix until clear (cooling system was filthy with brown shiz!)

In process of ordering and replacing bearing in compressor wheel

Head Gasket replaced with a friend. Skimmed, pressure test, reseat, cleaned block and follow torques and rave manual to the letter.

Oil, Oil filter, thermostat and airfilter replaced

Temp sits below half up hills and under load so all good there

So heres the main problem that I can't seem to google an answer for.

When I start the engine from cold theres large amounts of black and then white/blue smoke and it STINKS of diesel or at least I think it's diesel. The white smoke settles after a minute or so but the smell is still very strong. It will blow smoke when I press accelerator and there is also black smoke randomly coming out when driving. I've done 200km since head was replaced. I'm not convinced that the valve clearance have been done properly as my mate seemed to think they where fine :-/ I wasn't around when this happened so just thought I'd mention it. No water in oil sump, or filler cap and no dripping of water from exhaust which is a relief. Ticks over nicely, doesn't seem to run rough thro the revs. Oil filler cap has the moves like jagger but doesn't get blown off but you can feel a very slight chuffing but no visible smoke.

It seems to pull away very slow at low revs then the turbo kicks in and it seems to accelrate well, then when the revs get to between 4200-5000 it seems to not want to pull hard. Not sure if this is normal as this is the first Disco I've drove.

So many problems, so little cash to fix them with.

Any ideas to the smoking. I'm Spending every spare second trying to get this beast back in good form

If I do get to the bottom of all this I do intend on updating this thread so that hopefully someone else can benefit.

Thank

[isuzurover]

Sounds like your timing may be retarded. Did you touch the timing belt?

(but make sure you check the valve clearances).

MR automotive should be able to sort it for you if you have the $$$.

[VonSwirl]

Getting the timing belt done is high on my priority list but wasn't even checed when we done the head replacement.

The smoke was non existent before the head was replace :( just overheating issue. No exhaust symptoms.

I very much a beginner when it come to mechanics but I was under the impression that when a timing belt fails it FAILS and roots your engine completely?

[VonSwirl]

Im hoping to do the clearance in the next day or so but need to make sure I'm 100% sure on how to do it before I commit. Got a few threads bookmarked and gonna read through RAVE a few times

[vnx205]

Are you sure there was no black smoke on startup before?

300tdi engines all blow a puff of black smoke as they are started.

[Pedro_The_Swift]

If the poor thing hasnt done it by 4K, pushing it to 5 wont help any,,,
especially if the timing is suspect:o

[VonSwirl]

When i first went to look at it the engine was cold and i checked the exhaust for smoke and smell but it didn't have any from what I could see. I've had a few diesel before that always blew a bit of black when first starting but this seems to be quite a lot.

So it's normal for the pulling power to drop at higher revs. I'm just going off a Punto turbo diesel that had pull all the way through the rpm range.

[101RRS]

A lemon at 17 years old and 290,000km - I don't think so - you have just purchased an old worn out vehicle. There will always be an expectation to have to spend some big dollars sooner or later on a vehicle of this age.

Good luck though - you nee to fix what needs doing now and leave those things that can reasonably be left to be a work in progress.

Garry

[VonSwirl]

Hey Garry,

I do hope your right. Such a shame the previous owner neglected her so bad. Shes had a new paint job and interior clean before I got my hands on her just a shame the cash wasn't spent on the important stuff.

She'll come good I'm sure

[superquag]

"...Head Gasket replaced with a friend. Skimmed, pressure test, reseat, cleaned block and follow torques and rave manual to the letter...."


- There's your problem, using a friend instead of a new gasket... :eek::eek:
-- After being skimmed, pressurised cleaned out and talked into submission.... no wonder you've got problems !

Wot Isuzu sed... sure you have'nt moved your timing (belt) by even one notch ?


You have'nt bought a lemon, merely paid too much for what you've got. - I know the feeling , so not in a position to take the shot.:angel:

[Scouse]

Shes had a new paint job and interior clean before I got my hands on her just a shame the cash wasn't spent on the important stuff.

That is the important stuff.




Important for a quick sale.
:(

[bigcarle]

GET.....AN.....ENGINE........MONITOR!!!!!!!!!!!!!! !!!!!!!!!!!:twisted::censored:
factory temp gauge is useless and tells lies
it is recommended to not rev the 300TDi over 3250rpm!! excessive wear occurs on the timing belt?
turbo comes in at around 1800-2000rpm

[spudboy]

....
It seems to pull away very slow at low revs then the turbo kicks in and it seems to accelrate well, then when the revs get to between 4200-5000 it seems to not want to pull hard. Not sure if this is normal as this is the first Disco I've driven.
...


A TDi 300 should be driven in the 2000-3000 RPM band. Maybe 3500 if you are overtaking. Below 2000 RPM there is NO power and when cold it is even worse.

Checking the valve clearances is not that complicated - there are a number of good tutorials on the web (maybe even something on YouTube from memory). Set Cold.

Good luck getting it sorted - sounds like you are pretty close to getting it back to 100% again.

Cheers
David

[DeanoH]

Hey All,

......................... then when the revs get to between 4200-5000 it seems to not want to pull hard. Not sure if this is normal as this is the first Disco I've drove...........................

Thank


:eek::eek::eek::eek: :wasntme:

This is an old style deisel, not a 2 stroke motor bike !!!

Be nice to it and don't rev it this hard, can you get 'valve bounce' in a diesel ?? :eek:

If you reckon the tappets may be out it would be a good idea to check, 0.2mm or 8 thou in the old language.

This is the sequence

No 1 valve with No 8 fully open
No 3 No 6
No 5 No 4
No 2 No 7
No 8 No 1
No 6 No 3
No 4 No 5
No 7 No 2

It's worth checking the the prime of the fuel system, air in the injector pump can give some very strange symptoms.

I do mine in stages, first at the fuel filter, then at the injector pump banjo then finally when running I 'crack' each injector connection. Works for me :) .


Deano :)

[Carnut1100]

Those revs sound more like when I'm thrashing my petrol weekend fun car....not a diesel!!!
When I test drive a Disco I was uncomfortable going above 3500, felt like I was punishing the poor thing!

[Landy Smurf]

I dont think I ever got above 3400rpm in the 300tdi. Maybe post a video of the smoke to see if others think it is a concern

[isuzurover]

I just checked. My 300tdi disco only revs to 4500. I had never taken it above 4000 before.

[VonSwirl]

Thanks for advise

I made a mistake with the revs it's seems to pull great between 2000-3000 rpm but fades after that. I haven't read all te replys yet but have will do when I've finished work.

Took it to M.R automotives at redcliffe yesterday they fitted 2 new pulleys on the belt drive so that irritating whine has stop yay! Priced me up to new cambelt cogs tensioners for $850 plus a tune. Still haven't had time to do the Clarence but will do soon!

Will read through and update soon.

Maybe A frame ball joint or transfer case root :-/

[loanrangie]

Most rpm i've seen on mine is 4200 when overtaking and usually 2800- 3200 driving in daily traffic.

[VonSwirl]

UPDATE:

Thanks for all the advise on the clearance procedure and also on how to bleed the fuel system

So finally done the valve clearance this morning and it's all but cured the smoke problem! Relief!!!

The clearance was way off!! My friend who I used as a head gasket ;) seemed to think they didn't need to be done... Well he was wrong and it did.
All of them where tight with zero clearance at all. Lucky that the piston heads didn't smash the stems to pieces!

I'm guessing that this caused compression issues which in turn didn't allow proper combustion resulting in poor fuel economy and loads of unburnt diesel being thrown out the exhaust. So next just waiting for the timing belt and tune up which is booked in in late feb.

Added a litre of oil to the transfer case and the gear changes are much smoother. It took the whole bottle so I'm gonna get some more and fill her right up. Poor thing was well thirsty!

Gearbox oil was full. Actually when I took off the filler torx plug a lot of oil came out?! About half a cup or so. I was a bit confused as to how the level got so high! The car was parked on a slight camber to the passager side so the plug was at the highest point.. :-/ ... Is there another way of filling the gear box?

I've notice my comment about the revs caused a few eyebrows to twitch lol. Ive not even revved it up to 4000 :), just got my numbers mixed up.

Still got a fuel filter to replace and sediment to clean and I'm hoping that should be it for the fuel system.. Am I missing anything?

I had a play around with the front prop while I was under and could hear a clunk in the transfer case, one in the diff... But there was also one on the passenger wheel hub is this a normal thing?

My wheels also rub on my chassis when on full lock not sure if its both sides or just one. Is there a way to prevent this.

I realise I'm asking a whole lot of questions here I'm just really keen to get her back to her full glory

Any advice is greatly appreciated.

Thanks a bunch peeps :)

[VonSwirl]

Oh and the timing Case wasn't touch and will be buying a monitor when my budget can afford one for sure!!

[spudboy]

Glad it is progressing in the right direction!

The wheels have stops to control how far they turn left and right. They are just like a bolt. If you extend the stops a bit this will probably stop the rubbing. What size tyres have you got fitted?


Oil can transfer between gearbox and transfer case if some seal or other is gone. Do a search here. I've not had it but the oil "migration" issue is not uncommon from what I've read....

Cheers
David

[VonSwirl]

Oil migration ay! That sounds like an expensive fix. I'll do some googling and check that out I reckon.

I'll get back to you on the tyre size not to sure off the top of my head.

Cheers mate

[VonSwirl]

Tyre are 245/70 R16 107 m+s

[rick130]

Glad it is progressing in the right direction!

The wheels have stops to control how far they turn left and right. They are just like a bolt. If you extend the stops a bit this will probably stop the rubbing. What size tyres have you got fitted?


Oil can transfer between gearbox and transfer case if some seal or other is gone. Do a search here. I've not had it but the oil "migration" issue is not uncommon from what I've read....

Cheers
David

You cant get oil migration between an LT77 or R380 and the t/case, there are two seals between each assembly plus a drain.

The old LT95 used in 110's and RRC's could though.

[slug_burner]

UPDATE:

...........................

Added a litre of oil to the transfer case and the gear changes are much smoother. It took the whole bottle so I'm gonna get some more and fill her right up. Poor thing was well thirsty!

...............................
Any advice is greatly appreciated.

Thanks a bunch peeps :)

The whole TC is only about 2.5 L capacity, if you had to put a litre in someone was stingy when they filled it or you have a leak.

[VonSwirl]

There is a small leak on the gearbox side of the transfer case. One of the mechanics that had a look at it said it was a common problem. I'm guessing that it has been left to drip for a long long time without being topped up. Can't think of any other reason. Im gonna fill her up and then check it again in about a month and see how much more she needs