D3 Breakdown

[Tinman]

Hi All, While Travelling home this long weekend from a great weekend I looked in my drivers side mirror as I was towing my van and to my surprise saw great clouds of look like smoke coming from the back of my D3. Pulled over straight away, thought it was a blown tyre on the van making all the smoke. It turned out to be the D3. Great clouds of smoke coming out from under the bonnet. On lifting the bonnet turned out to be radiator fluid evaporating from contacting the hot motor. Couldn't find any hoses that had burst added water but kept running out of the motor. Had it towed home with the van. I filled the radiator to see if I could find out where it was coming from. Turned out to be the water outlet assembly. This assembly is located directly under the air intake manifold at the top of the motor. Seems that this assembly has a front cover that has the fittings to connect to the radiator hose. This cover is glued on. The glue has let go and the radiator water has spray out. Tried to take the back section out, it has four 8mm head bolts holding it in have removed these. But due to the air intake above having troubles getting it out. Has anyone replaced this assembly and do you need too remove the air intake manifold completely to replace the assembly. Had a look at the LR manual but nothing there. Cant understand how land rover could put such a crappy part in its motors.
Cheers

[Ean Austral]

Hi All, While Travelling home this long weekend from a great weekend I looked in my drivers side mirror as I was towing my van and to my surprise saw great clouds of look like smoke coming from the back of my D3. Pulled over straight away, thought it was a blown tyre on the van making all the smoke. It turned out to be the D3. Great clouds of smoke coming out from under the bonnet. On lifting the bonnet turned out to be radiator fluid evaporating from contacting the hot motor. Couldn't find any hoses that had burst added water but kept running out of the motor. Had it towed home with the van. I filled the radiator to see if I could find out where it was coming from. Turned out to be the water outlet assembly. This assembly is located directly under the air intake manifold at the top of the motor. Seems that this assembly has a front cover that has the fittings to connect to the radiator hose. This cover is glued on. The glue has let go and the radiator water has spray out. Tried to take the back section out, it has four 8mm head bolts holding it in have removed these. But due to the air intake above having troubles getting it out. Has anyone replaced this assembly and do you need too remove the air intake manifold completely to replace the assembly. Had a look at the LR manual but nothing there. Cant understand how land rover could put such a crappy part in its motors.
Cheers


There has been several posts about this part cracking and causing problems. I haven't replaced mine yet but did buy one because of the previous posts about it failing.


I have not done it but looked at it and wouls assume you need to remove the intake pipe, which is not hard, give it and the MAF a good clean whilst its off.


As a matter of interest how many kms on your car.


Cheers Ean

[Tinman]

192000klms Thought I would have to take it off. Very poor design I think. Was the assembly easy to get hold of.
Cheers

[Ean Austral]

192000klms Thought I would have to take it off. Very poor design I think. Was the assembly easy to get hold of.
Cheers


Yep I get all my stuff from TRS in Lonsdale SA, cheap from memory, but only problem with that is its likely the reason they don't last.


One member was looking at getting a metal one made but think it just got to difficult.


Cheers Ean

[Tinman]

Yeah I am not that excited about putting the same design one back on. Are there seals that need to be replaced when removing the air intake manifold. It looks pretty straight forward. Ran out of light this afternoon so will continue when I get home from work tomorrow

[Glynhouse]

Bought my D3 with 88K on it, service is being done by Hypertune in Cairns, when I had a big service all fluids +, can't remember just when but they strongly recommended that while at it they change this fitting. In the overhaul cost it did not add much so changed it.
MY07 now done 140K they are suggesting that I should consider changing the turbo hoses, I do a fair bit of remote travel.

Dd

[Ean Austral]

Yeah I am not that excited about putting the same design one back on. Are there seals that need to be replaced when removing the air intake manifold. It looks pretty straight forward. Ran out of light this afternoon so will continue when I get home from work tomorrow


There are 2 O-rings where the manifold splits and goes into either inlet manifold, the manual says to renew them, but I have had mine off several times and haven't replaced them, just put some vasilene or similar on them and all good.


Just watch the fuel pipe that sits on a slot on the pipe near where the oil filter housing is. you will see it if you have a look.


Don't be surprised by how dirty the plastic pipe is from the EGR entering it.


Have plenty of rags handy.


Cheers Ean

[Tinman]

Thanks for that, those o rings have a pretty good life, have changed the fuel line you have spoke about. Havnt changed the hard to get turbo hose yet but reading the forum I think I better
Cheers 🍻

[Ean Austral]

Thanks for that, those o rings have a pretty good life, have changed the fuel line you have spoke about. Havnt changed the hard to get turbo hose yet but reading the forum I think I better
Cheers 🍻


Good luck with it.


Cheers Ean

[KOOS BEST]

a Common problem here in Africa, this part needs to be replaced every 100 - 120 000 km.
This is how to replace
Beware:d3 tdv6 water outlet assembly - 4x4 Community Forum (http://www.4x4community.co.za/forum/showthread.php't=156975)

[Tinman]

Replaced the water outlet assembly, quite an easy job,the hardest part was reinstalling the clips on the EGR tubes. Was a bit nervous how the motor would run, it fired up as normal and runs a gem. I reckon another minute of driving with that failed water outlet assembly I probably would have seized the motor. Got the parts from TR spares Padstow, Scott told me he had sold quite a few of these units lately. I also wanted the right angle pipe that plugs onto the water outlet assembly, l virtually had to buy every hose associated with the cooling system as they were all linked together, anyway it came with a new thermostat as well so have replaced all hoses for good measure. The EGR was pretty clean too what I have heard others have experienced. Well back on the road and feeling pretty good with myself.
Cheers

[winaje]

Well done Tinman. This thread alerted me to an issue I was unaware of, and that housing will be one of the first things I change on my new to me D3.

[Tinman]

Yeah prior to it failing I was in the same boat. Must have missed the threads on it.
Cheers

[Rich84]

Did you get any warning from the dashboard about LOW COOLANT LEVEL??


Theoretically it should come on when the level of coolant in the expansion tank drops below a certain level.


This warning has saved my missus' Audi A4 (which she takes barely any care of) and my two other Audis so many times I couldn't count. The thing is all cars have weak points in the cooling system that show themselves when the cars start to age. ABS plastic seems to suffer the most from the age/coolant/cold-hot cycles.


I have heard that on some LR expansion tanks the level float swells and jams in one spot, making it ineffective. It'd be wise to test/replace the tank if this happens, good preventative measure.

[Tinman]

Yeah I have had that annoying low coolant indicator has been coming on since I had my arb bar fitted. Just one of those things I should fix. The rate the coolant was pouring out of the failed water outlet assembly I think you probably wouldn't really be looking at the dash in time to realise you had a problem. It was only when I looked in my drivers side mirror that I saw all the steam behind me, nothing in front view too suggest anything happening.