Clunk.

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Originally Posted by Woolly

....I noticed a bit of paint rubbed off the firewall where the sound deadening cover on the top of the intake manifold was touching it. Removed the sound deadening to give a bit of clearance, took it for a short drive and no noise. As the noise was intermittent, I am not celebrating unreservedly, but my hopes are high.
Once again, thank you for the suggestions.
Cheers,
Woolly.

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I'd say there's your issue.
the noise cover shouldn't be rubbing on the firewall at all!

Mine doesn't, and there's at least a fingers width of clearance between both. Yeah, it's tight, but I it should be rubbing.

So like others have said, investigate the mounts more closely.

Logic would point more so to the T/C mounts more so as they will tilt the engine rear and downwards a bit and cause the rubbing.
But also a collapsed passengers side engine mount could do the same thing too.

Can you post a photo with the sound cover on and the clearance to the firewall?

FWIW too, I've added extra sound insulation to the firewall on my D1 to help with some deadening. This insulation is about 25mm thick, and still leaves this fingers width of clearance to the firewall(sound deadener).

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Originally Posted by Woolly

Great! Another excuse to spend time on my back on the garage floor!
Cheers,
Woolly.

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That is the purpose of D1 ownership. Didn't you know?

Not confident about attaching photos but will try.
Think it’s worked, one with the cover and one without.
Incidentally, Tins, I can think of many more purposes for a D1, including removing excess money from your wallet, transferring oil from a contained area to an unrestricted one, but the one that makes me stick with it is getting from one place to another without the help or hassle of computers.
Cheers,
Woolly.

Attachment 183510

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Originally Posted by Woolly

Incidentally, Tins, I can think of many more purposes for a D1, including removing excess money from your wallet,

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??? What's that?

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Originally Posted by Woolly

transferring oil from a contained area to an unrestricted one, but the one that makes me stick with it is getting from one place to another without the help or hassle of computers.
Cheers,
Woolly.

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Totally agree. It's why, when I get myself together, I'll be moving on the Ford and the D2. I like them both, but the simplicity of the 300 TDi, and the Perkins Phaser in the OKA, are why they are keepers. The 109 is a keeper as nobody wants to give me money for it.

Hi Tins, I will concede, yours is bigger than mine, gap, that is, but only by about 5 mm.
Just thought of another purpose of a D1.........ideal real estate for spiders, mine is the same!
Cheers,
Woolly.

It's kinda funny now, but wasn't at the time............

My POS had a rhythmic rattle from ihe front left when turning right................. classic CV failure.

Bought the last genuine old stock CV from P&S in Geelong at a huge discount and fitted it............

no change.

Fitted a complete front hub / swivel from a different vehicle................no change. Fair bit of work involved in all this.

Turned out to be an ageing engine mount letting the LH bank extractor collector to just touch the chassis rail, (tight fit both sides), when turning right.

Sorted at the time by just jacking up the mooring block and moving the mount in the slot.

David L