Thread: 300Tdi engine knock

A bit of an update.

Had a chat to my local friendly engine builder/mechanist.

He thinks the valves have been hitting the pistons for some time like 100s to 1,000s of Kms.

He thinks it has been detonating for some time, broken rings and worn ring groves.

Probably cam belt timimg out in both cam and pump.

The cylinder head is quite new. (The only piece of good news in this motor yet)

The valves that have been hitting the pistons, are not the valves that are currently in the motor.

The crank is quite likely not recoverable.

I have been offered a bare short motor with 2 melted pistons, but the young fella has decided to pull the motor from his other ratty Disco and fit that.

Tony

Just to close this out.

We had a big weekend of Disco.

The young fella came up Thursday night, Friday morning we started disassembling the the green Disco.

(300Tdi manual 500k km on the speedo, unknown mileage on the motor and box, generally ratty)

Radiator, plumbing, wiring and other under bonnet stuff, console and interior stuff removed, up on the host, transfer, tail shafts, exhaust and any under car stuff.

Friday night one of his mates drove over from Bendigo to help.

Sat.
My other boy came and joined in.
Engine and box came out as one. Don't do this, it's much easier to remove the engine and box separately.
Removed the pedal box.

Rolled the now brakeless green one out of the shed.

Rolled the white one in
(300Tdi auto 300k km, front bar, winch, side rails, side steps, long range tank, twin lockers)

The motor was already out, removed console, shifter, disconnected tail shafts, remove auto and transfer as one, auto cooler and lines.
Removed pedal box

Did a degrease and wash of the motor. As we had decided to refit the motor and box separately, we split them, to find the the rear main leaking, removed clutch and flywheel and replaced rear main, replaced vac pump and various gaskets and hoses.

Found lots of play in the turbo, swapped the one off the dead motor, and found a stripped exhaust manifold stud.

Sunday.
Sourced a M8 helicoil, fixed the manifold stud
Fitted the manual pedal box, motor, gearbox, original transfer, tail shafts and exhaust.
Cleaned up, repaired and refitted console and gear sticks.
Reconnected brakes, clutch, wiring, hoses, refitted radiator, new radiator hoses.
Lost one helper back to Bendigo and one home to Wodonga, the young fella and I pushed on and got the clutc, brakes and fuel bled, oil and coolant refilled, put the battery on charge.

Monday.
A bit of a check over, put the key in and it fired straight up, no leaks, no horrible noises, no smoke.
Checked fluids again, took it for a run to get it up to temp. Gee for a 27 year old car, it's quiet, comfortable, it got a nice interior that still looks up to date.
Found a couple of hoses weeping coolant, tightened them.
Did a few other things that needed doing.

They got in and drove it from NE Vic back to Geelong.
It's still loosing a bit of coolant, leaking a bit of oil from the transfer rear output and the diff lock lights not working.

It's a better car with the manual box.

All in all happy with our weekend effort.

Thanks for everyone's input to this thread.

A host, transmission jack and engine crane are a great thing

Tony