With the exception of the change from plastic to steel head dowels there should be little difference in reliability of the Td5 engine between pre and post-facelift d2s. Fuel coolers, fuel pumps, fpr are the same design and suffer from the same issues. The primary advantage of the 03/04 vehicles in this regard is that they are younger. Once they hit the same age/mileage as the 2000's you'd expect them to experience the same kind of issues, and that is borne out by forum posts.
The majority of the "fixes" for the 03/04 are relatively small but worthwhile improvements. Off the top of my head these include:
- Revised rear diff breather (in the 02 as well)
- Revised SLABS ECU with improved TC/ABS programs and improved tolerance of low sensor output
- Revised brake master cylinder and callipers for better brake feel
- Revised front hub carrier (altered camber)
- Revised ACE ECU
- Revised spring/shock rates
- Revised suspension geometry
- Revised transfer case design to reduce operating noise
- User operated diff lock
- New front propshaft design on Td5 Auto models to reduce noise/vibration transmission
Ultimately the 2004 D2a is the most refined of the D2 series because of these kinds of changes and incremental improvements, but they don't make it immune from the problems that afflict the earlier D2's.
cheers
Paul
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