What happened to your Discovery 2 today?

The turbo let go on the way to Pirie last month, about 2-5k out, so nearly got there. RAA brought car and myself back to Elizabeth same arvo so not much stress other than wondering how much this fix was going to set me back.

Attachment 188810 Attachment 188811 So out it came and the rattling culprit was found upon disassembly, I had noticed a bit of play in the shaft whenever the intake was off but hadn't seemed to get any worse than when I bought it. The impellor initially seemed solidly siezed but I was able to turn it with some force. The arrow is the oil feed to the centrifuge assembly which has been tapped and plugged. Much easier access to things.

Attachment 188812 I put a bag around the oil feed, unplugged the injector plug and a few turns proved oil was flowing ok. Turbo core arrived and got fitted to housings which were unscathed as far as I could tell and turbo refitted with new gaskets.

Then since I was off the road I thought might as well unravel the looms and check some of the under bonnet wiring sooner rather than having it catch me out rubbing through and shorting down the track later. So that became a work in progress for the last 3 weeks roughly.

Attachment 188813 Attachment 188814 Attachment 188815 Attachment 188816 While I was at it I chopped up the battery box to give me better clearance to the intercooler and radiator hoses and removed the jack pocket to better access the wiring loom.

Attachment 188817 Attachment 188819Attachment 188818 Attachment 188820 Made up a longer crank sensor cable with new fittings and pins to re route along the firewall along with the fuel temp and oil pressure wiring.

Attachment 188821 While I was at it I modded the wiring to include both 3 pin and 4 pin plugs for the airbox lid as I have both sensors/lids so makes it easier to play around with msb and nnn tunes.

Attachment 188822 Attachment 188823 Attachment 188824 Attachment 188826 Attachment 188827 Attachment 188828 Attachment 188829 Roughing in the wiring to get the position and lengths sorted takes a while.

Attachment 188830 Attachment 188831 Attachment 188832 Attachment 188833 Attachment 188834 Attachment 188835 Attachment 188836 Attachment 188837 Attachment 188838 Attachment 188839 Covering up with new convoluted split tubing and fixing in place.

Attachment 188840 I use deutsch connectors but order the solid contacts separately as I prefer them to the fold over crimp types and use a good compression tool for a lot easier to make connection.

Attachment 188841 Yesterday when I finished the wiring (more to be done around the ecu area to clean it up later in the year) I also took out the low compression V8 trans ecu I have been running since I fitted the V8 stall converter and swapped it out for a high comp one and see how that performs. Went grocery shopping last night and seemed much smoother on the upshifts but lots more around town driving will give me a better idea.

I wanted to initially just check the loom for serviceability and re tape and replace old split tubing but decided to re route to suit my repairs/tinkering with the engine.

At this point the oil pressure, fuel temp and crank sensor route along the firewall then turn and tuck between the guard and fuse box, through an existing aperture to the red ecu connector.

The water temp, air con, wastegate module, maf, airbox cabling now routes along the top of the intercooler and leaves the front of the head more accessable when adjusting the cam sprocket .

The MAP and Injector cabling go straight under the start of the intake manifold rather than the way they were bundled with the battery cables down low and coming up originally between the first 2 intake runners.

Starter solenoid cable runs alongside the main battery feed to the starter. The alternator plug wiring runs alongside the alternator output cable.

The pics down the side of the inlet manifold and front top view shows how I have separated it. No fuel cooler allows for much easier access and troubleshooting.

Eventually the mess of deutsch connectors will be replaced with a cleaner arrangement with no visible connectors other than the red and black ecu ones.

Now it's parked up on the front lawn ready for the next breakdown. And I still have to go back to Pirie to complete the job so it will get a little bit of a shakedown to test the turbo core. A real bargain at 115 to the door. Jumped to 195 day after I bought it so got lucky, or not, depending on how much of a run I get out of it.

The circuit breakers are 50 ampers, one for the anderson plug and one for the electric brakes, I run full cabling, ie earths come all the way back to under the bonnet rather than using chassis, just the way I do it, but it works just as good if you use a chassis return (and saves on cable) as long as you maintain the electrical connections.

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Originally Posted by johnp38

The turbo let go on the way to Pirie last month, about 2-5k out, so nearly got there. RAA brought car and myself back to Elizabeth same arvo so not much stress other than wondering how much this fix was going to set me back.

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Hey John, how many km's on it, and do you run standard boost or have you upped it? Just any thoughts on why/when they let go.

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Originally Posted by Slunnie

Hey John, how many km's on it, and do you run standard boost or have you upped it? Just any thoughts on why/when they let go.

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It's done 463000 and the shaft was wobbly from the day I got it, from all the rest of the things needing repair I would say it has not had a good service life for quite a while before it came into my possession.

I run standard fueling but modded the tune to allow boost up to 21psi when there's enough exhaust movement to push it that high.

Had been looking at changing turbo core or for used vnt units last 12 months so it forced my hand.

Quote:

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Originally Posted by johnp38

It's done 463000 and the shaft was wobbly from the day I got it, from all the rest of the things needing repair I would say it has not had a good service life for quite a while before it came into my possession.

I run standard fueling but modded the tune to allow boost up to 21psi when there's enough exhaust movement to push it that high.

Had been looking at changing turbo core or for used vnt units last 12 months so it forced my hand.

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Cool, thanks for this! I'm at 300k and have upped the boost, but the servicing is spot on. Just trying to gauge where I'm up to and what to expect. Thanks again.

Now I know what this switch is for..
Attachment 188881

Never had these in the 14 years I've owned it. And I probably will never use them...

Attachment 188882

And the number plate light doesn't work, I notice.....

Still, one step closer to a RWC and rego. Been a while. Thing is, when it was out of my life for so long I forgot how good it is to drive. It's almost alive, and it makes my BA Fairmont seem like what it is, an appliance.

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Originally Posted by Tins

Now I know what this switch is for..
Attachment 188881

Never had these in the 14 years I've owned it. And I probably will never use them...

Attachment 188882

And the number plate light doesn't work, I notice.....

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Very useful on dusty roads...

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Originally Posted by RRT

Very useful on dusty roads...

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Yes. And up here where I am in winter. They just **** me off when used when the conditions don't suit. At least the Disco turns them off after each journey so you must switch them back on next time.

My console is broken around the window switch area. The actual switch panel has nothing to secure to, and the cosmetic cover, with its idiotic pins, well.... So I thought I'd try something. Not stumping up for a new console, and all the S/H ones I see are as bad as mine. Before you say anything rude, "Design" is NOT my middle name.....
Attachment 189050


I took someone else's design for the cover, and added the buttress type things to act as locating things.. and printed it in ABS.
Attachment 189054

The idea is to make the two panels into one, and have them removable by simply a little gentle prying.
Attachment 189051


I already see a number of areas where there is considerable room for improvement, and I reckon the console will need some reinforcement, but it stays put for now, and is therefore better than having it flopping on the wires.
Attachment 189052
Lick o' paint..

Also made this, to replace the rear ashtray. I hav a USB power socket for the other hole.
Attachment 189053
I didn't design this. Spotted it on Thingiverse. But it has given me ideas😱