Thread: Trip preparation 2004 D2a td5.

Filters, fluids, hoses, brakes, globes, tyres, suspension, bearings, electrics, cooling system.

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starting from the front...
Clean the internal and external of:
- air con (external only)
- intercooler
- radiator

Replace the hoses and thermostat, if not at least carry the thermostat and fancy hose as spares.
Check the fuel cooler for leaks, it may be worth ordering in the o rings for it anyway, they are a cheap spare.
Check the fuel pressure regulator, replace if leaking.
Replace the crank position sensor and keep the existing one as a spare.
Clean the MAP, IAT and MAF.

check for bearing play - replace if needed, a bit of a job on the D2 and not something you can really carry as a spare.

Check the propshaft UJ and donut. Pay particular attention to the double cardan, and consider putting some tube into the air con outlets to direct the condensed water away from the double cardan. It's give or take the same size as garden hose.

Replace the fuel filter, keep the non-water sense plug from the new filter to use in case the water sensor gets smashed and maybe put that in before any off road work to avoid getting broken.

Check the rotors and pads - replace as needed. Consider that if you need to do the rotors soon, you might want to do it now, they are an easy replace while you have a spare.

As said, engine oil, both filters, rad fluid (as you do the flush), may as well empty the power steering and ACE, it's not a flush, but it's a 80% change probably.

Brake fluid is supposed to be changed from time to time.... you can short the abs pump and empty everything out of the one bleed valve for a major change and then do a minor flush out of the others.

check the steering balljoints and the ujs on the steering column, steerings ones are straight forward, never done a D2 steering one.

Inside, check around the control pedals for any carpet wetness, if you find some then you need to wonder if the heater matrix o rings or matrix is leaking. Even if it isn't consider carrying an elbow or short u pipe to bypass the matrix should it go.

Inside
Consider adding a switch to disable the rear passenger light, stops it being left on and for some reason it's the only one children are likely to touch and doesn't have a total off..
check for any step drops of the passenger and driver windows, it would indicate the nylon roller has broken up. It can keep working for ages and then just stop the window going back up.
Easy fix with a bit of nylon cutting board to create a slide.

Spares
Might be worth taking some super rover specific spares that you would find it hard to work around
- water pump
- fancy rad hose
- thermostat
- wheel nuts

- fencing wire
- amalgamating tape
- gaffer tape
- zip ties

I think with the manual you have a few less things that need checking over.

Check & Wrap the fuel hoses at the tank with some form of insulation. It is a common fault of the TD5 plastic fuel hoses to wear away from abrasion from the fuel tank edge. something you don't want to have happen kilometers from nowhere.
Re: the Dayco Tensioner, Dayco was the O.E/Genuine manufacturer for quite a few models
Cheers, Mario
PS.
As mentioned before : spare wheel nuts, if you still have those useless lock nuts, turf them and replace them with standard ones. When you have a puncture and those darn lock nut keys or the head strips, you'll wish you never had them.

Robbo was "stuck in the snowies" with a worn through fuel hose so he knows about that Mario!

I'd add:
Change your alternator brushes
Change your starter contacts.

What he said^^^^^^^^^
Get a torch and a mirror,have a good look at the fuel lines where they run above and then into the tank,just under the body.Also follow the lines under the vehicle ,they can chafe on brackets off the chassis.

Check ALL hoses and lines in the engine bay for chafing.The low pressure power steering line is often a issue.Wiring harness across rear of engine can rub through as well.Top rad hose on AC compresser pipes.

The D2a is a damm good touring vehicle.Mine was one of the best vehicles i ever owned.

Good luck,have a good trip.

Originally Posted by scarry

What he said^^^^^^^^^
.The low pressure power steering line is often a issue.Top rad hose on AC compresser pipes.

Yes , 2 of the most stupid locations allowing hoses to rub. What were they thinking.