D2 bloody nightmare!!

**WildOne** · 14th August 2008, 10:08 PM

Just got home from a very enjoyable dinner in melb. had Lamb Shank with a very nice Cab Sav or three..........
Just wanted to mention that i spent the best part of today removing my inlet manifold, changing my fuel block regulator and reinstaling the afore mentioned manifold

Now i realised when i started disassembling everything that the manifold was going to be difficult to re-install but i have to say, if i could get my hands on the bloke that designed it......

Anyone that does any sort of maintenance for a living would know that designers give no thought to the poor suckers that have to do maintenance on their "vision" of excellence. Now dont get me wrong, i love my TD5 but i have to admit to cursing it more than once today as i removed more bark from my hands while dropping one of the 8 manifold bolts or one of the two manifold nuts for the 100th time today, you need the hands of a 12 year old to get a socket into the space available to tighten bolts up

The landrover gods were obviously not pleased with me either because when i started the job today i noticed a small coolant stain on the fuel cooler and by the time i had finished an alarming leak had developed

So another job gets bumped to the front of the queue!!

On the positive side, a big thankyou to Stuart (on Aulro) from Rovacraft for excellent service and parts, i would'nt hesitate to recommend giving him a call if you're looking for parts for your Rover.

Cheers all, Phill

Rangier Rover · 14th August 2008, 10:29 PM

This is why I don't have and won't have a TD5

They go well but can be annoying at times. You will get used to it. Hope its sorted

Tony

**WildOne** · 14th August 2008, 10:36 PM

Originally Posted by Rangier Rover

This is why I don't have and won't have a TD5

They go well but can be annoying at times. You will get used to it. Hope its sorted

Tony

A bit more to do yet, but in the next couple of days i hope to have all the small problems that have been bugging me for awhile sorted out, thats the secret i think to a happy TD5 relationship, when a small problem presents itself, fix it before it bites you in the wallet, or before you have heaps of small problems that bite you in the wallet

**Redback** · 15th August 2008, 06:24 AM

The secret is too move the aircon pump

for that hard to get at bolt

I feel your pain

Baz.

**WildOne** · 15th August 2008, 07:38 PM

After yesterdays painfull saga working on the inlet manifold and replacing the fuel pressure regulator i did'nt hold much hope of todays work going smoothly

Today i removed the serp belt, moved the aircon pump, removed the turbo and finally the exhaust manifold, awkward but no real problems, took me about an hour to drill and tap the broken stud on no.5 port. Also ground out the webbing from the manifold to "de-stress" it. I found the warp in the manifold reduced from around 2mm to 1mm over the full length so not too bad.

Then started removing the other 9 studs, all went well until i started removing the last one.......the most difficult one to get at, snapped

. I called it quits at this stage as it was getting too dark and i was not in the best frame of mind.

So, have dropped the coolant and will remove the top hose tomorrow to allow me a bit of space to get at the last bloody stud, or whats left of it. Then have to change the water pump and reassemble everything, will also change most of the coolant hoses, thermostat and serp belt. Not pleasant work as its all fiddly, with lots of dropped bolts, bark off knuckles and copious amounts of swearing

**DeeJay** · 15th August 2008, 11:10 PM

Another case of Landrovus Handritus

**BradM** · 16th August 2008, 08:48 AM

All us D2 TD5 home mechanics all feel for you. At least it will be a lot happier when it's back together.

Landrover = "Love/Hate"

BradM

**LandyAndy** · 16th August 2008, 06:45 PM

Did same to mine a few weeks back,wait till you finish dealing with the hose clamps!!!! Replace them with worm drive clamps.
You should have been able to do the fuel pressure reg without removing the inlet manifold,I did.
Goodluck
Andrew

**WildOne** · 16th August 2008, 06:58 PM

Originally Posted by LandyAndy

Did same to mine a few weeks back,wait till you finish dealing with the hose clamps!!!! Replace them with worm drive clamps.
You should have been able to do the fuel pressure reg without removing the inlet manifold,I did.Goodluck
Andrew

Yeah, i wanted to clean the inlet manifold out as when i removed my EGR a few months back i found the manifold coated in heaps of sludge, EGR must have been stuck open for a long time

Unable to work on the Disco today as we went to visit a mate in hospital. Probably good to take a break. Back at it in the morning if anyone wants to have a look at the darker side of home mechanicing

**WildOne** · 17th August 2008, 06:03 PM

Success today!!!! Got everything back together with no real dramas

Changed the serp belt without removing the fan, only managed to change 2 coolant hoses though as i ran out of time, one of those changed was the little one behind the turbo going to the oil cooler, i was a bit worried about this one as i'm sure it has'nt been looked at before.
Refilled the coolant, bled the system, and took it for a test drive. Motor is running noticeably smoother and no leaks yet

Next big planned maint will see the rest of the coolant pipes changed, full service, including the auto and perhaps a new MAF sensor.

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