Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
gstuart wrote:
Hi
Am totally green with envy from u having the post lift
How come that garage looks like a tardis once ur disco is pushed inside
The air vent just pull off, mind the clips though as they have an amazing trick of flying past u , never to be seen again
Carefully pull the air vent cover from the bottom, u will see it slightly hooks in at the top
Ref that panel will double check to see if mine is also flush , never noticed it
I thought they just pulled off. Lol
It’s been a long time coming. The jobs I could have done so much easier with it !
It’s not the biggest garage but it is surprising actually.
Yeah I had that style panel and changed to the later “3 piece” one with the piano black inserts. It doesn’t seem to want to sit flush at the top. Perhaps something needs trimming...Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
10th Jul 2018 6:23 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 14136
Know it’s the wrong side , but just gives u an idea , of course u have the wire behind
10th Jul 2018 6:26 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
I need both sides off so that’s great. Thanks for the video mate that’s made it simple. Wish I was still in the garage tonight now but had to leave to sort some work crap out. Will start a photo heavy write up soon... Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
10th Jul 2018 6:29 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 14136
Glad it helped
Just noticed that comparing the centre panels being slightly different , wonder if the centre panel isn’t sitting right in the centre air vents or a wire being trapped as u push the centre panel back, loose clip ????
Awesome, look forward to the piccies please
Wonder if ur garage works like chitty chitty bang bang, drive it in , close the doors and wait , then wait some more
Then is all done on opening the doors again
10th Jul 2018 7:08 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
I don’t know why but I’m of the opinion something like the side lugs needs filing out. Almost sure I read something somewhere once....
It’s definately not ! If I don’t get in there and do it I could close the door and a year later it’s still not done. It’s taken us 2 months of work to empty all the crap out to be able to get the disco in there !
I can’t wait to get the body off now and get on with all the work. Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
10th Jul 2018 8:14 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 14136
10th Jul 2018 8:30 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Can anyone point me in the direction of guides and how to’s for any of the body off stuff. Eg the turbo actuator mod/fixings mod etc etc. I’m trying to compile all the info I need before hand so that when the body is off the chassis I can get on with all the bits. I can see the timing belt guide in the wiki but can’t find much info about the turbo. Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
10th Jul 2018 8:42 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 14136
Hi
Are these any use to u
Turbo mod ,
Remove the turbo, fit new modified actuator rod. Take out the studs and drill the threads out to 8mm. Use 2x M8 flange bolts to refit. This aids future turbo removal massively, and is also much quicker.
Brake pipes
Front + rear upper arms
Cambelts
Silicone hoses/big intercooler
Turbo actuator rod
Autobox filter
Clean in-tank pump gauze
Carefully inspect the wiring for damage, and repair if req
Check EGRs & turbo & turbo pipes
Check High Pressure Fuel Pump
Front & Rear Belts
Front & Rear Tensioners plus Bolts (In the Kit)
Two Idlers Pulleys Plus Bolts (In the Kit)
Oil Pump Casing
Oil Seal for Crankshaft
Crankshaft Bolt
New Auxiliary Belt
New Auxiliary Belt Tensioner
In addition to all belts (front & rear) replace both idler pulleys, bolts & tensioner & bolts.
Fit the latest design oil pump, front crankshaft oil seal, and crankshaft pulley bolt -
3 hours extra labour when doing all belts etc.
Consider replacing water pump - flush & replace coolant.
Consider changing intercooler hoses, particularly the 2 small ones for silicone.
Consider replacing and possibly upgrading intercooler. At very least clean intercooler & radiator.
If manual consider fitting new clutch (& flywheel) - 1 hours labour as opposed to 6 to 8 hours.
Replace rear brake lines
Check anti-roll bar bushes & shims - takes around 60 seconds with the body off.
Check cross-over pipe at rear of the engine
Wash chassis & underside of body, rub down and underseal any rust reapply Waxoil where necessary.
Remove the turbo, fit new modified actuator rod. Take out the studs and drill the threads out to 8mm. Use 2x M8 flange bolts to refit. This aids future turbo removal massively, and is also much quicker.
Check all suspension bushes & shims.
Ask for the old parts from the cam belt change, especially the rear tensioner pulley & check that they are using LR parts.
Engine injectors
Engine glow plugs
If a manual clean XY sensor
Suspension bushes, you can get carried away with. Most common are the rear uppers and front lowers. Body off makes no difference to front lowers, but the rear uppers are 5 mins a side, as opposed to 2 hours with the body in place. A A perfect excuse to upgrade to the RRS arms.
10th Jul 2018 9:56 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Thanks for all that mate really appreciated. I get the bolt mod. What’s everyone on about actuator arm mod then ?
Incidentally I’ve got the silicone hoses ready and the t bolt clamps from your guide a while back. Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
11th Jul 2018 10:57 am
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 14136
No worries , is amazing the amount of info everyone has shared along the way
Not 100% about the actuator arm mod, unless it’s about the bolt instead of the knuckle ball joint ???
Must admit found those T bolt clamps really good, was always worried of over tightening them and breaking something
Looking forward to the piccies
11th Jul 2018 4:12 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Well I’ve been a busy boy today... managed to finish work early so decided to have a few hours prepping the car for the body off. Most of the front end stuff was off from when I was looking into the crossover pipe/intercooler problem.
I used disco mikey’s Guide which is cracking to be fair and also the March ? Issue of LRO which also has a guide
As has been said it’s fairly straightforward. A couple of observations I’ve noticed.
Cheap eBay mudflaps... fixings last no time ! Had to drill a few off.
This pair of pliers is invaluable for getting the million or so trim clips off...
Looks like the handbrake cable is rubbing one of the airlines. Will address this when I have access
More to follow...Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
12th Jul 2018 4:03 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 14136
Can’t Unsee that excellent angled drill now
Also noticed that on mine where the handbrake cable is close to the air compressor airline, i used some plastic sleeving
12th Jul 2018 4:11 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
That drill is a godsend. I actually bought it to repair the thread on a 300tdi disco that had snapped its rocker shaft by stripping the thread on the windscreen end bolt. It’s a fantastic tool.
I’ll probably do that but I think it’s almost rubbed through so I may need to repair it first. Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
12th Jul 2018 4:24 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Couple more things I’ve noticed.
1, there seems to be a lot of play in the lower part of the steering column. If you grab the part shown in the picture you can move it around quite a bit. Is this normal ?
There seems to be quite a bit of “soot” engine block side of the turbo. Need to investigate this when the body is off. I suspect the small pipe is split.
Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
12th Jul 2018 4:29 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 14136
Not sure ref the steering , I did however find some info regarding the bottom uj joint and done a thread
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