Only had a quick look at the underside of the car last night. General impressions are the body is fairly well protected against rust. The chassis on the other hand, has a lot of flaking paint, and surface corrosion. Nothing structural though. A quick wire brush, and some stone chip to protect it again
Dropped the sump, to swap it, and the ladder frame over...
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After having rinsed the shrapnel, it was even more clear that the old engine was
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The sump and ladder frame got a bloody good clean, and fitted to the new engine
While the engine was out, the autobox was removed, and the sump/filter changed
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Nice to see there was no issues with this sump
Some rough cookie replaced 1 brake pipe, but they were both replaced completely anyway
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New front-rear pipes done. Just need a little tidying up
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Now, the car is an 05/05. Rust is not really an issue, it is all surface rust. Again, looks worse in the photos than it actually is, and not bad enough to worry about. While it is in bits though, it will be taken care of, and protected before the rebuild
This is just above the rear diff:
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In behind the heatshields above the rear silencer:
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Rear chassis crossmember:
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Cleaned and covered in stone chip:
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O/S chassis leg:
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O/S engine mount:
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And for good measure, the front brake pipes were also done
New engine was from a Jag, so sump and sensor was completely different
Rear wishbones were replaced, along with more new brake pipes:
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Difference between the D3 + RRS bushes:
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There was a little play in the rear ARB bushes, so some shims were fitted:
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Also needed a passenger side upper hub bush
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For any possible future turbo removal to be made as easy as possible, the turbo was removed, the studs were taken out, and the threads drilled out to 8mm. 2x M8 flange bolts were used to refit. This aids turbo removal massively, and is also much quicker. The small silicone hose was also fitted to the turbo at the same time. Big respect goes to robbo770 for fitting this hose with the turbo still fitted to the engine
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Same with this hose too. Easy in theory...
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EGR valves have been removed, and blanked at the exhaust manifold. Does away with the valves altogether. Once I have some spare time to compare the difference between EU3 + EU4 cooling systems, I will be doing away with the EGR coolers and associated pipework altogether too
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The big I/C hose was a doddle to fit
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The corroded parts of bodywork were wire-brushed down, and waxoyled. The whole car will be done fully, when the colder weather is here (but before the salt goes down )
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The 2 halves were then joined together, a few connectors rejoined, and it started almost furst turn of the key. The only issue is a faulty oil temp sensor, which is hopefully causing the following problem. This was with no throttle input at all...
SRS light is currently on, but there is a loose wire underneath the passenger seat. Will have that fixed this morning, and is booked in for an MOT at 4pm today
Jobs left to do are:
Refit front mudflaps
Clear sunroof drains, and dry out carpets
Bloody good wash and polish
Enjoy permagrin
The MOT was a success! Passed, with 2 advisories. One for having an engine cover fitted, and one for having an undertray fitted, despite them both being 10 mikes away from the car, next to my toolbox
It was a pretty uneventful drive back from the MOT, and equally so on the drive home (on trade plates)
A decat pipe has been ordered from the group buy, and fitted shortly. Needs the front PDC sorted still, and a bloody good clean
And, not forgetting the obligatory D3 forum sticker :thumbsup:
Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated My D3 Build Thread
Last edited by Disco_Mikey on 15th May 2013 5:00 pm. Edited 1 time in total
15th May 2013 4:59 pm
DiscoDunc
Member Since: 08 May 2006
Location: Bristol
Posts: 16390
looks good so far Duncan
-----------------------------------------------------
If I'd known I was going to be so thirsty this morning I'd have drunk more beer last night.
FFRR Autobiography 4.4 SDV8 MY17
D4 HSE MY13 SOLD
FFRR 3.6 Vogue TDV8 SOLD
D4 HSE MY10 SOLD
D4 SE TECH MY15 SOLD
D4 XS MY12 SOLD
D4 HSE MY10 SOLD
D3 HSE MY06 - Re-Cycled Worldwide
15th May 2013 5:09 pm
euangibson
Member Since: 24 Dec 2010
Location: Borders
Posts: 11027
That's going to be a very big "How To" guide Mike "Better to remain silent and be thought a fool,than to speak out and remove all doubt" ?.....what rubbish...
Locking rear E-diff
RLD spare wheel protector & sump guard
Extended roof rails
Series 111 mudflaps
Black side tubes,grill and vents
Timed climate remote
Hids4u interior lights
D4 Firenze my2012 HSE
D3 Java 2005 SE manual (sold,sadly,thanks for the memories)
1966 '88 Series 2a....still starts in the morning better than I do...
Last edited by euangibson on 16th May 2013 8:52 am. Edited 1 time in total
15th May 2013 5:18 pm
geoff.
Member Since: 24 Jan 2010
Location: West kent
Posts: 8531
15th May 2013 5:19 pm
Alan B
Member Since: 12 Feb 2013
Location: Fife
Posts: 6528
Bet your glad you hung on before breaking for parts
Glad things are going right again Mikey
D3 57 xs Stornaway grey
D2 02 commercial silver gone but a great servant and won't be forgotten
Iid Bluetooth
15th May 2013 5:45 pm
haroosh
Member Since: 16 Nov 2010
Location: Perth & Kinross
Posts: 624
I think the Haynes manual may need updating once Mikey gets stuck in here??
15th May 2013 6:01 pm
robbo770
Member Since: 29 Jan 2013
Location: Aberdeenshire
Posts: 2294
Member Since: 27 Aug 2012
Location: Orkney Islands
Posts: 597
Dave Neil
2018 Outlander PHEV
2005 Discovery 3 TDV6 S (went up in flames)
1972 Series 3 109 200tdi (@alfredthe109)
1972 MGB GT (in bits)
15th May 2013 7:16 pm
tomtom86
Member Since: 09 Mar 2013
Location: Here and there
Posts: 590
15th May 2013 8:16 pm
robo
Member Since: 30 Jul 2010
Location: solihull
Posts: 298
very best of luck watching this with interest gone not forgotten 2 classics
gone forgotten 2 p38s
current d3 se 2006 td standard for now
15th May 2013 8:42 pm
Discoed
Member Since: 16 Jun 2010
Location: Yorkshire
Posts: 1020
good news
15th May 2013 8:44 pm
mickyd4
Member Since: 26 Jun 2010
Location: North
Posts: 786
Good desicion not to sell or break ....
Would have been a huge mistake, you'll be enjoying the soon 2023 Ineos Grenadier 3.0 Diesel Commercial
2022 Mini John Cooper Works Hatch
2021 Golf MK8 GTD
1978 Land Rover SIII
1993 Range Rover Classic 3.9 V8
2007- Range Rover TDV8 - SOLD
2020 - Discovery 5 3.0 SD6 Landmark - SOLD
2020 - Defender 110 D240 First Edition - SOLD
2012- Discovery 4 3.0 SDV6 HSE - SOLD
2009- Discovery 4 3.0 TDV6 XS - SOLD
2007- Discovery 3 TDV6 GS- SOLD
2001- Defender 90 Td5 - SOLD
15th May 2013 8:52 pm
Russell
Member Since: 23 Aug 2007
Location: Kent
Posts: 10564
Said you should hang in there MY17 D5 1st Edition Namib Orange
MY15 D4 HSE Kaikoura Stone
MY12 D4 HSE Nara Bronze Sold and gone
MY11 D4 HSE Stornaway Grey Sold and gone
D3 S spec Silver Sold and gone
Tow bar, full length roof bars, side steps, tow bar storage unit, surround camers.
D4 camera club
15th May 2013 8:53 pm
stew 46
Member Since: 01 Dec 2011
Location: cornwall
Posts: 10147
-------------------------------------------------
if you cant hold on dont let go , it ill come in handy for something even if you never use it.
D3 SE 05,
110 s wagon 300 tdi SOLD
h top transit
crew cab transit
transit connect
ausa dumper, muck truck .
peljob 2.5 digger
06 L 200 crew cab
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soon 
