Member Since: 21 Oct 2016
Location: kent
Posts: 13672
So around midday I dosed myself up with tablets and managed to do a little bit
Getting that air intake pipe was a complete and utter , having to push one end and pulling from the other
In the picture with the 2 x nuts and 1 x bolt, the far left bolt has stripped , has a welded nut on the back , think I may have to drill out the thread and see if I can get a short bolt and nyloc in there , holds an A/C pipe
Got the short turbo intercooler hose on, but looking at the pictures I think I need to undo the bottom clamp , move it slightly away from the turbo shield and push the clamp down a little bit , currently there all tight , didn’t go to mad as was worried of cracking the turbo outlet pipes
Then need to simply fit the scavenger pipe which shouldn’t be to bad to refit
Does anyone know where the front diff breather pipe attaches to the diff please as noticed it’s come off
So all in all I feel a very productive few hours , will have to leave it I think till the weekend as I’m absolutely crucified and my own fault but in agony
Will feel a lot happier once I’ve got the upper and lower cowl back on , hoses, then working on top of the engine
Few piccies
31st Jan 2022 3:57 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 4695
Has that bolt actually stripped the thread Gary, or is the head rounded? An induction tool on the captive side might get you out of it if the threads are OK.
It's not going to be easy drilling that out.
Yeah just turn town the bottom clamp so that it doesn't foul on the heat shield.
EDIT: Sorry, the diff breather is on the top shoulder of the n/s diff housing, roughly the 10 O'clock position in relation to the inner shaft CV as you look at it from the wheel well. yµ (idµ - eAµ) ψ=mψ
31st Jan 2022 5:13 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13672
Hi mate
Many thanks , It’s just the welded back nut that’s stripped , thread is M6
if it’s going to be difficult to drill out , what about using a smaller M4 bolt, washers and a nyloc nut as could then just push the bolt through that welded back nut seeing it’s just supporting an AC hose
That’s Brilliant regarding that bottom clamp , thk u , shouldn’t be too difficult moving that, must admit the clamps arnt super tight , don’t think the turbo would blow the hoses off
Got a new jubilee clip for the scavenger hose
Then got to somehow get the 2 x new nuts on that bracket and another bolt on the side for the air inlet pipe , blimey talk about awkward
Am really pleased the hose is on and clamped , thank u so much about the diff breather , I was worried at first I had accidentally pulled off a wire , doesn’t look in very good condition but have a roll of 10mm plastic pipe that’s used for the suspensions airlines so no hardship running a new line if needs be
Plus might be easier to check it before i refit the bottom rad cowl
Thks so much as always buddy and hope ur good
31st Jan 2022 6:31 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 4695
Will the old bolt come out? You could try re-tapping the captive nut if that's where the problem is which shouldn't be too difficult.
If that's not a runner for you try an m8 and see if it will go through, then ny-lock it and a washer.yµ (idµ - eAµ) ψ=mψ
31st Jan 2022 7:18 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13672
Managed to get the bolt out but was really difficult right to the very end
Awesome ideas as wouldn’t have thought of that and do have a tapping/dye set
Thks so much as always and will of course update u as I progress with this
31st Jan 2022 7:45 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13672
So just a few more bits to be done
Undo and adjust t bolt clamp on turbo hose
Bolt- nuts for the bracket , options - run a tap through the thread or fit smaller nut and bolt through existing nut hole
Sort out front axle breather
Refit lower and upper rad cowl
Refit fan
Refit TCM module
Refit throttle body Y assembly
Reconnect EGR pipes
Refit top air inlet pipe
Fit lower intercooler silicone hose
Test all the various sensors for the 5Vdc signal feed
Replace all the crumbling engine loom conduit
3rd Feb 2022 11:44 am
classic kev
Member Since: 12 Feb 2021
Location: Mold
Posts: 197
Oi! Ain't you got that fixed yet
How'd you get on, is it breathing again?
3rd Feb 2022 5:24 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13672
Sadly not I’m afraid, nothing like stretching a job out , lol
Driving me nuts as my back keeps deciding it’s had enough after a couple of hours , don’t mind admitting really struggled big time with that air inlet pipe that goes onto the turbo
Regarding that air inlet pipe, u have to sort of pull one end whilst pushing it up along with pushing the other end so it clears the small bracket one end and suspension chassis bracket the other end , a right to do
Sorry I’m waffling as per usual , Am hoping to see if I can do a little bit more this weekend , can’t see it being done for at least another few weeks but just trying to do it bit by bit
3rd Feb 2022 5:34 pm
classic kev
Member Since: 12 Feb 2021
Location: Mold
Posts: 197
Sorry to hear about your back. Back issues can be pure misery, FWIW no car is worth your health. Maybe rest for a couple of days and amble back out to it when you feel stronger. Much as I hate it, that's what I have to do. Sometimes a break helps you to see an answer to a problem.
Anyway, I wish you well and good luck with it.
3rd Feb 2022 5:49 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13672
Bless u and that’s so kind of u
Sorry to hear mate ur also suffering and indeed as u say no motor is worth our health
Have been resting up so hopefully I’ll feel stronger by the weekend to carry on, it was that dam pipe that threw a spanner in the works , I’ll be very happy once I can get those nuts / bolts sorted out at that bracket , inner liner back in and new lsilicone intercooler hose
Once that’s done I’ll be able to drop it back on its wheels , that in turn will make life a lot easier working on the ECM and TCM
That’s so very true with regards having a break, even if it’s stopping for a cuppa
Thks so much once again and u also stay safe and well mate
Ps, have been spending my time as I’m seriously thinking of removing my 3rd row seats , as I’ve got a sliding floor so will be ideal putting bits underneath
3rd Feb 2022 9:51 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13672
So didn’t get much done but at least a very small amount of progress
Bracket , scavenger pipe , plus undone the t bolt bracket , rotated and dropped it down , refitted the axle breather on the diff , thks again Den letting me know where it was in saving me time
However looking at the picture I think i might need to remove that bottom T bolt clamp and replace it with a jubilee clip , need to make sure it’s 100% , will first turn it over so the bolt is furthest from the turbo casing and go from there , just not happy
Undone the earth points that the ECM uses , ordered some brushes for my dremel so I can clean the terminals and earth post , easier than trying to use some emery cloth
Next step will be to get the lower intercooler hose on, earth wires , then the inner wheel arch liner back in , got all new clips for that as well
At last I’ll then be able to move into the engine bay , starting with the lower rad cowl and securing the air inlet pipe
5th Feb 2022 1:30 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13672
Apologises Forgot to update this , managed to get the lower silicone intercooler hose on , just need to do up the T bolt clamps , many thks
Talk about a long winded job, lol, in the mean time did sort out all my tools in what I needed
Can’t wait to get the disco back on its wheels , might see if I can do that this weekend , plus think it will hopefully take my mind of things going on
Must also secure the axle breather hose, is near the driveshaft , think a cable tie will be ok to use, got all new plastic clips for the plastic wheel arch liner and will be fantastic to get that refitted after cleaning up those earths
Blimey I’m waffling as per usual , thks again for the tremendous help as it’s been invaluable
At the end of the day can’t wait to finally clear that DTC coming up N/A actuator
11th Feb 2022 5:00 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13672
Quick update
Finally got it back on its wheels , replaced the T bolt clamp on the turbo intercooler side with a wide stainless steel jubilee clip
Plus cleaned the earth post and terminals with a dremel, finally putting some coppaslip on the threads
Got the plastic inner wheel arch refitted , went to fit the wheel arch but alas just need to get a few clips that’s at the front of the wheel arch , they look different than the other yellow clips
Really pleased it’s at least now off the axle stand , next step will be the fan cowl , fan, TCM module, Y piece throttle body
27th Feb 2022 5:47 pm
Captain Crosscheck
Member Since: 03 Sep 2021
Location: Oslo
Posts: 311
Good on you Gary! Reckon it'll be good to get the car back on the road, and hopefully all is sorted out
27th Feb 2022 11:15 pm
DN D3 Decade
Member Since: 24 Jun 2006
Location: W.London.
Posts: 2298
gstuart wrote:
Plus out of curiosity how do u get the gap iid picture to show up in ur signature please, many thks
Sorry, I missed this Gary. It’s actually so long ago when I did that, I cannot remember how I did it . Maybe someone who has done this recently can explain it
Update….. here is an image ( from PatGapInnov gallery), there are some others too, ie. if you have the Pro version….. Try putting it in your signature…..
D3 owned from new, P017 brake recall, BAS FBHIC, new FBH, LR013487 oil pump, new water pump. RRS front lower suspension arms. New suspension compressor/ relay. New Denso alternator. CuNifer rear brake pipes. New GKN rear propshaft. New HPFP belt & tensioner. New A/C Condenser.NO WARRANTY for many many years.
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