300 Tdi Rebuild

Al2O3 · Mar 11, 2017

Unfortunately, I've got a rebuild thread to put in this part of the forum.

I think I've had a few things go wrong simultaneously.
No 4 injector looks like it has failed. Light grey in colour and only one hole barely visible. This (apparently) causes it to run lean and hot. This has melted the surface of the piston, inside the combustion hole (if that's what it is called) Also, it had a brief runaway so I suspect the turbo bearings must have been letting a small amount of oil through. Not a lot of movement on the blades though. I have a video I could post, of blade movement, if anyone is interested. (might be handy for future searches I suppose

)
Anyway, borrowed an engine hoist and started to take front end off.

It started to rain but bashed on and got the rad and intercooler off.

Got sickened by the rain and realised the garage was in such a mess I had nowhere to put the parts I was taking off, so decided to tidy garage up.
While I was tidying up I realised it was going to be no use with the engine just lying on the drive. I needed an engine stand.

I've been googling them and put a post on the general forum. I'll order one tomorrow.
Unfortunately, next Saturday I have to go away for a week with work and so it going to be a few weeks before I can make any progress.
I could do with a list of parts, bearings, seals etc that I'm going to need so I can buy them in readiness to put it all back together after the re-bore.
Got a list anyone?

Steviecops · Mar 11, 2017

Bad luck with the engine. I thought they were bomb proof. I'll be following this thread because I love my 300 tdi and won't let it die! It's all good now, but there might come a time when I need to rebuild it.

Al2O3 · Mar 11, 2017

Steviecops said:
Bad luck with the engine. I thought they were bomb proof. I'll be following this thread because I love my 300 tdi and won't let it die! It's all good now, but there might come a time when I need to rebuild it.

Funnily enough, that's exactly what the guy at the turbo recon place said.

Well, a small bomb must have gone off in mine

and it didn't cope with it. It doesn't make me feel any better to think that I have been really unlucky. Why me!

I think it would have coped with the run away, but the injector going dodgy seems to have been the bomb it couldn't handle.

Al2O3 · Mar 12, 2017

Decided not to lift it out today, bought an engine stand from SGS Engineering today and will wait for that to turn up.
Just took some other bits off. Alternator, air filter mounting bracket, air pipe, disconnected wiring harness around engine to alternator and starter, accelerator cable etc.
I think the only things left are the power steering pipes to the pump and the fuel line to the FIP.
Thought I'd crack the nuts around the bellhousing. Pleased I did as the very top one won't shift. I think it has been slightly rounded in the past. I had an imperial socket on it, but I think it must be a metric 15mm. I think I'll see if I can get one this week. 15mm ring spanner is not doing the biz.
Looks similar to yesterday, but a few more bits missing.

They're all being collected in the garage

Not long since I cleared this of Landy parts

Saint.V8 · Mar 12, 2017

How do you intend to lift the engine? just curious as the lifting points/brackets are usually mounted on the head!

Al2O3 · Mar 12, 2017

Saint.V8 said:
How do you intend to lift the engine? just curious as the lifting points/brackets are usually mounted on the head!

They are!
I'll have to put it back on. I've still got the head gasket. I was thinking of torquing it up to the initial torque setting. Or, do you think I should do the quarter extra turn thing too?

jamesmartin · Mar 12, 2017

Al2O3 said:
They are!
I'll have to put it back on. I've still got the head gasket. I was thinking of torquing it up to the initial torque setting. Or, do you think I should do the quarter extra turn thing too?

just use a short head bolt in the center most hole to attach a lifting eye

Saint.V8 · Mar 12, 2017

My 300Tdi is mounted quite a way back in the engine bay so had to use my crane at full extent and really close to the front chassis rail to reach, hopefully yours is a further forward and as such reach isn't an issue!

Al2O3 · Mar 12, 2017

jamesmartin said:
just use a short head bolt in the center most hole to attach a lifting eye

ha ha, you'd think you had done this before

Cheers, JM.

Al2O3 · Mar 12, 2017

Saint.V8 said:
My 300Tdi is mounted quite a way back in the engine bay so had to use my crane at full extent and really close to the front chassis rail to reach, hopefully yours is a further forward and as such reach isn't an issue!

Mine looks further forward than yours.

Saint.V8 · Mar 12, 2017

Al2O3 said:
Mine looks further forward than yours.

Yep, mine is mated to an LT77 gearbox using the 2.5N/A bellhousing, this makes the engine sit very far back in the engine bay due to the short bellhousing. I was wondering if my crane was going to reach but it performed admirably.

I found my bellhousing bolts were a mix of 15mm and 17mm heads which I thought was odd!....have you tried jamming on a 9/16 6pt socket - 9/16 comes in at 14.3mm or thereabouts and if yours is rounded off, it may just work.

Al2O3 · Mar 12, 2017

Saint.V8 said:
Yep, mine is mated to an LT77 gearbox using the 2.5N/A bellhousing, this makes the engine sit very far back in the engine bay due to the short bellhousing. I was wondering if my crane was going to reach but it performed admirably.

I found my bellhousing bolts were a mix of 15mm and 17mm heads which I thought was odd!....have you tried jamming on a 9/16 6pt socket - 9/16 comes in at 14.3mm or thereabouts and if yours is rounded off, it may just work.

Thought you must have had a different gearbox combo.
I've got a 15mm socket on it's way too. If that doesn't work I'll have to try and wack a 9/16 socket on. There's very little space to swing a hammer between it and the bulkhead though.

@jamesmartin what if I get a couple of these LINKY ?

Steviecops · Mar 12, 2017

My 300 tdi is a disco and you can't get to the top bell housing bolts very easily! You can't even see them. I struggled for ages trying to slide my gear box back, then found I'd missed one bolt right at the top. I left that one out when I put it back together because it was so difficult to reach!

Al2O3 · Mar 12, 2017

Steviecops said:
My 300 tdi is a disco and you can't get to the top bell housing bolts very easily! You can't even see them. I struggled for ages trying to slide my gear box back, then found I'd missed one bolt right at the top. I left that one out when I put it back together because it was so difficult to reach!

You can see them easily when the cylinder head, air box and air pipe are off.

Reckon that's why it's a bit rounded though, from when I had the clutch fork and clutch replaced years ago.

Saint.V8 · Mar 12, 2017

Steviecops said:
My 300 tdi is a disco and you can't get to the top bell housing bolts very easily! You can't even see them. I struggled for ages trying to slide my gear box back, then found I'd missed one bolt right at the top. I left that one out when I put it back together because it was so difficult to reach!

I beleive the usual method is as you say, drop the gearbox down and using a bunch of extenstions over the top of the box and a willing assistant to guide it onto the bolt from the engine bay is the way to get to the top bolt on the Disco

jamesmartin · Mar 12, 2017

Al2O3 said:
Thought you must have had a different gearbox combo.
I've got a 15mm socket on it's way too. If that doesn't work I'll have to try and wack a 9/16 socket on. There's very little space to swing a hammer between it and the bulkhead though.

@jamesmartin what if I get a couple of these LINKY ?

id just use a bit of angle with 2 holes

Marmaduke · Mar 12, 2017

Steviecops said:
My 300 tdi is a disco and you can't get to the top bell housing bolts very easily! You can't even see them. I struggled for ages trying to slide my gear box back, then found I'd missed one bolt right at the top. I left that one out when I put it back together because it was so difficult to reach!

That's how you can usually tell if the clutch has been done on a disco

jamesmartin · Mar 12, 2017

Saint.V8 said:
I beleive the usual method is as you say, drop the gearbox down and using a bunch of extenstions over the top of the box and a willing assistant to guide it onto the bolt from the engine bay is the way to get to the top bolt on the Disco

it is box will drop down far enough to get a 1/2 snap-on battery gun in

Al2O3 · Mar 12, 2017

jamesmartin said:
id just use a bit of angle with 2 holes

Have you seen the picture of my garage above, JM.

Not as well equipped as yours I suspect.

No angle iron, mate. The lifting eyes are a great idea though.

jamesmartin · Mar 12, 2017

check thread of the head bolts its not std iirc

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