300 Tdi Rebuild

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chris-the-gerbil said:
Actually it'll be 49mm if you happen to need to reference by size but thats the later smaller one that you should have on a 96 truck. You want the 1580mm belt.
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49mm, ok, ok, it was dark and I was using a torch! Also, I'm getting on just a bit and my eyes are a bit dim :D
That'll be ERR5911 then?

chris-the-gerbil said:
Is there a penny behind the tensioner? If so get a new tensioner and chuck the penny away. What happens is that the tensioner wears and the wheel gets pushed off to the side, moving the belt away from the block so it then rides up and shreds on the waterpump pulley. People stick the penny in so the tensioner is now in the right position but skewed across the belt and the belt whines and squeals like you woulnt beleive....
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No penny, but I did try that the other day and it stayed the same or even made the noise a bit worse. I replaced the tensioner with a Dayco OEM one yesterday. Sounded the same. Found the rubber trapped in some of the pulley V's. Cleaned them out, Took off water pump and PAS pulleys, cleaned and put back on. Sounds a bit better today. Tried to get a new belt from local Independent, but they didn't have one :rolleyes:
 
If you have ribs stuck in the pulleys it makes a real row. Mine started on the drive home it'll be one little bit Im sure making the noise and it takes ages to find. Dayco belts seem to be crap all of a sudden for it.
 
One silly thing, Are all pulleys clean. I know someone who used WD40 or similar and it caused the belt to break down and fail over time .


Cheers
 
chris-the-gerbil said:
If you have ribs stuck in the pulleys it makes a real row. Mine started on the drive home it'll be one little bit Im sure making the noise and it takes ages to find. Dayco belts seem to be crap all of a sudden for it.
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Watched a video on youtube where the guy said Dayco belts were noisy.
 
So how is the oil consumption issue getting on, I imagine as you are now diverting your attention to squeaks that you aren't too worried about it now?
 
Kwakerman said:
So how is the oil consumption issue getting on, I imagine as you are now diverting your attention to squeaks that you aren't too worried about it now?
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I've stopped worrying about it so much since I put the new turbo on. The lack of performance, oil usage and smoking at start up all combined to worry me. The new turbo has transformed it, so now I think to myself that it can't have too much wrong with it to be flying along the way it is now. I go out to drive it now for absolutely no reason whatsoever, just cos it's great fun to drive. I put a thread on LZ about changing my UJ's, a few weeks ago, because of the vibration and noise. No need to change them now! I must have been thrashing the Landy so hard, it was revving too high and making a hell of a noise. Now it pulls smoothly and quietly (for a Defender) through the gears, it has been a very big change! I have been distracted by the belt squeaks, but will keep an eye on the oil consumption and smoking. I was talking to the owner of the local independent about it being better and he said wait until it's done 10k miles and it will be even better. So, maybe it's going to take a little longer to run in than I thought and I need to be more patient. The Mrs hasn't been working the same shifts, but is back to usual as from tomorrow. I'll be able to make a direct comparison again next weekend and keep a closer eye on it in subsequent weeks now that it'll be back to it's regular weekly mileage.
 
neilly said:
One silly thing, Are all pulleys clean. I know someone who used WD40 or similar and it caused the belt to break down and fail over time .


Cheers
Click to expand...

chris-the-gerbil said:
washing up liquid and hot water will degrease them. Neilly is right any excess oil will make them delaminate.
Click to expand...

jamesmartin said:
just get a tin of brake cleaner if you need to clean any
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New belt arrived mid week and have just put it on. First though I cleaned all the pulleys. Started with brake cleaner and a wire brush on the V pulleys. Then brake cleaner and blue roll, including the smooth pulleys this time. Then I cut a piece of thin garden wire on an angle so it had a sharp point and went around each pulley V with that to scrape it out. (except crank pulley cos you can't rotate it and it was a right fanny on) Then I boiled some water and made a pot of hot soap water. Cleaned all pulleys with that and a toothbrush, scrubbing around every V including the crank pulley. Then rinsed each one with boiling water.
Put the new belt on (Another Dayco one)............................nice and quiet :D Hopefully it stays like that.

Kwakerman said:
So how is the oil consumption issue getting on, I imagine as you are now diverting your attention to squeaks that you aren't too worried about it now?
Click to expand...
The oil was down to the bottom notch on the dipstick. :( I've carefully filled it until it got to the top notch, so I have an exact reference point. I think I might go extreme OCD and get a small measuring jug so I can find out exactly how much it's going through.
 
Hmmm......... @neilly I'm wondering which part of the post you liked? :confused:
a) The OCD cleaning of the pulleys
b) The OCD suggestion about using a measuring jug to measure the oil usage
c) The fact that it's stopped squeaking for now!
I'm betting on b) ;) :) Go on, admit it :D:p
 
Bit of an update. In fact for me it's a big update!
She's used no oil this week at all! :eek::D Actually the oil had sneaked slightly above the top notch on the dipstick. Not sure how. I was expecting it to be near the bottom notch after a week taking the Mrs to work and back. So, either the original recon turbo was passing all of this oil. Or, it's getting run in. Or a combination of both!?
The other thing is there's still no squeaking from the new aux belt. :D Maybe I had got some oil on the other one and it caused it to degrade and squeal.
 
Another update. Just in case anyone is still following this, for future searches, but also for my own gloating, satisfaction cos things seem to be going well! :)
Checked the oil tonight, still on the top line of the dipstick :eek: :D That's two weeks of the Mrs' weekly work drive with no oil use. The engine has now done 3400 miles since the rebuild. When first back in and running it was using 1.5 litres per week of the Mrs' work driving. I'm over the moon.

As an aside, I've bought another auxiliary belt. This time a Gates make, as recommended in a thread on LZ. The back of the belt is certainly harder and shinier than the Dayco belt. I'll put it on tomorrow, if the current Dayco one is still chirping. Just asked the Mrs and she's not sure if it's still doing it :rolleyes: I'll check du matin.
 
Al2O3 said:
The engine has now done 3400 miles since the rebuild. When first back in and running it was using 1.5 litres per week of the Mrs' work driving. I'm over the moon.
Click to expand...

Good news, More miles than I do in my 90 in two years...LOL.

Is the reduction in oil usage due to the replacement turbo?

Cheers
 
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