300 Tdi Rebuild

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Al2O3 said:
Ha, ha, by that I presume you mean the honing?
Click to expand...

I did!

Was pondering the driveway honing today, maybe you could cut the bottom off of some medium sized paint / thinner tins and have a few cracks practicing on those in advance of the main event?

Fingers crossed again for the discovered potential easy fix.
 
Well, changed the oil cooler pipes this morning. I've either ordered the wrong one or they sent the wrong one cos one of them isn't right. The one that has the straight fitting in to the oil filter housing. The metal pipe bit was too long, so the rubber part of the pipe has a tight bend in it as it's up against the inner wheel arch. I'll have to order another one. Anyway, took it up the road for spin. Stopped in a field gate after a mile to look underneath for leaks. There was oil dripping pretty rapidly off the diff. :(:mad: Thought one of the rubber O rings must have dropped off as I was fitting the pipes so I popped the bonnet to see which connection was leaking. Discovered diesel coming out of the FIP :eek: That was washing the old oil off the diff and making it look like oil was dripping off! Drove home and found this
FIP Spill off union.jpg

Must have caught it with the 22mm spanner when taking the oil pipes off :rolleyes::oops:
To cap it all, I though the clutch wasn't pushing as hard as it should when I took it up the road. Took the cap off the reservoir and no fluid in! :mad: So, I've got a leak on that anorl. Can't see anything yet, so suspect the slave cylinder at the moment.
So, it's off the road until I can get another spill pipe union, which means I can't test to see if it's still using oil yet. Feel like adding to that 'One small job leads to another' thread. :D
 
Looked up the part number for that pipe union. ERR3306. Put the number in to Ebay to realise it's the full spill kit. Hold on I thought!
spill pipe union a.jpg

I bought a kit when I refurbed the engine. Strangely, it didn't come with a new olive and nut and so I didn't put it on at the time.

I faffed about and got the old one off. Re-drilled it up the middle to fit the new pipe. (it had been compressed on to the old pipe)
spill pipe union.jpg

On a winner here I thought. However, I hadn't pushed the olive far enough on and so when I was tightening it, it just pushed the olive off and squashed it :mad:
So, I need to source a new olive and possibly a nut. Anyone know the part number? I think the spill pipe is about 6mm O/D
EDIT
No, it might be about 8mm O/D
 
Last edited:
TorsionBhudda said:
NRC9771 or 542846 I think might the part number for the olives also I seem to remember them being 5/16"
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Cheers, TorionBhudda. I was planning to go to Scewfix this morning to get those 8mm olives. I've just Googled the fraction conversion and 5/16 is 7.9375mm So I think I'll give them a try. If it doesn't seal I'll order one of those NRC9771 or 542846 any idea if they those two are very different?
 
TorsionBhudda said:
I'm not sure why they are diffrent one might be a softer material than the other
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Just fitted the Screwfix one and it's nipped up no bother. Had it running and all good.
spill pipe red.jpg

Even replaced the last bit of black spill pipe with the boy racer red I used, between the injectors, on the engine rebuild. It matches the engine block colour :oops:
Typical of Screwfix I now have 19 spare Olives (Cost £2.79 for the lot) So, if anyone reading this needs one, PM me your address and I'll post one to you!
 
Al2O3 said:
Well, changed the oil cooler pipes this morning. I've either ordered the wrong one or they sent the wrong one cos one of them isn't right. The one that has the straight fitting in to the oil filter housing.
Click to expand...

James gave the right part numbers, I had the same blank "I've bought the wrong one" moment on my disco, new outlet fitting from the oil filter housing much longer than the old one. Don't know why but the new style has superseded the old pipe, which you can't get new anymore. I just set the heat gun on it til it softened slightly (at wise suggestion of someone on the forum) and then it bent far better, have another go and it'll be cricket I bet you!
Troublemaker.jpg


If this is the pipe you're having trouble with, anyway (The bit on the left?)
 
Goc3k said:
James gave the right part numbers, I had the same blank "I've bought the wrong one" moment on my disco, new outlet fitting from the oil filter housing much longer than the old one. Don't know why but the new style has superseded the old pipe, which you can't get new anymore. I just set the heat gun on it til it softened slightly (at wise suggestion of someone on the forum) and then it bent far better, have another go and it'll be cricket I bet you!
View attachment 149390

If this is the pipe you're having trouble with, anyway (The bit on the left?)
Click to expand...
That's the one!
My worry was that with it being now bent more that the old one it might be restricting the oil flow?
 
It should bend to 90 degrees fairly easily without deforming, don't think it will be detrimental to oil flow. I didn't look to hard, suppose it might be possible to get an old stock original somewhere if too concerning?
 
Goc3k said:
It should bend to 90 degrees fairly easily without deforming, don't think it will be detrimental to oil flow. I didn't look to hard, suppose it might be possible to get an old stock original somewhere if too concerning?
Click to expand...
How long have you had your replacement on?
 
6 months or so i think? Maybe it's less of a bend on the disco. Will have to remind myself tomorrow, will grab a pic if its worth anything.
 
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