BennehBoy's D2 adventure

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GINGE said:
Great re build thread, just read this from start to finish.. Some useful tips in there too.

Nice one :D
Click to expand...

Cheers.

Done loads of stuff that I forgot to add in too. Before I got the D2 I'd never done a thing with cars, not even an oil change, dunno why I've always had a way with mechanical stuff :)
 
Bought some bits to crack on with the provent install...

Just waiting on some brass 19 to 25mm inline hose connectors to arrive in the post.

They'll look something like this:
barb-coupling-250x250.jpg


8x jubilee clips...
IMG_20140419_111013.jpg


3 metres of marine grade fuel hose 19mm ID and 1 metre 25mm ID.
ACtC-3fex9xkgBdkO8eRbPdLoqb-UxACIJ6ByuCU64r-_Q0ZaGjFPcJgO1ig_8NPUDYb-jEZPrC6a-BZlvvzAKmegf5nPFmQYObgX9LL5FRdpwRXdO9z9OhP8ug6auaXYtuDP6kqQpct1iEyrOtekPOz61DVFQ=w1678-h1258-no


The inlet/outlet on the Provent are 1 inch, so I'll use a short length of 25mm hose and the brass reducers to match that up to the normal breather diameter of 19mm.

I'm going to just stick a catch can on the drain outlet of the provent to start with but will hopefully get it T'd into the turbo oil drain once I find someone who can braze it in for me.
 
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The Provent has a built in over vacuum valve, so theoretically the stock PCV can be removed - although in reality it would mean I'd have to buy an elbow to connect the marine hose to the turbo inlet so I'll just leave the stock PCV inline.

ACtC-3e282jKcs5GLyVgtCBMGcCNLMtGKqiL5PEfSdHnVS7Pvj9jP3V8flcL6caLGu8_jTj9-63qeFwypCRPsR6qESCg8wV8hKhqQ1v2tlUm4QbSp1E5pbCgMa1jaROMHo5Dh1K2z1LPOdYDIyMMKt0vO-qfXA=w1678-h1258-no
 
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Started the fitting....

IMG_20140419_134603.jpg


The 19mm ID hose fits into the 25mm hose, so I'll temp fit it that way until the reducers arrive...

PCV was filthy:
IMG_20140419_134942.jpg


As was the main duct back to the IC from the turbo:
IMG_20140419_141312.jpg


Flushed all the intake side with white spirit which brought it up nice and clean.

Fitted:
IMG_20140419_144812.jpg


Went for a quick test drive, and popped the tank cap off - mist circulating in there already.

The tank is just draining onto some wadded paper towel for now, but will fit a steel catch container shortly (old water bottle from walking).

Might need to reroute the main breather run to prevent oil coalescing and pooling in the low point.

Next job is to flush the intercooler and intake manifold.
 
Well, only just finished flushing out the IC and inlet manifold, 5 hrs solid!!

The inlet manifold is just such a bastard to remove, not room to get tools onto the bolts, but got there in the end....

IMG_20140419_183203.jpg


Stripped down the front end to allow the IC to be removed, then unbolted the fuel cooler from the inlet manifold. Discoinnected the harness for injectors, maf, IAT, coolant sensor, wastegate modulator and fed that though the inlet manifold legs. Removed the MAP, removed the De-Egr pipe, unplugged the glow plugs then fiddled like buggery getting all the bolts off the mani.

It was in pretty **** state:
IMG_20140419_183220.jpg


Loads of thick gunge inside
IMG_20140419_183225.jpg


Worst thing was that the front three lower bolts weren't even finger tight, so all and crap had been leaking/blowing out - gah!

Hoping this is oil blow by from the mani, and not the start of a failed HG.
IMG_20140419_185355.jpg

IMG_20140419_185407.jpg


I'll degunk it tomorrow and jetwash.

Inlet manifold full of white spirit:
IMG_20140419_185434.jpg


Did this twice, then did 3 lots of gunk and jet wash, got it a lot cleaner but not mint.

IC was next, it had a full bottle of white spirit:
IMG_20140419_185443.jpg


Set my hot air gun onto the manifold to dry it out. And blew the IC out using my airgun & compressor.

It's all back together now, and she's a rocket ship again :D
 
Bravo that Man!

A most excellent and interesting thread - I will be looking forward to seeing how it goes with the Provent as I have a Serck intercooler in the shed, but don't fancy it getting bunged up with oily gunk and having to flush it out on a regular basis.

I would be most grateful if you can tell me where you got the Provent from.

By the way, I live just the other side of Halifax. We pop over Huddersfield every few weeks as we have friends at Lockwood. So if you see a pale green facelift D2 with a Poppy on the front grille, it might be me.
 
I'm sure I've read all this before somewhere :D

I keep looking at this pic

_MG_9622.jpg


and wondering whether I could sneak a 'camel cut' in on the rear arch and cover it over with one of those small S spec arch trims
 
Maaarrghk said:
Bravo that Man!

A most excellent and interesting thread - I will be looking forward to seeing how it goes with the Provent as I have a Serck intercooler in the shed, but don't fancy it getting bunged up with oily gunk and having to flush it out on a regular basis.

I would be most grateful if you can tell me where you got the Provent from.

By the way, I live just the other side of Halifax. We pop over Huddersfield every few weeks as we have friends at Lockwood. So if you see a pale green facelift D2 with a Poppy on the front grille, it might be me.
Click to expand...

I got the provent from the Leeds branch of this place -> Filter Services (UK) Ltd chap called Mark, was dead helpful. 95 + VAT

Should pay for itself pretty quickly with improved milage.

I'll deffo look out for your motor, shout if you ever need nanocom sticking on it.
 
ifloochies said:
Stunning thread :clap2:
Click to expand...

Cheers, lots more to come yet, got loads I want to do to this vehicle, main job being....

Galv chassis - got a donor lined up, just waiting to check it over! When I do this I'll be fitting new shockers, brake lines, cranked front radius arms, new bushes all round, galv rear wheel arch flaps, and hopefully will get a set of replacement axles that I can mint up.

Suspect I might be tempted to go +2 or more on the body and fit 35's also.... but I do too many motorway miles for that at the moment and have a good compromise road use and decent offroader just now.
 
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Bennehboy said:
Your new boots rubbing mate?
Click to expand...

Yeh just a little bit on the lower rear part of all the arches. It's not enough to stop me going out on the plains etc. But I suspect a decent P&P would be tricky in parts.

Think I'm going to invest in one of those 20 tonne presses you were looking at, get some castor correction bushes and lift another inch.

I keep getting tempted by this cut though . .
 
Thanks for the info Benneh as well as your kind offer of a good Nanocoming - I might need to take you up on that later in the year if I don't get a little windfall.

Currently "de-restricting" mine, so when I get to the final stage (re-map by Dynajet) I will want to be sure that everything is tip top.
 
I'm 3/4 through a tank of fuel after fitting the provent and initial signs are encouraging - got 350 miles on the clock, which is 50 more than it would usually be at.

I didn't record how many miles in I was when I fitted it but think it was somewhere between 7/8 to 3/4 full, which makes the extra 50 miles pretty good in my estimation.

I'll post up again when I've done in the whole tank just in case I'm being over optimistic.

Some maths...

Normally I stick ~ 85 litres of fuel in at each fill up. It costs arounf 1.36 per litre, so that's £115.60 per fill up.

I was averaging between 400 & 420 miles per fill up so let's say 410 per £115.60 which works out at 28p per mile, OUCH!

So assuming I've regained 50 miles per fill up, that's a saving of £14.09 per tank.

Total cost of the provent install was £114 (95+VAT) + £50 for hoses and clips, so £164.

So that means the install will pay for itself after £164/£14.09 = 11.6 fill ups.

I brim the tank roughly every 2 weeks, so that's about a 6 month pay back period. (not that it's really about the cost of running)
 
Interesting stuff this. I'm showing my complete lack of knowledge here, but how does catching oil vapour translate to improved fuel economy?
 
Orch said:
Interesting stuff this. I'm showing my complete lack of knowledge here, but how does catching oil vapour translate to improved fuel economy?
Click to expand...

It stops the oil vapour lining the inside of the intercooler, which would reduce its ability to cool the compressed air coming from the turbo, meaning it's hotter (and thus not as dense as it could be) when it enters the combustion chamber, so given the hefty remap I have there is then incomplete combustion == fuel being spat out the exhaust system as black smoke.
 
Gutted :(

I guess I know why that Clarke parts washer says not to use paraffin now... the motor has died already. Looks like the paraffin ate the sealant that held the power cable into the sealed block of the motor.

What a pile o crap.
 
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