Daves D2 TD5 Project

Hello Dave. I have just caught up on your progress. Good job. And good read. Last time I caught up was when you were being hauled off to the cells by the local police and tortured until
You revealed your secrets. Or was that the bond movie. Getting confused lol .
Keep up the posts.

D15KOE has now surpassed himself

Very happy bunny here

I left early yesterday morning for a 220 mile round trip to the NE Highlands, this is his furthest round trip yet, and then Mel and I went out in him last night, another 50 odd mile round trip all good and in some foul weather / nice weather too.
All I have to say is, and remember I'm a fussy old git, but he is absolutely PURRRRRRFECT
Couldn't fault the vehicle at all, pulling like a train, no vibes etc, did exactly what he says on his tin
He actually kept up with a local guy through the lanes in a new Navara Pick Up, and on the way outta Inverness all the way home nothing kept with me or overtook me

The only niggle was the one I already mentioned, which is the 5 cylinder drone from the center Silencer delete pipe, but I came back armed with a stainless circular straight through muffler, which I am hoping will make that disappear
It's not so much annoying, can't say it drowns out the music, but on the first leg of the journey I had the Stereo off, mostly noticeable if pulling hard up a steep incline in top gear .......................

It's the kinda drone that would probably send me to sleep on a long motorway trip towing, so far from ideal.

I took the delete pipe off today, and have welded the Silencer into it, being a straight through type it is the best of both worlds, it won't affect Turbo performance like the standard one does, and should kill the drone, I will find out if I'm correct when I next take him out.

Whilst on the lift a thorough check over especially for any leaks, all looking good
VHT Paint is drying, I'll fire the new centre section back on in a minute before I pack up ....













I also bought another set of alloy Wheels with BFG All Terrain Tyres, D15KOE's "winter" set, picked up a few other little trim pieces, got to play with Roddy's D2 to program it's BCM with his new additions etc, and we prepared the other Discovery that I bought for it's journey over here, probably late November.
I removed it's Calipers to make sure the Brakes are 100% free, so it now rolls nicely when I gotta move it around here before it gets stripped completely

All in all a great day out followed by a great night out, well worth all the hard work and struggles

A straight through type Resonator addition is a great mod to a Silencer Delete Pipe ...........................

Exhaust no longer has the droning noise, but there is another upside ....................

The D2 now feels like it pulls better, it does not feel like it is doing 80mph, last night I glanced at the Speedo, yup 80mph, before doing this I would know when he was doing upwards of 70 .....................

2 possible reasons for this :-

1) Because the whole vehicle is quieter without the droning it doesn't sound like it is working hard

or ....

2) The resonance it previously had was creating a back wave that upset the Turbo performance

I will know which one it is when I've driven it on a few more journeys, last nights test run was about 22 miles

So after last weekend off for a family wedding, on Monday I was just getting back into some work, so I fixed another D15KOE small issue ...............

The Blind Catches Hook on my passenger side front Sunroof Blind was broken, I doubt you can buy these separately, but anyway, Roddy kindly supplied me with the blinds cloth mesh part cut from one of his breaker Disco's, that piece had a good catch so I very carefully un glued it's 2 halves, and replaced D15KOE's busted one

The broken one removed ....



New one fitted with a dab of Superglue between its 2 halves locating lugs ....



Works a treat ....



Next Up, parts are arriving on a daily basis, NNN ECU, 4Wire AAP / IAT Sensor, Wiring Plug and Air Filter Box Lid so I can get D15KOE's 15P Engine running 100% with the correct ECU and Sensor Mod etc

Jury is still out on whether it actually needs a 3 Track Throttle, but D15KOE will get one if needs be

Lots of little wins add up.

I finally got started on stripping out D15KOE's Engine Loom to add the extra wire for the 15P AAP / IAT Sensor, which is a prior requirement before swapping in the 15P NNN ECU, pleased to report I only snapped one bolt getting the Battery Box outta the way, and that should come out with the old "weld a nut on the broken stub trick" tomorrow

Also a pleasing sight is the outer edges of the inner wing are actually still there
In actual fact the right Inner wings look quite good from what I can now see, yeah it does require a bit of welding, but nowhere near what I had expected, so will get to that soon

I'll get some pixels up tomorrow when I'm a bit deeper in and got that Engine loom free enough to pull it one way and the other through the Manifold in order to completely encase the new wire, may not need to completely remove it from the Car if I can get it moving how I think I can

Battery Box out ....



TTFN

Here's the update from this w/e, the hard part of adding the extra wire through about 2m of Engine Loom that snakes it's way around the Engines bowels is now completed, and along the way I tidied up a few more "Mookie" bodge rectifications and also found a misaligned Heater Hose that has chafed on the rear Engine lifting bracket, it's just through the outer rubber, wouldn't have been long before it went pop I've put a sleeve over it just to run about locally if needs be, and ordered a pair of Heater Hoses which will be here in a few days and get changed as soon as they are.

Also these D2's do not have a "Low Coolant" warning light, so I plan to be adding one very soon !!
The TD5's are one of those Engines that gets naffin HOT before the Gauge says so

The new Air Filter Box lid with Sensor and Wiring Plug photo'd on top of the early 10P one still fitted to the D15KOE until the NNN ECU arrives, at which point I can swap them ....



The new length of wire has to go between ECU red Plug and the Airbox Sensor, (plug marked with red tape) ....





So basically I freed up most of the Engine Loom, and started by carefully crimping and soldering the wee ECU Terminal on the end of the length of wire, then remove trunking pieces and un-tape one section of loom at a time installing the wire, re tape, re-instate trunking etc etc until I got to the Airbox Sensor end ....













All back together for the week ....



So all that is left to do is to plug the NNN ECU in and program it to Immo, and a few Version Codings ....



and fit the new Airbox Lid and Sensor ....



Then splice in the 4 Pin Plug to replace the original 3 Pin one ....



So that's the hardest bit done

Once I am real happy it's all good I will get the Re-Map sorted

Oh, btw, that broken Battery Carrier Bolt stub was a bear, I welded a nut on it twice, and got a couple of turns each time before it snapped off, so I resorted to plan B, which was weld a washer on then a bigger nut to the washer, which got the last bit out ....





I ran a tap down all the threads then Copperslipped all threads and used all new bolts and washers so now they will come out again should the need arise !!

Cheers for now

This'll be better than when it left the factory by the time you're finished. A few years ago this sort of spend on an old Disco would have been unthinkable when you could pick up decent ones for a couple of grand. But the prices of them now are getting almost as silly as Defenders. You are probably still a way from spending more than it's worth on it.

Thanks

Yes, I'm almost certain I've not got much more to spend now, until Chassis time in a couple of years +
I am going to buy a couple of nice to have's for Xmas which is a Single DIN Flip Up / Out Screen Erisin Android Head Unit, and some decent Speakers, plus I can add TPMS and Reverse Cam to that, also it has Navi and SD Card / USB for Digital Music and the D2 Steering Wheel Controls can be programmed into it This model :-

https://www.ebay.co.uk/itm/194022625177?ssPageName=STRK:MEBIDX:IT&_trksid=p2060353.m1438.l2649

Final thing to get is a full set of Silicon Hoses too, I planned on changing them all anyways to prevent future issues, but thats it, hopefully now on will just be Servicing Jobs, D15KOE is running well now and driving superbly

Hopefully the NNN ECU will be here for the w/e to finish that job

You certainly get a lot for your money with those Chinese head units. I had one in my Defender years ago. Not as fancy as that one as they've come a long way since then. Playing with all the features gave me something to do while I waited in Tesco car park for my wife to do the shopping.

Double post

They are very good especially for the money, I have 2 of my older Mercedes that have had them a long while, a 2001 S Class and 2002 SLK that have them, and had one in another Mercedes we sold (2006 C Class), plus a lot of guys on MB Forums have fitted them ....

As a rule I don't like using Chinese stuff full stop, but these are aren't made in the usual district and have proved to be very good and very reliable
We all use Erisin or XTrons brand, and I have had 1 Xtrons as well, the one in my S Class is Erisn has been in the Car 6 years now, still going strong, that one even has DVB TV and Headrests with DVD Players for rear seat passengers.
The one in my V8 SLK is Erisin been in 3 years ......... Same story from other guys as well

The nice thing is you can easily have Reverse Camera, TPMS and Navi without having 3 separate screens littered around the Dashboard area, and everything works as if it came from the factory that way

Dave2302 said:

Yes, I'm almost certain I've not got much more to spend now,

Click to expand...

And oh how they larrrrrfed!!!!

Interceptorxj said:

And ow how they larrrrrfed!!!!

Click to expand...

Hello Dave.
You are such a discoveryahollic.
Good read. And good work.
You skint yet.

Nah, but I can't take it with me so might as well spend it on Car projects

Bought these for D15KOE today, already done the Boost Set when I did the Radiator and I/C

When fitted that will be every single Engine Hose pro actively replaced, and I'll have a complete set of good spares
I will also fit a new OEM Thermostat unit at the same time





Also have a Low Coolant Alarm kit to fit as well as a box full of other stuff already bought and yet to fit

D15KOE's Christmas Present :-











Plus upgrade the 4 Door Mid Range Speakers, and add 2 more Tweets in Rear C Pillar trims likely be Focal's

My NNN ECU finally arrived today, so just got to find some time later this (busy) week to fit it and then can test it for a while before remapping it

Apologies for late link, I continued my Project here :-

http://www.thed2boysclub.co.uk/viewtopic.php?f=3&t=63930

Thread Title D15KOE in "Members Own Vehicles"

Mainly I moved because there are a lot of fellas in the Highlands who frequent D2BC
I actually now own another D2 Auto for breaking, so I can build up a Galvy Chassis with those Axles etc etc, to make my Chassis Swap go a lot quicker when the time comes !!
I also got a set of BFG Mud / Snow Wheels and Tyres and a set of 18" Wheels / Tarmac Tyres, still yet to collect a lot of it when the weather gets a bit better
Yes I am very happy with my D2 now, I have completed a ton of work including I now have 3 Working Keys / Plips, which required a BCM ............ As usual I had the weird fault no-one else had had, BCM has some internal fault and was not supplying the Power to the RF Module in the Roof

D15KOE is now running on the correct NNN ECU, together with a 3 Track Pedal and the 4 Wire AAP / Airbox lid which was a huge improvement and this ECU has Stage 1 Re-map, in Discovery 2 "Towing Brick" terms, and with the Low Stall H/D Torque Converter D15KOE is pretty darned quick now, and a helluva lot more refined in the way the 15P Engine now runs.

I've just completed a Single DIN ERISIN Android 10.1 Head Unit, a full installation including Active Sub, TPMS, and Reverse Camera as well as all the other standard benefits of a decent Multimedia system, it also works with the D2's Steering Wheel Controls

The current D15KOE "jobs to do list" is down to single figures now :-

1) A small roughly 3" X 2" Plate to weld onto the rear left side of the Inner Sill's underside before the end of February 2022 (MOT)
2) Fit the Facelift Headlamps I bought, including Spraying the "Hockey Stick" trims that go underneath them to Body colour
3) Pro-actively change the rear Prop U/J for a GKN H/D item and fit a new OE Donut at the same time
4) Pro-actively fit the Blue Silicone Full Coolant Hose Set and a brand new metal Coolant Pipe Manifold under the front of the Engine at the same time
5) Pro-actively later on during 2022 finish off a few more bits of Chassis Welding and more Schutz / Waxoyl, they don't need doing now, but will mean the mean the Chassis will be good for at least the next two MOT's in Feb 2023 and 2024.

So in the meanwhile, before the Chassis finally gets condemned, I have at least a couple of years to finish off all my other projects and start the D2 Mega Chassis Build, that may include installing my recently acquired 270CDI OM612 ML Engine with 5 Speed Auto ...............

BUT, as my 15P TD5 and ZF 4HP powertrain is now running and performing so well I may stick with it