Discovery 3 Engine re-build

tyregeezer · May 20, 2024

Well well replaced battery today cleaned every thing I could think of no change, went through codes again one code was intermittent fuel pressure decided to take a break from wiring and change out the rail sensor had an oem fuel rail so robbed it fitted to 09 fired it up to check pressure on live data no lights, no codes, no giant F on dash, suprising but happy everything appears to work, so far, happy days, suspension up, fitting trims and liners booking mot for next week, once have driven still need to get box hot enough for final level check, brakes pads and discs to do, then booking south of france for august time

gstuart · May 21, 2024

tyregeezer said:
Well well replaced battery today cleaned every thing I could think of no change, went through codes again one code was intermittent fuel pressure decided to take a break from wiring and change out the rail sensor had an oem fuel rail so robbed it fitted to 09 fired it up to check pressure on live data no lights, no codes, no giant F on dash, suprising but happy everything appears to work, so far, happy days, suspension up, fitting trims and liners booking mot for next week, once have driven still need to get box hot enough for final level check, brakes pads and discs to do, then booking south of france for august time

That’s great news mate , would never have guessed a fuel rail pressure sensor in a million years

So pleased for u that you’ve managed to resolve the issues my friend , hats off to u

tyregeezer · May 21, 2024

Me neither Lol on that day I re-bled the brakes using the ap200, then checked codes and decided to replace the pressure sensor as was getting intermittent pressure codes and ecm fault, changed for a OEM one I had don't think the one fitted was, got in fired it up to run live fuel pressure data and to my surprise no more lights, gongs or whistles suspension returns to normal.
Just a wild guess is it possible the pressure sensor/ecm was actually triggering the other faults? I was actually looking in the wrong direction for the trigger if you see what I mean? Would love to know what you think?
Ordered brembo discs and pads, wipers, bonnet cable and other bits and Bob's from mr craddock today so going to bolt the trims/liners/brakes at the same time, will probably have to test it in the meantime green lane is only 50 yards away Lol many thanks for your help was much needed and appreciated at a taxing time, all the best mate

gstuart · May 22, 2024

tyregeezer said:
Me neither Lol on that day I re-bled the brakes using the ap200, then checked codes and decided to replace the pressure sensor as was getting intermittent pressure codes and ecm fault, changed for a OEM one I had don't think the one fitted was, got in fired it up to run live fuel pressure data and to my surprise no more lights, gongs or whistles suspension returns to normal.
Just a wild guess is it possible the pressure sensor/ecm was actually triggering the other faults? I was actually looking in the wrong direction for the trigger if you see what I mean? Would love to know what you think?
Ordered brembo discs and pads, wipers, bonnet cable and other bits and Bob's from mr craddock today so going to bolt the trims/liners/brakes at the same time, will probably have to test it in the meantime green lane is only 50 yards away Lol many thanks for your help was much needed and appreciated at a taxing time, all the best mate

Ur so welcome my friend

Alas to be honest not 100% but suppose it must be in one way or another seeing the lights went out

That’s awesome getting brembo brakes , should make an improvement that’s for sure

Funny enough still got to bleed mine after air was left in them after I got all my discs, callipers , pads etc replaced , went with the ceramic pads this time to see what there like , fingers crossed won’t have to plug diagnostics in, but alas not sure if he allowed air to enter the ABS module, time will tell as I’ll use a pressure bleeder on them

I’ve also ordered some 5/40 millers XF engine oil , mahle oil filter along with a pair of Bosch aerotwin wipers , as I’m going to try it to see if the 5/40 makes a difference , heard a lot of people have gone over to it , plus mines just clocked 100k , every little helps I suppose

Will also be a good time to try out the new vacuum pump I got , also handy I can attach it to my air compressor but will see if it works ok in manual mode

Then after that will be the attempt to change rear lower wishbones and panhard rods

Have got that new impact wrench which has some 1780nm of torque so hoping that will make life easier, along with a 2 & 4” angle grinders in case the nuts don’t come off , will of course get all new nuts and bolts , then 4 x wheel alignment

Also need to remove the drivers side door panel to fit the new window switch , as the window works on the passenger side but not drivers side

Then replace the window rain strips as mine are bubbling

That just leaves the timing belts and ATF oil change , then next year fit the 19” rims I got a few years ago along with a new set of wildpeak tyres, following year will get my chassis redone with dinitrol

Did get a DB app for my phone so will see what the noise readings are before and after I change the engine oil , will take a reading at the engine and then inside the cabin , yeh I know i need to get out more , lol

Once again great new mate and indeed plse let us know how u get on

tyregeezer · May 22, 2024

Yes have put it down to now infamous knock on effect, for self preservation Lol, surprisingly brembos and ebc ultimax pads were only around £50 more than cheaper non brand, only the price of two door weather strips, I don't normally run diagnostic bleeding when changing fluid or minor pipe work as long as you don't let air in, unless you are flushing the fluid of course,
Would be very interested in your findings thoughts running 40w my 07 is still running 10w 40 this 09 is on 10w 30 both shell helix, try noting valve train noise too, before and after personally don't think the oil 10w 40 is a big deal sure they will run happily on either my 07 is living proof 12+ years 20010k, my Norton I run on silko monograde 30 winter 40 summer and since the 80s Lol, I have a large dremel type tool which with a tungsten bur tool can cut through the nut I make a groove down to the bolt relieving pressure and it gets in tight areas usually can still getcha spanner on, good luck with working through your list, no worries I'm also told to get out more but I like it in my workshop it's my happy place

tyregeezer · May 25, 2024

Fitted front brakes today, gave hubs, carriers and calipers a good clean, replaced turbo heat shields on left side and arch liners, wheel arch trims, waiting for rear discs, changed wipers also ran through lights all good, also picked up a leak off test kit, still have list off little jobs before mot, but off work for ten days so hopefully can get sorted

gstuart · May 26, 2024

tyregeezer said:
Yes have put it down to now infamous knock on effect, for self preservation Lol, surprisingly brembos and ebc ultimax pads were only around £50 more than cheaper non brand, only the price of two door weather strips, I don't normally run diagnostic bleeding when changing fluid or minor pipe work as long as you don't let air in, unless you are flushing the fluid of course,
Would be very interested in your findings thoughts running 40w my 07 is still running 10w 40 this 09 is on 10w 30 both shell helix, try noting valve train noise too, before and after personally don't think the oil 10w 40 is a big deal sure they will run happily on either my 07 is living proof 12+ years 20010k, my Norton I run on silko monograde 30 winter 40 summer and since the 80s Lol, I have a large dremel type tool which with a tungsten bur tool can cut through the nut I make a groove down to the bolt relieving pressure and it gets in tight areas usually can still getcha spanner on, good luck with working through your list, no worries I'm also told to get out more but I like it in my workshop it's my happy place

Many thks as always and will be interesting to see how u get on with the leak off test

Did u mean 5-30/40 instead of 10-40 plse, lol

Plus 1 to the dremel, used one to cut off my drop links , replaced them some 4- years ago and wondering about changing them again when I do the rear lower arms and rods , seeing they don’t cost alot and for peace of mind , the current ones are from meyle

Talking of workshops I happened to see a property in wales that had a 3 x bed house and a workshop 75 x 50’ for 100k , that would suit me as could then install a 4 x post lift to make any jobs considerably easier and a huge dream with tons of room along with being remote so no neighbours to worry about in noise complaints and the beauty of the countryside

Amazed to see how much cheaper properties are in certain parts of wales

Good to hear ur progressing well with the brakes , indeed will do that ref noise before and after changing the oil

Also when I bleed the brakes I might as well change the fluid at the same time , got hold of 2 x litres dot 4 class 6 fluid , also got a small torque wrench as my neighbour said he will help me as I thought using a torque wrench will stop them being done up to tightly , think it’s 10 Nm (7 lb.ft). for the bleed points

Sorry I’m waffling , lol

Thks again and always look forward to the work that ur doing , appreciate u taking the time for sharing the details mate

tyregeezer · May 26, 2024

Yes mate sorry had an oil flashback Lol, rain stopped play today brakes anyway, easy day today fiddling with the jag, also have to make some adjustments to my lifting cradle as xf has only one attachment at the rear of engine, and cleaning pistons for my 06 D3 in after jag, did the same thing when bleeding 09 brakes sucked out the fluid in the reservoir replaced fresh, then bled, off work until week on Tuesday so plenty of time to finish brakes and mot, yes workshop sounds great prices in norfolk crazy could do with bigger one myself, with a self contained engine building area would be nice, so many cheap projects out there been offered two D3s in the last month or so but looking for a D4 as next project but space is my limitation, all the best

gstuart · May 26, 2024

tyregeezer said:
Yes mate sorry had an oil flashback Lol, rain stopped play today brakes anyway, easy day today fiddling with the jag, also have to make some adjustments to my lifting cradle as xf has only one attachment at the rear of engine, and cleaning pistons for my 06 D3 in after jag, did the same thing when bleeding 09 brakes sucked out the fluid in the reservoir replaced fresh, then bled, off work until week on Tuesday so plenty of time to finish brakes and mot, yes workshop sounds great prices in norfolk crazy could do with bigger one myself, with a self contained engine building area would be nice, so many cheap projects out there been offered two D3s in the last month or so but looking for a D4 as next project but space is my limitation, all the best

Thought it was mate about the oil

That’s a shame , raining here as well

Talking of D4’s if I was ever able to would buy the petrol 5 x litre V8 , in red , drool , lol

Awesome mate and look forward to the progress and indeed will do that with regards to the brake fluid in replacing the entire system, out of interest don’t know how much is in there , can’t be much

At least if the manual bleed doesn’t work I’ve got the gap iid and the Autel tablet , will be so nice just getting that done for now

Indeed ref prices around the country , would be a massive dream if I was ever able to get a workshop, would spend most of my time in it , lol

Thks again

tyregeezer · May 26, 2024

Two litres is ample for a flush, bled 09 using ap200, have used icarsoft too be aware it makes an alarming noise when abs pump kicks in, sorry if you knew that, will keep an eye out for a petrol too, doing bits inside and during showers and outside when it stops

gstuart · May 27, 2024

tyregeezer said:
Two litres is ample for a flush, bled 09 using ap200, have used icarsoft too be aware it makes an alarming noise when abs pump kicks in, sorry if you knew that, will keep an eye out for a petrol too, doing bits inside and during showers and outside when it stops

Bless u for the info as peace of mind Ive got enough brake fluid , funny enough only seen a few videos of the abs module making a noise

Was also surprised when I first heard a front suspension valve block making a similar noise as the solonoids operated whilst being activated via diagnostics

see there are different software versions of the AP200 ,

Reminds me I want to get another aux battery , my main starter battery is a yuasa 019 and think an AGM might be best to use as a leisure battery

Got a renogy kit comprising of a DC to DC charger , monitor for inside the cabin and a 175w solar panel , managed to find after alot searching a box which will house the wires by removing a roof aerial blank , so this box will replace that , by doing so will keep it waterproof

Got to work out how to secure the solar panel , think I’ll get some L shaped bars to go across and secure to some roof rails, have the short roof rails but think I’ll get some long ones

really hope the resin will work to repair my front nudge bar

Sorry I’m waffling again , thks again my friend and so nice being able to share notes so to speak

Few pics of items that’s made my life easier , will do a full scan with the Autel tablet and will be interesting to see what menus are available

tyregeezer · May 27, 2024

Thanks mate break out box is at the top of my list, rear lower tailgate has decided to fail today switch clicks then fades with repeated presses reading up seems to be a actuator fault, got it out to test, its fomoco everything else going ok on holiday so taking my time, another little project mate?, where are you planning on fitting the battery? From the photos you showed me before, and how much work and improvements you have made I can't see you parting with it for a petrol mate all the best

gstuart · May 27, 2024

tyregeezer said:
Thanks mate break out box is at the top of my list, rear lower tailgate has decided to fail today switch clicks then fades with repeated presses reading up seems to be a actuator fault, got it out to test, its fomoco everything else going ok on holiday so taking my time, another little project mate?, where are you planning on fitting the battery? From the photos you showed me before, and how much work and improvements you have made I can't see you parting with it for a petrol mate all the best

Always the way mate with snagging projects , I thought I saw somewhere there’s like a timeout if u keep pressing it , of course might be totally wrong, but I assume yours is an actual fault

Think the ford fiesta ones are cheaper , think this was the one ?? ,

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Will be fitting the aux battery on the other side of the engine bay in the spare battery tray

Indeed really hope I can keep it as long as possible, plus i really hope in 3- 4 x years time I can move well away from the M25 , be it Dorset or even wales seeing places etc look very affordable ,therefore won’t have to worry about the ULEZ scheme , time will tell

Bodywork on mine is in exceptional condition, chassis is also very good , will have to give it another dinitrol treatment to look after it

Ref the breakout box I like the one I got as u can also test modules outside the vehicle as u can wire it up and comes with multiple leads ,

Hope ur having a relaxing time in the workshop, can’t think of anything better , assume u have a fridge in there and a kettle, lol

As a side note I’ve been spending some time organising my tool box, got some socket, plier holders etc, certainly makes life easier when looking for things

Meant to add the nudge bar I got came with no fixings , managed to get them all made m think I’ve got some pics somewhere , plus found the spotlight and front grill fixings

Christ the nudge bars are selling for silly prices , think I’ve seen them going for around £5-600 , I think though I might be shocked what I paid for mine , see if u can get near plse

Similar to the boot sliding floors as also got one and that was a great price ,last one was I think sold for £500

gstuart · May 27, 2024

Few piccies , yeh I know I’ve got a problem, lol , my pops bless him helps me as he’s often said he would rather see me enjoy having the tools now and really makes life easier, things like plastic trim removal pliers , hose clips etc

Plus of course at the end of the day I would be mortified if it ever came across as a show off as that’s the last thing I would ever want

gstuart · May 27, 2024

Hope I’m not boring u to tears mate

Also that switch for my spot lights I fitted inside the front overheard light utilising the sunroof switch seeing I don’t have a sunroof , was extremly lucky finding a genuine D3 spot light wiring loom , included the fuses and relays , is basically all plug
on
The spot lights come with built in drl’s, the switches u can have many different symbols and light up around the switch and backlight , I’ll try and find the video which shows them better m the symbols are etched in not lables so don’t wear off

If there’s anything here please let me know and should be able to find a link , oh and got a deeper centre console tray seeing the oem ones are so shallow

Indeed great shame I’m not nearer as could have compared notes,

gstuart · May 27, 2024

Apologises if you’ve seen this before

tyregeezer · May 27, 2024

You always have such nice things mate, always interested in seeing, many of your things are on my list, been buying blue point and snap on one or two at a time as replacements or if I lose something, also found a blue point 8mm 3/8 long reach on the jag undertray bonus, did you get on ok with epoxy on nudge bar? Looks almost ready to prime. You would certainly get a deal on a property in Wales my brother in law lives on outskirts of Cardiff nice area. Strange prices Lr parts what I think I going to be cheap normally expensive and vice versa, ordered new set of oem height sensors going to go through this suspension arms, compressor and bags dunlop as you recommended when have assembled all the bits over next month or two. Fitted rear liner and trim today, hopefully rear discs come tomorrow found out some basic info on the chip in 07 apparently stage one 190hp to 220-230hp and more boost. Yes mate kettle always on here funnily enough one of the best things I bought for the workshop is Alexa all your favorite music or radio without making anything oily, always nice to hear from you

tyregeezer · May 28, 2024

Oh hi guys. @gstuart sorry had to show you this, 07 this morning one job left to do automatic handbrake not functioning on dash still works but amber light too, plugged in diagnostic no communication with tcm, so corrosion I thought, half right anyway but someone had beaten me to that see pic snapped pin on tcm tapped into loom and attached a wire must go to contact on the inside side of tcm, they didn't even drill the hole looks like has been punched with a nail, going to see if I can get the pin out and replace the tcm, not sure if their coded but have cleaned the pins and will replace for now whatever next?

gstuart · May 29, 2024

tyregeezer said:
You always have such nice things mate, always interested in seeing, many of your things are on my list, been buying blue point and snap on one or two at a time as replacements or if I lose something, also found a blue point 8mm 3/8 long reach on the jag undertray bonus, did you get on ok with epoxy on nudge bar? Looks almost ready to prime. You would certainly get a deal on a property in Wales my brother in law lives on outskirts of Cardiff nice area. Strange prices Lr parts what I think I going to be cheap normally expensive and vice versa, ordered new set of oem height sensors going to go through this suspension arms, compressor and bags dunlop as you recommended when have assembled all the bits over next month or two. Fitted rear liner and trim today, hopefully rear discs come tomorrow found out some basic info on the chip in 07 apparently stage one 190hp to 220-230hp and more boost. Yes mate kettle always on here funnily enough one of the best things I bought for the workshop is Alexa all your favorite music or radio without making anything oily, always nice to hear from you

Many thks and have built it up over many years

Alas haven’t tried the epoxy yet , fingers crossed it will work , tools wise I quite like Halfords professional range plus good they provide a lifetime warranty

Would certainly be a dream that’s for sure having my own little workshop, mainly to keep it out the eliminates along with enough room to organise all the bits , even saw a church for sale, but abit creepy for me with all the graves , lol

Good luck with the suspension mate , shouldn’t be to much hassle having to complete the calibration seeing you’ve done it all before

Plse let us know how things go with the brakes my friend

gstuart · May 29, 2024

tyregeezer said:
Oh hi guys. @gstuart sorry had to show you this, 07 this morning one job left to do automatic handbrake not functioning on dash still works but amber light too, plugged in diagnostic no communication with tcm, so corrosion I thought, half right anyway but someone had beaten me to that see pic snapped pin on tcm tapped into loom and attached a wire must go to contact on the inside side of tcm, they didn't even drill the hole looks like has been punched with a nail, going to see if I can get the pin out and replace the tcm, not sure if their coded but have cleaned the pins and will replace for now whatever next?

Oh wow , surprised it ever worked , assume u would have to code it unless the gearboxes module is the master so to speak , will be interesting to see if a second hand one is plug and play , will find out once another one is plugged in, plse let us know as will be interesting if u do or don’t

Drives me nuts as I imagine ur the same when some people try and bodge things, was the same with my suspension in such a mess

As ur off work at least u have some time to try and work through the items step by step

Thks again for sharing them as always very interesting

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