Discovery 3 Engine re-build

tyregeezer · Mar 1, 2023

managed to paste a few pics fuel tank all together bit fiddly but done the pipes do actually hold the regulator roughly in the right spot now going to re-fit when it stops raining will try to put a few more pics on later

tyregeezer · Mar 2, 2023

few pics

tyregeezer · Mar 6, 2023

Finally have the answer to my knock sensor conundrum D3 2009 Euro 4 does not have them I think its the same for 07-09 but still have to double check have also noticed that many sources advertise engine wiring looms as 05-09 this is not correct as the looms change from 07 as there is a change of fuel pump and the removal of the diverter rail, up to 07 two plugs for the pump one for the diverter rail, after 07 on pump has two plugs only, but has a plug for the sensor on the front of the left hand distribution rail not on pre 07 it really was difficult to find this info for myself fitting fuel tank when weather gets a bit dryer and warmer going to put some of the trim back on ready for mot, brakes all serviced the just have to top up auto box

lynall · Mar 6, 2023

tyregeezer said:
Finally have the answer to my knock sensor conundrum D3 2009 Euro 4 does not have them I think its the same for 07-09 but still have to double check have also noticed that many sources advertise engine wiring looms as 05-09 this is not correct as the looms change from 07 as there is a change of fuel pump and the removal of the diverter rail, up to 07 two plugs for the pump one for the diverter rail, after 07 on pump has two plugs only, but has a plug for the sensor on the front of the left hand distribution rail not on pre 07 it really was difficult to find this info for myself fitting fuel tank when weather gets a bit dryer and warmer going to put some of the trim back on ready for mot, brakes all serviced the just have to top up auto box

gbox sump warm to the touch and oil should just dribble out of filler, wrong level can make box act weird

tyregeezer · Mar 6, 2023

Thanks mate will do plan on running and cycling through the gears a few times and re-checking/ topping off until happy before moving

lynall · Mar 6, 2023

tyregeezer said:
Thanks mate will do plan on running and cycling through the gears a few times and re-checking/ topping off until happy before moving

I think proper sump temp is 40degc and a real thin spiders web string of oil out of the filler plug, I have always assumed the instructions are so precise as its so important, myself I just use the warm touch method.

tyregeezer · Mar 6, 2023

Yes I use same method but is a good excuse to trick the missis into buying me a laser thermometer LOL

tyregeezer · Mar 15, 2023

Hi still waiting for puddle to dry up so i can re-fit the fuel tank this weekend started cleaning the block that broke its crank have attached picture of clean up of block one picture shows the engine numbers and the turbo return blank one on each side for twin turbo which is used in s type Discovery 3 returns into the sump extension and they are blacked of will changed the o rings I also have solved the crank problem there is a 13 cast under the fuel pump

tyregeezer · Mar 15, 2023

tyregeezer · Apr 17, 2023

Removed the HP pump yesterday took three hours tested the low pressure side first had 6.25 bar to the HP, jury rigged a old fuel line from the rail to a bottle very little flow re-con exchange HP pump £360 added a few pics either below or on next post

tyregeezer · Apr 17, 2023

tyregeezer · Apr 18, 2023

Was a bit fiddly and difficult to reach when you have a bad back, removed the cooler pipe first, then the wiring including the l/h injector plugs this let me move it one side and out of harm, hard lines, disconnected, unclipped and moved aside, oil filter, throttle body, and breather going to be tricky to put back, then pump to fuel rails undone at unions and moved enough, then belt cover and part of the back plate 2 x10mm, tensioner off being careful to not damage threads, belt off, next was the trickiest job for me any way there are two torqs each side of the pump inside timing cover had to use 1/4 drive as access is tight, two more 10mm from above and its out, may have missed something out. just to bore you further there are two different pumps for the D3 5ws40157 pre 07 euro 2/3 also has a distributer rail on pump giving you an extra plug, also listed as XF and peugeot and another 5ws40273 from 07 on euro 4 fuel rails and hard line connectors including fuel rail pressure sensor, and engine loom are all pre or post so be careful ordering these parts because their often listed as 04-09. 09 euro 4 does not have knock sensors either apparently will put pics in next post as it wont let me post on same page as text

tyregeezer · Apr 18, 2023

tyregeezer · May 25, 2023

Finally running few communication issues at moment working on heads for next build going to ivor searle for refurb having a break for a day or two friend coming round has a better diagnostic than me so should get to the bottom of issues

tyregeezer · Jun 14, 2023

Oh no done it again bought another D3 07 manual runs and drives couple of suspension clunks needs a compressor it came with a new Hitachi unit and bracket its giving me two error codes one for r/h rear height sensor the other is a pressure too slow it states on dash normal height only I have a spec sheet for the hitachi but it doesn't mention if its plug and play either does anyone know? Back in the workshop now not so busy in my day job

marjon · Jun 14, 2023

tyregeezer said:
Oh no done it again bought another D3 07 manual runs and drives couple of suspension clunks needs a compressor it came with a new Hitachi unit and bracket its giving me two error codes one for r/h rear height sensor the other is a pressure too slow it states on dash normal height only I have a spec sheet for the hitachi but it doesn't mention if its plug and play either does anyone know? Back in the workshop now not so busy in my day job

If it’s the same pump on the car then yes plug and play (well it was on the 322).
J

tyregeezer · Jun 14, 2023

Hi on the sheet that comes with it it just states direct replacement comes with it's own mounting doesn't mention coding or anything but comes with it's own relay

marjon · Jun 14, 2023

tyregeezer said:
Hi on the sheet that comes with it it just states direct replacement comes with it's own mounting doesn't mention coding or anything but comes with it's own relay

Yes they all come with a new relay. To replace the old 1.
but if somebody previously fitted an AMK then it’s not a direct replacement, so as long as it looks the same as the 1 on it at the moment it is straight swap.
There is quite a visual difference between the 2 so easy to tell.
It has come with a new drier attached as well hasn’t it? Because they can clog the filters in them whoch doesn’t help air

J

should have looked at the pic yes it has the air drier on it..

tyregeezer · Jun 14, 2023

marjon said:
Yes they all come with a new relay. To replace the old 1.
but if somebody previously fitted an AMK then it’s not a direct replacement, so as long as it looks the same as the 1 on it at the moment it is straight swap.
There is quite a visual difference between the 2 so easy to tell.
It has come with a new drier attached as well hasn’t it? Because they can clog the filters in them whoch doesn’t help air

J

should have looked at the pic yes it has the air drier on it..

Yes all ready to go several bags of new bits while fitting kit I think no one would fit it for him, plugs look the same generally looks the same will fit after weekend sensor came today its gonna be another live and learn hopefully @stuart might know? Thanks for the advice same as I was hoping fingers crossed it will just burst into life LoL

tyregeezer · Jun 16, 2023

Hi all fitted compressor today but more issues all original fault codes have gone suspension rose to normal height seemed ok no lights on dash selected off road rose fine then the dreaded ping and new code c1a13 pressure does not decrease when venting gallery fronts return to normal rear stuck in off road anyone had this issue it has stood fir 6 months valve block stuck? Any one have an idea?

Discovery 3 Engine re-build

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