My journey towards an "as good as I can get it" D2

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D

DutchD2

New Member
Posts
9
Location
Netherlands
After taking my previous D2 for granted and not giving it the love it should have received, I bought a second one and intent to make it nice. Instead of buying a nice mint one, I decided to buy the cheapest one I could find and do all the repairs and upgrades myself.

starting point:
1733061953231.png
1733061938970.png

Goals:
I would like it to be a reliable vehicle. Will try to get rid of the all small nuances, instead of letting them build. And will try to use quality parts.
It does not have to be super fast, but it must have more than enough power towing.

Intended upgrades:
- get a monitor system for coolant temperature, egt etc including an alarm functionality
- do a full service.
- replace harmonic balancer, it seems to be broken
- replace engine mounts, the rubber is hitting the holes.
- upgrade intercooler
- validate and or upgrade exhaust.
- replace exhaust manifold, its leaking.
- upgrade turbo.
- replace roof trim.
- replace rear bumper
- replace airbags
- upgrade steering wheel
- chair covers
- get some kind of aftermarket apple car system. The current implemented system overheats (or so i think) after 15 minutes.

and probably many, many more:D

In this thread I will try to keep a log of what has been done, what parts and instructions I used etc. For my own reference and your entertainment:D.
 
harmonic balancer:

When I bought the car there was a nasty rattling noise near the front of the engine.
searching for "TD5 rattling noise" it turns out the crank pully is a "consumable" on this car. luckily there is a nice instruction how to replace the harmonic balancer:

the instruction is clear and complete in my opinion. The only problem: as far as I could tell LandRover does not make the harmonic balancer anymore. Most of the forum post indicate you should not go for imitation. That leaves me with very little options. Of the available options, I had the most confidence in the turner engineering balancer.
LHG100580 Damper crankshaft
Installing it was not that hard of a job, although you do need a lot of force:

1733063784735.png

don't worry, I only used the second d2 as a stationary object:D

The only rare equipment used is a 450nm torque wrench. btw the turner engineering one is a bit shallower. Therefore, the torque wrench would fit between the radiator and the engine. But that would not have been possible with the original one.

All in all a job of 3 hours, but second time would probably be like 40 minutes. Most difficult parts of the job:
- creating custom tool to hold pully (the first attempt was not strong enough and bent.
- applying enough strength by myself to get the main bolt undone.
- getting the new seal in its place.

job successful:
- rattling noice is gone.
- less vibrations in the engine.
- one less oil leak.
 
Excellent. Look forward to watching this. Don’t think you’ll go wrong with turners.
What’s the screen on centre of dash? Looks like one of the old wagon rear view screens.
Quite a few options for your Egt/coolant etc. on my 300tdi I have a Range Rover cap and level that sets off alarm if expansion tank drops then just gave gauge for temp. How’s the condition of rear end? Of the disco that is 😂
For reliability I’d go through your known td5 faults too just to get them out the way! Injector loom and good clean of plug, fpr and a Siemens/VDO fuel pump. Pump would be first thing I’d do if I had one again. Check if it’s had a stat change too?
 
resto_d1 said:
Excellent. Look forward to watching this. Don’t think you’ll go wrong with turners.
What’s the screen on centre of dash? Looks like one of the old wagon rear view screens.
Quite a few options for your Egt/coolant etc. on my 300tdi I have a Range Rover cap and level that sets off alarm if expansion tank drops then just gave gauge for temp. How’s the condition of rear end? Of the disco that is 😂
For reliability I’d go through your known td5 faults too just to get them out the way! Injector loom and good clean of plug, fpr and a Siemens/VDO fuel pump. Pump would be first thing I’d do if I had one again. Check if it’s had a stat change too?
Click to expand...
The screen is a china implementation of apple car play. Its quite nice when it works, it just start restarting every few seconds after about 15 minutes of use. So it probably needs a bit of an upgrade:d

I am a bit doubtful about the rear end. At least no holes etc, but there is rust. There indeed might be some work there...

Will do a separate post about the gauges, have done quite a bit of research and ordered something.

check and clean plug -> will add to list
Injector loom -> will add to list, but only if plug is oily right?
fpr -> will add to list, probably should not put it at the bottom, right? any recommendation about brand etc?
fuel pump -> will add to list, would indeed be a shame if broke.
Thermostat -> I already ordered a new water pump, so might be nice to replace them together.
 
👌 yeah it’ll probably be hiccuping and all sorts of there is already oil in the plug. I actually opened my ecu up very carefully and cleaned it out.
I think I got a Bosch FPR. While ago now. Fuel pump will make some noise if going but mine didn’t give much warning.
 
The last landrover partly died after not indicating overheating. It might not be a surprise that I want good monitoring of temperatures and levels, complemented with nice alarms.

I spend the good part of a day googling my options. I found the following:
- ODB2 -> TD5 does not support ODB2 so something like a scangauge will not work.
- Separate Gauges -> I would like to monitor quite a lot of values -> (boost, egt, coolant x2, trans etc) would not like to fit them and a whole set of gauges is also not cheap.
- madman ems3 td5 -> kind of plug and play. Even instruction videos. But super expensive (would be about €800-1000 including duties etc).
- ebay multi gauge -> need at least 2. still kind of pricey, and does not seem to have a buzzer. Only a visible alarm.


Almost gave up on finding something that monitors all and just finding a EGT gauge.

But then I found: the utcomp pro
I did not find it on any of the rover forums, but for me it seems perfect.
You can add 10+ sensors.
I can 3d print my own display case, so I can find the perfect spot for it.
It does session logging(you need to buy that seperate on the madman).
configuration (incl screen setups) via laptop.
It can even connect to an android tabled or phone and have extra functions.
Price is ok for me(€170 excl sensors).

Its ordered and on its way. Hoping it's as nice in person as on the internet:D
 
My first big oopsie on the new Rover.

Since I am not a big fan of the EGR i ordered a simple ebay kit to get rid of it. Did not only want to block it but totally remove it.

When working on the EGR I noticed the exhaust manifold was leaking. It is even missing some nuts....

Getting the flexible pipe from exhaust to the EGR cooler was hard to remove from the exhaust. Since I ordered a replacement exhaust manifold, I decided to not bother. I just put the blind plate on the end of the flexible pipe and fix it with a tie wrap.

This turned out to be a big mistake. on a drive i started noticing less power. figured the manifold was leaking a bit more. Then something fell off the engine. Turns out the flexible pipe started leaking and broke at the end. I severely over estimated its ability to hang on for a few days. This resulted in some melting of wire protection and the temperature sensor... It seems the wires itself are not hurt. even the insulation is still ok. maybe at some point this part of the wire loom will be replaced. for now the rover is grounded till the manifold arrives. Hopefully the aircon pump is not damaged. Will replace the belt as a precautionary measure. And off course add extra protection for the wires.

1733250265694.png
 
DutchD2 said:
harmonic balancer:

When I bought the car there was a nasty rattling noise near the front of the engine.
searching for "TD5 rattling noise" it turns out the crank pully is a "consumable" on this car. luckily there is a nice instruction how to replace the harmonic balancer:

the instruction is clear and complete in my opinion. The only problem: as far as I could tell LandRover does not make the harmonic balancer anymore. Most of the forum post indicate you should not go for imitation. That leaves me with very little options. Of the available options, I had the most confidence in the turner engineering balancer.
LHG100580 Damper crankshaft
Installing it was not that hard of a job, although you do need a lot of force:

View attachment 331066
don't worry, I only used the second d2 as a stationary object:D

The only rare equipment used is a 450nm torque wrench. btw the turner engineering one is a bit shallower. Therefore, the torque wrench would fit between the radiator and the engine. But that would not have been possible with the original one.

All in all a job of 3 hours, but second time would probably be like 40 minutes. Most difficult parts of the job:
- creating custom tool to hold pully (the first attempt was not strong enough and bent.
- applying enough strength by myself to get the main bolt undone.
- getting the new seal in its place.

job successful:
- rattling noice is gone.
- less vibrations in the engine.
- one less oil leak.
Click to expand...

The way to do the main bolt by using a decent breaker bar & use the starter to crack it. :)
 
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