Project: The impossible utopia - Freelander S TD4 3 door (2002)

weemac · Jul 8, 2019

I'm tumescent with anticipation of the new turbo which obviously isn't here. Most of the other required bits are, though and we've err'd considerably on the side of caution. New solenoid, MAP sensor, silicone vacuum hose and turbo to intercooler hose. Hopefully it digs me out of that hole.

The IRD blanking plate represents something entirely different. I'm [still] waiting on the filler and drain plugs to arrive from Rimmer before getting into that.

New HD drop links, track rod ends and ARB bushes show I'm reasonably confident I can fix the turbo issue. Or very, very stupid. You decide.

Trailstar · Jul 9, 2019

First freelander thread I've ever followed
Looks good mate....

Colthebrummie · Jul 9, 2019

Makes yer wonder why people rave on about Diesel engines. They seem to be nothing but expensive trouble.

Col

weemac · Jul 9, 2019

Colthebrummie said:
Makes yer wonder why people rave on about Diesel engines. They seem to be nothing but expensive trouble.

I hear you, @Colthebrummie and some days I really wonder why we do it. I reckon with regular maintenance and sensible preventative work, the TD4 would be as reliable as anything else.

This one had clearly been neglected for a long time. Some simple jobs on the previous owner's part and a bit of TLC would very likely prevented this. Now I'm picking up the pieces, and the bill.

To be fair, the cost of the vehicle and parts (so far) has not exceeded the price of buying a Freelander that runs well. We got it cheap and, as I'm from up North, I only spend proper money where I have to. If I can repair something, I'll try that first. It's about imagination.

For example:
The coolant expansion tank has the inevitable cracks around the neck. We didn't buy a new one. Just keyed the surface and hit it with half a dozen coats of clear lacquer. Because that's what I had lying around. Should maintain pressure long enough for me to eat the apple pies

weemac · Jul 24, 2019

Turbo done. The new unit arrived but without the gaskets and I'd really had enough of waiting to get this done. Out came the wire wheel and the gasket paper along with copious liquid gasket.

We're golden. Or we're not. I genuinely have no idea whether it will work long term. Photos from two weeks ago and it hasn't leaked yet. Besides, we've been busy elsewhere and potentially have bigger fish to fry. I may not have had to replace the turbo at all...

weemac · Jul 24, 2019

To preserve the alleged 'warranty' on the turbo, we're compelled to do some checks. These checks involved lots more bits coming off the hippo. After some resistance from the most awkward bolt (inside the hatch in the wheelarch) the bumper is removed to reach the intercooler. Sump pan off, inspect pickup, 'test' the crankcase breather, as well as the oil feed and return for the turbo bearings. Also replaced all the fuel line I'd used for vacuum hose with lovely, slippery silicone and secured it all sensibly.

The intercooler was filthy. To my surprise, the crankcase was not...

weemac · Jul 24, 2019

"Secure that s**t, Hudson"

weemac · Jul 24, 2019

Back together for a road test...

Results were inconclusive.

weemac · Jul 25, 2019

While we're in here... Won't win any awards but it'll slow down that rust a bit...

weemac · Jul 26, 2019

As a distraction from my turbo bungle, thought I'd investigate the IRD once the new filler and drain plugs arrived. For once, it was straightforward and there were no nasty surprises. The filler plug was well stuck on there thanks to the copper washer but it came off without damage. Drain plug was easy. The oil was a bit dark but looked and smelled OK. The lack of metal chunks and metallic sheen put a smile on me face. The drain plug magnet had some filings on but nothing I'm worried about. Decided to pull the pinion out completely and blank the cavity with a stout 6mm cover plate. Pinion is in remarkable condition considering the state the prop shafts and support bearings had got into. Finally, some half decent news.

weemac · Jul 26, 2019

IRD cleanup and blanking plate installation...

DanClarke · Jul 26, 2019

weemac said:
Turbo done. The new unit arrived but without the gaskets and I'd really had enough of waiting to get this done. Out came the wire wheel and the gasket paper along with copious liquid gasket.

We're golden. Or we're not. I genuinely have no idea whether it will work long term.

I helped one of my son's friends to make a 1/4 inch thick gasket to go between the carb and the inlet manifold on his Dis-Astra estate. He had tried all the silly-cone gasket goo's but they just got sucked into the engine; Pox-all wanted silly £40's for a new part.
We made a multilayered gasket out of old fashioned thick gasket paper all stuck together with red hermetite that was 2 years ago. Its still working fine!

weemac · Jul 26, 2019

DanClarke said:
We made a multilayered gasket out of old fashioned thick gasket paper all stuck together with red hermetite that was 2 years ago. Its still working fine!

Nice. Some bodge fixes can really be as reliable as a correct parts, then?
It was the high temperatures that concerned me. I thought lots of heat + paper gasket could come back to bite me in the proverbial. Done 400 motorway miles on the new turbo without a drop of oil getting past the seal. I'm going to stop thinking about it

FlatbedPilot · Jul 27, 2019

Is it going to be permanently 2WD then?

weemac · Jul 27, 2019

I hope not! Prop shaft been off for ages, though. Carrier bearings are knackered so the pinion is just spinning for nothing. Decided to remove it in't interest of preservation.
Wanted to investigate the IRD to look for evidence of VCU failure. Need to be sure it's worth repairing the prop and that I'm testing the VCU on a sound IRD. Looks rosy.

FlatbedPilot · Jul 27, 2019

The usual reasons for removing the propshafts are because of knackered bearings or VCU seizing up. Are you familiar with the "one wheel up" test? You'd need to refit everything to do it but it will tell you if your VCU is working or not.

weemac · Jul 27, 2019

DefenderPilot said:
Are you familiar with the "one wheel up" test? You'd need to refit everything to do it but it will tell you if your VCU is working or not.

Indeed

Only way I can really test it I believe.

Previous owner took prop off so I've never seen it working. If the VCU had seized prior to removal, I'd expect to see some damage on the pinion and crown wheel, no? Because I found no damage or even many filings, I can only assume the VCU is still in reasonable enough condition to put back into service. Or at least fit and test.

I'm looking forward to new bearings and getting it all back together

weemac · Jul 27, 2019

Started breaking the old prop shaft and VCU apart today as it happens. Safety third.

Image-fest to follow...

weemac · Jul 29, 2019

Breaking down the prop shaft and VCU: Part I

weemac · Jul 29, 2019

Breaking down the prop shaft and VCU: Part II

So, despite not being able to crack it with the UJ intact, this one wasn't too hard. A few sharp hits with the persuader and we're off.

Hammer no worky...

Sketchy puller setup no worky...

Let's see how a good soaking works out. Otherwise, I'll take a trip to a garage for once and have it properly pressed off

To be continued...

Project: The impossible utopia - Freelander S TD4 3 door (2002)

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