Had a long chat today with a mate who's a bit of a TD5 guru.

He suggested that the symptoms I have DO NOT sound like ring issues or stem seals - his reasoning being that I do not have any lumpy running, idle issues, or blue smoke production, in fact the engine runs really well.

So, what could it be???

It turns out that the oil pump has a pressure relief system, basically as rpm increases a sprung loaded bypass opens to lower the oil pressure (think it's at ~3 bar?). He suggests that it's reasonably common for this spring to get gunged up and fail.

Next job is to check the oil pressure...

See diagram:
29985d1330877578-oil-pressure-dropping-when-hot-oil-pump.jpg
 
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Well, the good news is that my turbo is NOT broken.

The bad news is that the Provent that I installed to STOP smoke, is the cause of all the smoke.

Seems my engine is so breathy that it's clogged the provent filter already.... wtf!

So, next step is to check oil pressure in case the oil pressure bypass spring has failed.

I emptied a tube of Forte Seal Conditioner into the crank just for good measure, but doubt it's the stem seals tbh....

IMG_20140519_102526.jpg
 
Bennehboy said:
Bought some new bits:

_MG_9698.jpg


Armortek synthetic rope, hawse, superwinch snatch block.

Got fed up of waiting for the 2nd gasket to come so rtv'd the gearbox onto the winch :tup:

Got the grill off to see how much chopping would be needed to fit the winch in the tray:
_MG_9699.jpg

Took the opportunity to hose the Tong mud out of the rad

Had to grind some of the crossmember off (had to further extend it from what's shown here):
_MG_9700.jpg


Winch in:
_MG_9701.jpg


Wiring in:

_MG_9703.jpg



Dash isolation switch:

_MG_9704.jpg


Rope on:

_MG_9702.jpg
Click to expand...
See right between the shackles in the pictures there is a black tubular piece? in front of the steering damper with a dint in it? what is that? i dont have that. should I? as ive previously posted my D2 steers/feels like crap. ive had a new steering box fitted, steering damper, and tracking etc to no avail.

Thanks
( nice d2, hopefully mine will get to this stage one day!)
 
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Hi, that's the factory steering 'protection', it's common for it to be removed if an after market guard or bumper is fitted.

Have you checked your knuckle ball joints for play? they can make steering fun when they fail.
 
OK, so I had suspected my head gasket was on the way out due to the sludge I'd been getting in the breather, suspicions now confirmed....

So, started to strip it down:

Bonnet off:
IMG_20140620_134134.jpg


Coolant drained, viscous fan off, top hose off, exhaust manifold removed, metal coolant pipe removed from head, turbo inlet hose off, breather off (LOADS of sludge in there):
IMG_20140620_150234.jpg


MAP sensor off, top loom off, header tank out, fuel cooler undone and moved aside, inlet manifold off, Alternator support brace undone, you can clearly see where oil/sludge has been blown through the inlet manifold:
IMG_20140620_150246.jpg
 
OK, so it's deffo HG failure of some sort, I can clearly see pink coolant in at the back of the cylinder head now the cam cover is off:

IMG_20140621_114837.jpg


Turned the engine over by hand to hit TDC on NO 1: There's also some evidence of prior damage to the cam chain timing sprocket :(

IMG_20140621_114422.jpg


Cam lobes and followers are a very pitted - This is No 2:

IMG_20140621_112414.jpg


And No 4 which is the worst:
IMG_20140621_134843.jpg


Next to do is pinning the flywheel, dropping the oil, removing vac pump oil feed, cam chain tensioning bolt, bolt NSF, but OSF front, and the chain tensioner allen bolt. Have already disconnected the FPR.

Checked the lash adjustment on the cam and the damage aint due to the lash not being backed off, so must be down to the coolant in the oil :(

Have managed to source a matched pair of camshaft and rocker shaft for 50 quid, shooting out to collect them now.
 
Replacement parts, need a clean and a tiny bit of scotchbrite work, but they're way better than the existing bits...

IMG_20140621_181023.jpg
 
Not good then then, But at least you're doing it yourself :)
You wanting a cam sprocket or reusing?
Might have one knocking about if needed.
 
Yours if you want it :) Better than sitting in the shed for another 3 years.
Collect it if you want or send me your address and I'll bung it in the post.
 
Removed the rocker shaft, spot the problem with the 2nd from last bolt...

IMG_20140624_182642.jpg


The bolts were ridiculously tight, and examining the stub of the bolt it looks to have a wear pattern so am reasonably happy it didn't snap on extraction.

Fingers crossed with the cam carrier off I can get the stub out with an easy out.
 
this is a great thread, thanks a lot for taking the time to take pics and post them up with some great descriptions.
keep up the good work.
 
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