Hi Benneboy, I just wanted to say that I have just finished reading your thread and I firmly believe it is the BEST AND MOST INFORMATIVE D2 thread I have EVER read.

First class projects with loads of pics and descriptions.

This should be locked as the definitive course for looking after and optimising a D2 TD5.

Thank you very much for taking the time and effort to share your experiences with us, they are invaluable.

Dave
 
So I collected the exhaust expander....

IMG_20140909_175240.jpg


And used it to push out the dents on both the inlet and outlet of the IC:

IMG_20140909_175137.jpg


Still got a coolant issue as you can see in the pic.

Anyhow, performance is up, it goes like stink, but the boost gauge is registering LESS psi??? Bit stumped - anyone who knows more about how this works care to educate me?
 
Have you got an aluminium sport radiator.i bought one for mine and had a coolant leak. no visible signs. the manufacturer replaced as its a hairline crack on the top near the small bore return outlet.new one fitted fingers crossed.
 
cambridgecockney said:
Have you got an aluminium sport radiator.i bought one for mine and had a coolant leak. no visible signs. the manufacturer replaced as its a hairline crack on the top near the small bore return outlet.new one fitted fingers crossed.
Click to expand...

No, it's a cheapo standard jobbie - the problem I have is the top hose. Replaced with a ****part one that was worse, so will be buying a brand new genuine one when I have some spare cash... off to Poland this w/e then to Munich for Oktoberfest so saving beer tokens.
 
Well, sorting the boost leak on the IC just created a new one, the 'new' clamp I put on the hose that connects to the turbo inlet exducer port may be what's causing the boost drop. I've reseated it and will see how it goes but might grab a mikalor clamp to replace it.
 
Been having issues with my serck intercooler to inlet pipe. they all seem to be too short and drawing air in.derby performance hoses made me one that was a piece longer. now fits over intercooler pipeoutlet right up against intercooler and well over egr delete pipe.also using extra wide pipe clips.sorted its great.
 
Fingers crossed my coolant leak is now also sorted, pushed the top hose as far as I could onto the elbow and reseated a higher quality clamp... so far no coolant loss or staining :cool2:

I've ordered a full set of replacement clamps for my boost hoses, all mikalor t-bolts.

I was looking at these:
Land Rover Discovery TD5 2.5 1998-2004 Boost Hose kit [RMS210B] - £124.17 : Roose Motorsport, Performance Silicone Hose Kits

Land Rover Discovery TD5 2.5 Coolant Hose Kit [RMS210C] - £104.17 : Roose Motorsport, Performance Silicone Hose Kits

Land Rover Discovery TD5 Ancillary Hose Kit [RMS210A] - £195.83 : Roose Motorsport, Performance Silicone Hose Kits

But at a grand total of £509 I think I'll give it a miss.

Would look pretty amazing alongside the red block though :D
 
Bennehboy said:
Fingers crossed my coolant leak is now also sorted, pushed the top hose as far as I could onto the elbow and reseated a higher quality clamp... so far no coolant loss or staining :cool2:

I've ordered a full set of replacement clamps for my boost hoses, all mikalor t-bolts.

I was looking at these:
Land Rover Discovery TD5 2.5 1998-2004 Boost Hose kit [RMS210B] - £124.17 : Roose Motorsport, Performance Silicone Hose Kits

Land Rover Discovery TD5 2.5 Coolant Hose Kit [RMS210C] - £104.17 : Roose Motorsport, Performance Silicone Hose Kits

Land Rover Discovery TD5 Ancillary Hose Kit [RMS210A] - £195.83 : Roose Motorsport, Performance Silicone Hose Kits

But at a grand total of £509 I think I'll give it a miss.

Would look pretty amazing alongside the red block though :D
Click to expand...
Ouch thats some serious wedge.dph who made my extra long intercooler hoses wont do the top hose says to much issue with bleed screw.will stick with genuine keep the britpart one for emergencies.
 
Also the DPH intercooler hoses are half the price of the Roose ones. I have always found Gareth at DPH to be very helpful.

They can also supply the wide clamps, but I am thinking of finding a thinner one (but stronger than a jubilee) for the connection to the turbo as the wide clamp doesn't seem to seal properly and every week I am wiping a bit of oily residue off that particular hose. Could be contributing to my own boost/wastegate problem.
 
So, I ordered some Mikalor wide T-bar hose clamps to try and sort my boost leak out...
IMG_20140919_190550.jpg


Fitted at the turbo side:
IMG_20140920_151426.jpg


Fitted at the inlet side:
IMG_20140920_151410.jpg


Boost maxing at 23.5psi now, so I'm still chasing a leak :/

Considering new boost hoses (roose motorsport), and a EGR delete with boost nipple next.

It still goes like stink though :screaming_bug_eye_f
 
Well, I'm again back to wanting to torch this motor :confused:

Thought I'd sorted the coolant leak, but the header tank has dropped again. No obvious signs of coolant loss at all - other than the sickly sweet smell of some gunk in the breather. I ditched the Provent a while back.

My gut is telling me that somehow I'm getting coolant in the oil. Fed up
 
Bennehboy said:
Cheers fella, had some great advice from the folks on here, I'm much obliged.

Special thanks to Aaron for the loan of his engine crane,
Maaaargghhhk! for his valve spring compressor,
Sabredylan (from the D2 Boys Club) for his fancy torque wrench, ring compressors and flex hone.
JamesMartin for phone support :D

I'm really chuffed that I managed to get it done :)
Click to expand...

fair play mate, this thread is epicly good, been reading the last 3 nights just watched the start video, better than eastenders lol
thumbs upto you:clap2:
 
Ha cheers fella.

Feels like Eastenders, there's always another drama!

New (genuine) top hose arriving today.

Some Roose Motorsport boost hoses and a new EGR delete with welded on boost nipple arriving early next.
 
Bennehboy said:
Ha cheers fella.

Feels like Eastenders, there's always another drama!

New (genuine) top hose arriving today.

Some Roose Motorsport boost hoses and a new EGR delete with welded on boost nipple arriving early next.
Click to expand...

yeah u do have a few dramas lol, thats y were all glued to this thread! which must become a sticky best all round d2 guide going!
 
Soooo, still got coolant level dropping despite rebuilding the engine with all genuine parts, replacing all hoses with genuine, and rebuilding the oil cooler.

I'm pretty confidant that the head is goosed, what I don't understand is how I can get coolant in the oil but not oil in the coolant...

So, I'm just about to push the button on buying a used known good AMC head off someone I trust on another forum.

Should be a raft of pics in the not too distant future.
 
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