gstuart · Jan 24, 2022

So removed the throttle body, made a test rig up and put a few Psi in , using some soapy water i sure enough found some air leaks just round the seals where the Egr stumps meet the throttle body

Going to take them apart again in the week , plus will be interesting to see if it has any effect on the turbo seeing it currently wont hold any air what so ever , will then do another pressure to ensure there 100% sound

fingers crossed that’s some of my boost issues , alas know it’s abit of any over kill making up a rig but just want to be 100% sure

gstuart · Jan 25, 2022

So taken them apart and resealed them once again, will leave it alone to allow the sealant to set , plus wider clamps which I’m hoping will also help secure the inlet pipe to the turbo better than before

hope u found the rig I made up interesting and fingers crossed will help other in the future, new small spanners turned up as I’ll need them to get a few nuts and bolts back in

gstuart · Jan 26, 2022

So using the test rig once again , retested the egr stub pipes , all now ok , so at least that’s one thing sorted , will be interesting to see how the turbo is after all this work

talk about opening a can of worms, lol, but to be honest a lot of that is my own fault as I asked myself, let’s check this and that whilst things were out

so my next plans are to get all the air intake and intercooler pipes back, all new stainless steel clamps, then I’ll get it back onto its wheels which in turn will also make life easier reaching the ECM and TCM connections, then I want to ensure all the sensor 5Vdc signal reference feed are all correct , it would just bug me in doing all of this and not checking them

looking forward to see how the turbo comes in this time ,seeing all the air leaks will have been omitted , useto start coming in around 2- 2,500 revs , plus the air leaks must have been there for months

These were the errors I originally got , fingers crossed by sorting out those Egr stubs it’s cured the P0402 regarding the excessive flow DTC

Engine TDV6
P120F-00 (28) Fuel pressure regulator excessive variation
P0402-00 (68) Exhaust gas recirculation flow excessive detected
P0046-00 (28) Turbo/supercharger boost control solenoid - circuit range/
performance

also been advised with air leaks at the throttle body it can also affect the Maf sensor

will update as I progress , apologises it’s been so long winded , just takes me time in being able to only do a few hours each time before my back decides it’s had enough

thks again

gstuart · Jan 27, 2022

So thought I would address the top bolt that secures the air inlet pipe onto the upper rad cowl , where the plastic thread keeps stripping

I drilled a M6 hole, used a 30mm long bolt, then washer and locknut , loosely placing a M6 flanged nut and penny washer on top for the air inlet pipe to be secured with

Finally using my glue gun on the back as an extra precaution to prevent the bolt from turning

Hope this may also be useful to anyone

gstuart · Jan 27, 2022

Also ordered some conduit due to the existing just crumbling when touched along with a gas soldering iron to save me messing around with an extension lead , got to sort out the iAT sensor connector

Spong · Jan 27, 2022

gstuart said:
ordered some conduit due to the existing just crumbling when touched

Hi Gary, looks like the same style conduit that's falling to bits on my D2 - where did you get your new stuff from?
BTW, a belated happy birthday for the other day!

gstuart · Jan 28, 2022

Spong said:
Hi Gary, looks like the same style conduit that's falling to bits on my D2 - where did you get your new stuff from?
BTW, a belated happy birthday for the other day!

many thks some the kind wishes

got the conduit from here , they do all different sizes, split on non split, hope that helps

https://www.ebay.co.uk/itm/362724035426

tyregeezer · Jan 28, 2022

Hi great pictures and info power driver top of my wish list. you are right to take your time and do everything spot on, its such a pain to miss something and go backwards. parts removed look clean and ready to go back together. pipes are awkward and as you said leads to removing something else (as usual) good luck your almost at the point where its all going back together TY

gstuart · Jan 28, 2022

tyregeezer said:
Hi great pictures and info power driver top of my wish list. you are right to take your time and do everything spot on, its such a pain to miss something and go backwards. parts removed look clean and ready to go back together. pipes are awkward and as you said leads to removing something else (as usual) good luck your almost at the point where its all going back together TY

thks so much mate , sorry what did u mean by “ power driver “ did u mean the ratchet driver plse , sorry for the confusion

must admit found it a lot easier doing up the egr pipe clips like this , ( learnt after removing them multiple times )

Put some clear silicone grease on the rubber seals
Leave the throttle body loose
unbolt the EGR pipe clamps from the engine
do up the pipe clips on the egr stubs ,
then push the throttle body into place and bolt up
Bolt up the engines egr pipe clamps

hope that may help later on

Must admit have gone over everything in detail as indeed i hope by doing so will sort out the issues , seriously not looking forward trying to get the air inlet pipe that fixes onto the turbo and the other turbo intercooler pipe back on

the short intercooler pipe that fits onto the turbo I’ve bought a new silicone one along with some wide T bolt clamps , replacing the thinner old jubilee clips , fingers crossed they will clamp the ends down properly and not allowing any air to escape

Did find air leaks on both egr pipes , ends of the intercooler hoses and on the turbo itself , At the end of the day really looking forward when it’s all refitted , mainly to see how the turbo is , must have had these air leaks for ages , then got to the stage where the error came up

Most of all found it very interesting that when u get a leak at those egr stubs on the throttle body that air is sucked away from the Maf sensor , therefore causes more fuel to be dumped into the engine , think I’ve got that right , lol

plus down the road I might fit a bigger intercooler , think they call it a RS500 but some of them are silly money , ie £500 +

almost forget , got an idea with regards to the egr pipe clamps to ensure they can’t come u done , will see if it works first, will then put a picture up here for u

thks again and always great on getting feedback as might have missed something or better way of doing something etc

hope ur project is also progressing well

thks again

tyregeezer · Jan 30, 2022

Hi gstuart yes nice ratchet i didnt know about those terminal cleaners either, Great question though

really tricky to get photos of much use, i have only had twist on type up to now i remove the fuel pipes at the point they turn to metal you have also made me ask questions as my pipes are marked blue and white and new filter yellow and red also has two arrows hard to see in pic will find out about. The two large pipes are supply from tank marked yellow and high pressure pump supply marked blue the two small connecters are cooler return marked white and vent pipe also marked blue (all on connectors) i think this is right check though. very tricky to see will work it out for future reference when motors out will get pic of top for you (learning every day myself) i am sure someone has the answer on here i have a few days off so hopefully will make some progress and can take more pics great work by the way i am sure your going to notice a big difference sorry answer later than said has been a slow start today it was minus 5 in shed this morning TY

gstuart · Jan 30, 2022

tyregeezer said:
Hi gstuart yes nice ratchet i didnt know about those terminal cleaners either, Great question thoughView attachment 257945 View attachment 257946 really tricky to get photos of much use, i have only had twist on type up to now i remove the fuel pipes at the point they turn to metal you have also made me ask questions as my pipes are marked blue and white and new filter yellow and red also has two arrows hard to see in pic will find out about. The two large pipes are supply from tank marked yellow and high pressure pump supply marked blue the two small connecters are cooler return marked white and vent pipe also marked blue (all on connectors) i think this is right check though. very tricky to see will work it out for future reference when motors out will get pic of top for you (learning every day myself) i am sure someone has the answer on here i have a few days off so hopefully will make some progress and can take more pics great work by the way i am sure your going to notice a big difference sorry answer later than said has been a slow start today it was minus 5 in shed this morning TY

bless u and very grateful, indeed if that’s ok to wait until u get the engine out please

I managed to take a very rough picture through the wheelarch but know it’s difficult , the reason being as I had a service done a little while ago wished to double check the connections were correct , trust the garage but didn’t want to miss anything

thks again and great things like the terminal cleaners etc have been useful , another reason I really like the forum where we can share ideas etc

hope things are going well for u and thks again , plus enclosed my picture as a comparison next to urs

alas I’ve not been able to do anything as my back has gone again , Christ knows when I’ll be able to start getting the bits back on my landy , so annoying

gstuart · Jan 30, 2022

Also found this which I hope is useful

gstuart · Jan 30, 2022

Just looking at the pictures im not so sure the pipes are correct on mine , assume it’s best to remove the wheel to gain better access to the filter

would anyone else be so kind to have a look plse to see what u think

many thks

tyregeezer · Jan 30, 2022

yes from what i can see looks the same its in a tricky spot i am going to have a better look when engine is out, and will change will be easier will take a photo as well. Thanks for diagram can work it out from that tank supply is 1 yellow (arrowed in), 2 is fuel cooler return white, high pressure pump is 3 (arrowed out) blue, and vent is 4 also blue small one please check out though let me know, its just a question of getting access and your eyes on it like everything else on d3 keep the faith TY

gstuart · Jan 30, 2022

tyregeezer said:
yes from what i can see looks the same its in a tricky spot i am going to have a better look when engine is out, and will change will be easier will take a photo as well. Thanks for diagram can work it out from that tank supply is 1 yellow (arrowed in), 2 is fuel cooler return white, high pressure pump is 3 (arrowed out) blue, and vent is 4 also blue small one please check out though let me know, its just a question of getting access and your eyes on it like everything else on d3 keep the faith TY

bless u and so grateful, thks for the input names as that’s also very helpful

ur so right in trying to get a picture of it, that would be brilliant if u didn’t mind taking a few pics when the engine comes out plse

Are u waiting for warmer weather before u take the engine out plse or waiting for extra help seeing that engine is extremely heavy

looking forward for when u do some more and following with interest

thks again

tyregeezer · Jan 30, 2022

Well the blacksmith is holding me up making a mk2 engine cradle for me it clamps onto factory lifting points it reaches under the scuttle (i think its called) and allows to lift up with out bending or stressing lifting points it attaches to my hoist will take pics hoist and lifting rig are rated at 800kg well over the top but its going to be tight with gearbox for space but apart from that is ready to lift out have another a 09 to get in (going to keep) I think has broke its front cam chain so will have one totally apart and one slightly less apart (hopefully) so if you need anymore pictures let me know TY

gstuart · Jan 31, 2022

tyregeezer said:
Well the blacksmith is holding me up making a mk2 engine cradle for me it clamps onto factory lifting points it reaches under the scuttle (i think its called) and allows to lift up with out bending or stressing lifting points it attaches to my hoist will take pics hoist and lifting rig are rated at 800kg well over the top but its going to be tight with gearbox for space but apart from that is ready to lift out have another a 09 to get in (going to keep) I think has broke its front cam chain so will have one totally apart and one slightly less apart (hopefully) so if you need anymore pictures let me know TY

that sounds an awesome bit of kit and yes plse if u would be so kind to share some piccies , many thks

also can u see if there’s an earth connector on one of ur engine mounts plse , think it’s the drivers side, know there hydraulic engine mounts

but indeed as I’m searching for this gremlin issue will also check all my earths, thks again

oh and have u seen this impact wrench before , produces 2440 Nm of torque , christ that’s some power and could u imagine if u tighten wheel nuts up by mistake ,

thks again and look forward to the progress and some piccies plse when the engine is out

gstuart · Jan 31, 2022

Also see they now do a 12Ah battery £192 and a 28 volt battery £261 , they’ve seriously moved on that’s for sure

Apologises I’m waffling again, lol

tyregeezer · Jan 31, 2022

Hi engine earth is on mount behind alternator there are other loom earths between the light and the air filter box on the body i am in workshop pics TY

gstuart · Jan 31, 2022

Bless u and thank u so much for sharing the pics, perfect as I now know where they are

Hope all goes well mate and can’t thk u enough

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