Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
twoakers - D3 HSE TDV6 HSE 2007
In the 2 years or so I have loads of maintenance and mods on my second Disco3 8)
Have received loads of help and advice from Forum members
So I thought would have to start listed the stuff so that others can benefit from my experiences :roll laugh:Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
2nd Nov 2014 8:44 am
twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
TURBO change time
On Sat 1 November 2014 started the job I have been putting off for a few weeks now,
knowing it would take at least 2 days of blood, sweat and tears
Yep - time to changing my sticking actuator turbo 8)
New Borg Warner Turbo with fittings and gaskets on the bench waiting in the wings
Together with a nice shiny Terrafirma De Cat pipe and nice new Blue Silicone Turbo pipes
Been doing the wiggly wire thing with WD40 for a few months now to keep the old one going
Spent the remainder of today over my pit trying to get at the damn turbo
So far have got exhaust system off ready to get access to the old turbo......
.....as usual snags held up progress
1. Seized bolts on gearbox crossmember - worked back and forth with impact gun and WD40
2. Seriously seized 3 nuts on back of turbo - chiselled off with long sharp chisel and/or worked with WD40 and 15mm and/or 14mm hex sockets and ratchet spanners
3. Old front pipe seized into rear section - brute force and WD40 did the trick
All this took extra time but at least my son-in-law was there to give moral support and help...
....especially brewing the numbers cups of tea
More fun tomorrow......Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
2nd Nov 2014 8:47 am
twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
and here is the parts waiting to be fitted:
nice new turbo - actuator is so free you can hear the turbo vanes
New Terrafirma decat pipe versus the old heavy cat thingy
Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
2nd Nov 2014 9:12 am
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
Now for the tricky bit! Best of luck as you need the hands of a 5yr old girl to get to some of the nuts
2nd Nov 2014 9:16 am
twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
Yes I know you are right
Wonder what my granddaughter is doing today
Why do I think that with other Sunday stuff that this will spill over into Monday Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
2nd Nov 2014 9:26 am
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
Better make sure she's nowhere within earshot as you will go through the entire alphabet of expletives and may add a few to it! Got to be one of the worst jobs on a D3 IIRC a 13mm spanner bent at 90degrees helps
2nd Nov 2014 9:43 am
twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
We have an old 13mm ready to heat up and bend
Quick question - the new turbo would appear to simply bolt onto the manifold with no gasket
Is this correct or should some sealer be used ?Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
2nd Nov 2014 11:09 am
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
Sorry was away for a bit No gasket on turbo to manifold, no sealant either
2nd Nov 2014 2:03 pm
twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
Thanks
Will use 'copper slip' on the studs and nuts etc.
Hopefully will have a chance of undoing 'em if have to do it again.... Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
2nd Nov 2014 2:20 pm
twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
Turbo Change - Completed
At last I have finished changing the turbo without taking off the body
It was to say the least difficult
As you can see below I do not have the hands of a 5 year old girl
Road test completed and the old Disco once again drives like new
No more waiting for the sticking actuator to move as you accelerate onto a roundabout
The power delivery is once again smooth and progressive.
The Terrafirma de-cat pipe give the exhaust note a nice deep growl together with a nice satisfying whine as the turbo spools up 8)Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
5th Nov 2014 6:57 pm
Bradders
Member Since: 21 Oct 2014
Location: Ashford, Kent
Posts: 126
Hi twoakers
Did your disco bring up the fault code P132B? Is that why you replaced the entire turbo unit? Mines showing that code and I'm not sure of my options, I've only had the car 4 days and it's already going wrong
Cheers
Brad
5th Nov 2014 10:29 pm
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
Twoakers - well done! welcome to the 'club' is that a smile or a grimace??
Bradders - what symptoms are you getting? a sticking actuator usually throws up an ESF on the dash
5th Nov 2014 10:37 pm
Bradders
Member Since: 21 Oct 2014
Location: Ashford, Kent
Posts: 126
No symptoms at all. Pulls like a train as it should away from lights or roundabouts, no smoke either. Im getting the code cleared tomorrow to see if it's been fixed but not cleared. Fingers crossed
5th Nov 2014 10:50 pm
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
Sounds like its just in the memory then, if the car is driving OK the fault code may have been stored and as you say not cleared after a repair, there is an outside chance that a sticking actuator has been freed off and may return, but you just got the car so lets look on the bright side
5th Nov 2014 10:55 pm
twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
Bradders wrote:
Hi twoakers
Did your disco bring up the fault code P132B? Is that why you replaced the entire turbo unit? Mines showing that code and I'm not sure of my options, I've only had the car 4 days and it's already going wrong
Cheers
Brad
Hi Brad, yes every few weeks it would throw up an EML and DTC P132B
Could fix it by freeing off the seized turbo actuator and clearing the DTC
Some members have been lucky by using additives or turbo cleaner etc
As a new owner don't let a little thing like this put you off
Good luck 8)Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
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Best of luck as you need the hands of a 5yr old girl to get to some of the nuts 
difficult
8)
