Diablo

The time has come for an overhaul I feel. My filler on the 90 is the old school 2 prong cap, attaching to the filler with a cork seal. The cap has never been in the best condition and now the cork seal has finally given up the ghost. Offroading now tends to leave a bit of diesel down the side of the truck - not good for a whole host of reasons. It would be better, I feel, if I could replace the whole lot with a newer filler - ie one with a locking cap and better seal arrangement. Has anyone done this before, or what are people's suggestions (I can only presume that a newer tdi set-up will fit in the gap and into the tank?)

I only do it because my boss makes me! And I definitely don't get £500 a day. Luckily I only have about 6 audits a year, but that's 6 too many for me

Trust me, auditing is never the job you want! It is beyond tedious.

I know you've checked about, but double check the back of the rocker cover gasket?

Mine's cork. and a semi knackered one at that too! Still works though.

In order to paint it you need to use T wash, followed by etch primer, followed by the paint Or do what I did, and buy a product for Vinylast - made by Rourkes I think. It goes straight onto the galv. 2.5 years later it still looks as good as new (underneath the filth anyway!) and no mucking about with t wash or primers

As has been said before, the 'ultimate' set up is as follows: vibration damper (eg Silent Coat, Dynamat) - only needs 25% coverage to dampen vibrations - although many people cover nearer 100%. followed by a layer of closed cell foam (separates the damper layer and the MLV) Then lastly Mass Loaded Vinyl - dense stuff that in effect blocks sound.

I've heard of people spotting rust upon delivery from the dealer

I like the way the doors open, not sure about the general styling at all though

Turner Engineering supply rebuilt engines in exhange for another. Will need a few bob though.

I've had a 200 for nearly 8 years and never had a problem with any parts whatsoever.

Right so almost a week later and the results so far: bonnet: A very slight misting, which I imagine is residual. The catch tank has a bit of oil in - but not as much as I thought that there might have been. Have just put a set of silicon hoses on in place of the rubber intercooler ones (which were very squidgy), so we shall we what happens next Will probably leave the catch tank in situ for another week or so.

Lift pump is probably a worthwhile change if you haven't changed it for a number of years. Pretty cheap too (over here anyway) If not that it could be something more irritating like a leak in a fuel pipe letting air in.

It wasn't continuous no, as you mention puffed in and out - I wasn't really looking for the in though. As the revs built up, it dropped noticeably to not much in or out.

Bought a new seperator (Genuine) a couple of months ago. Pics on page one - no valve as such, just a spring. And yes, the only intended vent is via the seperator to the air inlet, downstream of the filter. There are unintended vents at the oil filler cap and the rocker gasket though!

Right, a quick measurement with a bit of rope gives me about 290mm - will do a more precise measurement at the weekend, but doesn't appear to be drastically out. Out of interest is a new one a 'fit and forget' with regards to setting any height? Regarding the breather hose, at idle there is are steady, regular puffs of air - at the strength of a light blow onto your hand. Not a continuous blow, but a cyclical one - about 3 puffs every 2 seconds. With a rev increase this drops away but is still detectable.

Yes, but on step 2 specfically where it mentions measurements, it only measures from that bracket, which isn't present on Defenders. I'll compare mine to your 295mm

http://forums.lr4x4.com/index.php?showtopic=7947 that? Doesn't seem to specify the exact details for Defender dipsticks though? (step 2)

this one: http://forums.lr4x4.com/index.php?showtopic=45031 where western states it should be 295mm? Pretty sure that was what I set mine upas but, again, will double check.

I don't get that either ejparrott, tended to ignore it. Regarding dipstick - it is possible that it is incorrect. It was the original that went into the new engine. will hunt the topic out.

Ah, I got the implication it had started since that. Could try adjusting the acc cable to give a bit more fueling at nil throttle.

did you bleed the fuel filter correctly?

I understand there is normally an amount - it's just a lot more than my last engine, hence the concern, particularly when doing lots of motorway miles when the consumption seems to jump. Regarding the air pumping out - I presume you mean at idle? I shall test tonight. Have just ordered some new hoses, so that's that problem 1/2 fixed.

Not sure about exact consumption, have never truly measured it. It depends on the style of driving I do: eg usual weekday commuting will use what you saw in my recent photos - allowing for an amount to not be squirted out (ie goes through the engine and burnt off) - I would guess 100ml a week - approx 150mls. So1/2 to 3/4 a litre / 1000 miles. However, if I'm doing a reasonable motorway drive it will dump a lot more, hence the comment regarding the high consumption. that day I had been to birmingham and back - something like 300 miles, and when I checked the dip stick it was on low, whereas I normally keep it between normal and high. As for amounts of oil, not sure. that's perhaps where the confusion has crept in. Either way, it's much higher than it should be, in my book.

A little while back and they suggested that slightly incorrect fueling could be the problem, but I don't think they got the jist of how much oil was coming out - and I wanted to rule out the turbo first.