Maverik

With this one - by mindful of how you plan to "tie" the center piece into the U channel - from a structural perspective it wont have much strength unless you fix it rather well at both ends.

I ran my truck on the VNT last year with the britpart rad and a VNT does run hot, and never had a problem with the Britpart rad. for the price you can replace it a good few times if you need too! - its a shame to have to revert to such logic in my opinion, but I was pretty much exactly where you are.

School day for me, I've not seen one like that before, thanks Daan.

300tdi is basically the same as a 200tdi, there's just a lip seal that's designed to keep dust/water from getting into the timing chest. Just not the same size - 300tdi crank shaft is bigger in diameter hence pulley and seals are bigger.

There was some good discussion on this very topic on here when LR announced the works V8 - just need to find the Thread.

Well I did definitely this last time, on initial installation I just remember wiping the pulley with some clean engine oil before installing. - I generally dont like to put to much grease on the inside of the timing case components at it inevitably gets spread around the timing chest. You know most oil seals come with a ring of lubricant pre-applied - I wonder if this might have been missing initially also. - but ultimately I think the seal wasn't seated far enough in due to the lip that was protruding.

After getting a quote for a Brass re-core - like above it was big money - the guy even said its probably not worth it - which I found a little odd. Anyway for the pricey sum of ~£90 I went for a Britpart Plastic/Alu unit. I know these had a bad reputation early on, but I've had a few fold who've been running them for a good while and they've not had a problems. I put one in last year and I've not exactly done huge miles on it it seems fine and does it job a hell of a lot better than a Brass rad less half its fins.

No just Viton I think. I reckon it was just on the hairy edge of not right as the noise only appeared when everything was nice and warmed through after a decent run, tough seal...?

Can't remember who I spoke to about this, the discussion went along the lines thatfull aluminium radiators if used hard they can be prone to cracking. - somthing to take into consideration.

😮 how had I never thought about where the exhaust of the vacuum pump goes.... jee whiz. School day indeed.

Still can't quite get my head around how it was making such a loud noise. Quite the (laborious) learning experience. Every day's a school day.

Had another thought, and this pictures confirms said thought... I had a couple of other oil seals sat in reserve and these are them. Brown looking one is a Gaco, the black one a Victor Reinz, the one I have in my truck is a Corteco type, which has a lip just like the Victor Reinz one. As you can see the Reinz seal the outer lip sticks out a good bit over the hard outer "base" of the seal just like the Corteco one I have installed. So there's obviously a couple of types of seal been offered for this job and the correct installation tool I used doesn't quite push the larger lipped seal far enough in.

Mk2 yes she's a bit sharper, but still both panels are awesome 👌 well done Sir.

Is the cost associated with a weeks repair or parts change? As fridge says there should be plenty of 2nd hand parts around.

Hmm interesting - during the normal aspiration combustion due to low engine speed, I'd not thought about that. 👍

Also worth using new bolts here too, they're the 12 point type and can be a pain to remove if they corrode just a little bit, if I go anywhere near my axle ends I replace the bolts out of habit, saves for headaches down the line.

So my thoughts: I fitted an ATB to the rear of the 90 in 2019, why? Not entirely sure other than curiosity and because i was looking for an "upgrade", I mainly drive tarmac roads and more recently the odd forestry track or grass field. What I wasn't really prepared for was how much nicer the truck handled on the road, especially in wet/wintery weather, its much more sure footed, meaning it feels much more controlled cornering. So impressed with the much nicer road handling I've ordered a 10 spline trutrac rediculously heavy duty build spec'd diff from Nige for the front which I'm planning to get fitted before winter comes in. Fun times 😁 quite the ATB fan.

A pain in the ass for sure but at least you've sorted it out. Not something you want playing on your mind.

Test drive number 2 and no untoward noises... 🤞

This could be the bearings in the tensioner pulley. There was a common fix for a chirping fan belt which was to put a penny in behind the tensioner itself. - but if this noise had just started I'd be looking for worn belt and duff tensioner bearings - I've also seen the water pump pulley have some small damage which caused this issue also.

The back end of the tank looks very close to the chassis, is it touching at all? With ~50 ltr of fuel in the tank it will settle down, try loosed the chassis bolts and it might settle a little lower too.

Kind words, thank you. She was becoming a fairly expensive garden ornament...

So on closer inspection of the pulley yesterday, I couldn't find the witness mark from the outer dust/lip seal on the pulley, but oddly enough, the corner of the pulley looked polished, more than I'd expected for this pretty "rough" machined pulley, which ties in with the last rational as to where the noise was coming from, ie the seal was engaged on a surface it didn't like nor was meant to be. So a word of warning for anyone using the correct tool below, it doesn't seam to allow the seal to be seated far enough in the housing if used. *this might all be pish if the noise comes back! If it does I'll update this.

That's brilliant! This hose is ESR 184, camel trophy 200tdi's need x2 usually for the hose that pops through the bonnet for the snorkel. They're like rocking horse poop to find and when they do They're not cheap. I was lucky enough to buy a box of old stock clearance when Mantec closed its doors back in 2019. A lot of these hoses have gone to refurb camel snorkels. Personally I like your idea! These do wear out and your idea is much more "sustainable". 😀

Ok test drive went well, got her nice and hot and out for a few hours, this is usually when the noise starts but this time, quiet as a mouse, not even a hint of a squeak... I'll need to do a few more runs before I'll be happy with it, its got my hopes up before.