edwardbahaw

Tried them already, they don't have it! Anyone else!

Hi Guys Does anyone know of an online supplier of the 300 tdi discovery transmission (zf4hp22) governor valve. Regards Ed

Leon I would be able to report back the outcome by Sunday. Ed

We should complete the reassembly soon and should be able to start her up over the weekend. Would be reporting back on the outcome then!

This is a video of a 300tdi block with new standard pistons and liners fitted It shows that the pistons can move up/down and left/right in the bores! Would this lead to problems? These are the specs The bore diameter is 90.47mm The piston diameter is 90.395mm The ring gap clearance is 0.4mm

This is a video of the block with the pistons re-fitted. Even though standard pistons fitted and bore re-lined to standard specs, the pistons can still move in the bores! Would this lead to problems? These are the specs The bore diameter is 90.47mm The piston diameter is 90.395mm The ring gap clearance is 0.4mm

Guys I need some advice about this, AGAIN! We're finally at the re-assembly stage and noticed that when we fit the new ring (top compression ring) about halfway down the bore, there is a clearance of about 15 to 20 thousandth of inch at the gap (where the two ends of the ring meet. Can such a clearance be tolerated, or would it loose compression? Regards Ed

Very interesting! I will investigate! Thanks Jim!

I will most definitely use this technique to measure the protrusion Thanks Jim

Hi Guys There is a significant backlash from the transfer case in my disco when I shift from D to R. The serial number on the transfer box is 36D648124G. I checked the input gear and the coupling and they are in perfect shape as they are the update cross drilled ones. If there is no wear on these, can the backlash be due to worn intermediate gears or worn main gears? Or is there another component in there which is worn and responsible for the loud clunk? Regards Ed P.S. The transfer case has enough oil and there are no leaks If

Can you use ERR3339? http://www.turnerengineering.co.uk/acatalog/info_265.html http://www.paddockspares.com/pp/DISCOVERY_1/Engine_Parts/Fuel_injector_-_new_-_EGR_-_300TDI.html Seems identical to me?

Thanks so much Jim! The guy at the machine shop have worked on a couple of 300 tdis in the past and he said that he has done this before (3 thou skimmed from the block) I was checking here in the forum to make sure he was not bull****ting me! I also did some research as well. The one hole head gasket is 1.37mm The two hole head gasket is 1.48mm or 4 thousand of an inch thicker than the 1 hole The three hole head gasket is 1.48mm or 9 thousand of an inch thicker than the 1 hole Of course when the head bolts are torqued, this will compress it bit ... at least I think so! I'm thinking that the 3 hole should be appropriate. When the crankshaft and pistons are refitted I will see how far up the pistons come up on top of the block. I will also check to see if the head gasket would provide sufficient space to avoid the pistons from hitting the cylinder head or valves.

Thanks so much Jim! The guy at the machine shop have worked on a couple of 300 tdis in the past and he said that he has done this before (3 thou skimmed from the block) I was checking here in the forum to make sure he was not bull****ting me! I also did some research as well. The one hole head gasket is 1.37mm The two hole head gasket is 1.48mm or 4 thousand of an inch thicker than the 1 hole The three hole head gasket is 1.48mm or 9 thousand of an inch thicker than the 1 hole Of course when the head bolts are torqued, this will compress it bit ... at least I think so! I'm thinking that the 3 hole should be appropriate. When the crankshaft and pistons are refitted I will see how far up the pistons come up on top of the block. I will also check to see if the head gasket would provide sufficient space to avoid the pistons from hitting the cylinder head or valves.

Will skimming the block 3 thou from on top cause any problems such as the pistons hitting the valves? Anyone?

Hi Guys Just sending an update! I had the block bored and the new liners pressed in. The guy at the machine shop said he skimmed 3 thou from on top of the block. Will this cause any problems such as the pistons hitting the valves? Regards Ed

Just curious are the liners wet or dry?

Guys I realized I made an error on my initial post! I really meant to say about 1/4mm wear on the liners. Thanks for your suggestion Newbie I still have to take it to the machine shop. I'm thinking that re-boring and using +10 thou pistons might be appropriate for this level of wear. This is exactly the symptoms I had before I removed the head ... and is what I want to remedy Regards Edward

Also, not bragging here or anything ... but cost is not really a problem! I think because where I'm from labour is quite cheap! Plus I have been saving for this project for over 2 years!

Anyone out there who would second this! Are there any complications that can arise from re-boring and using bigger pistons? I take it that if the cc increase then I may have to increase fuel pressure and boost. Anyone with experience on this? Regards Ed

Hi Guys I have removed the cylinder head from my 300tdi in preparation for an engine rebuild. The cylinder liners are wore about 1 mm. Putting cost aside, what is the best option for this rebuild? Bigger pistons or replace liners? Regards Ed