My D3 Project

[gstuart]

@Big Sandy , would it be possible plse to change the title to “ My D3 project “. Plse

Hope that’s ok and u didn’t mind me asking , just thought then I can post everything in one place,

Many thks as always

Ps, hopefully it will also help others in the future

 

[gstuart]

@Big Sandy

Am after a massive favour pretty plse with a cherry on top

Is there a way if this can be incorporated into my other thread please , the D3 gauge panel one , so everything is in one place

Apologises being a pain ,many thank as always

 

[Big Sandy]

No worries @gstuart, that's done.

 

[gstuart]

No worries @gstuart, that's done.

Perfect , thank u kind sir

Did u like the test rig ,as I think I need to get out more lol

 

[Big Sandy]

It's waaay over my head (some would say it's a vacuum in there too...) but I think that's impressive, shows what you can do if you put your mind to it.

 

[gstuart]

It's waaay over my head (some would say it's a vacuum in there too...) but I think that's impressive, shows what you can do if you put your mind to it.

Shucks , ur have me believe I know what I’m doing next , lol

Think a lot of the knowledge is from my boiler days when I had to find gas leaks etc, making up rigs so could isolate different sections , etc

Once I start testing will post up some more piccies ,

Thks again

 

[gstuart]

Bonnet letters now removed , found using a rubber wheel got the sticky backing off very easily , along with some compound to help clean the edges off

Think I’ve got to go over it again and the sun was right over top

Don’t know what peeps think

The scuttle panel and A trim pillars I painted am pleased with

Finally got round to cleaning the windows properly , used some window cleaner and Stanley blade , has helped a lot with them not sticking anymore

Found a trim had come loose , think that might have been a slight whistle noise I heard in the motorway , just tapped it back properly

Got to sort out the fading door handles at some strange , might use a hobbyist spray gun to do them

 

[gstuart]

Gave the interior a good clean , also finished fitting the puddle light properly , needing a very fine sand to get it to fit just right

 

[gstuart]

As a side note this is what the engines look like when there out the vehicles

The small belt at the rear is the one that a lot of garages have issues with and insists the body needs to come off, which isn’t true , watched the rear belt being replaced by a skilled mechanic in less than an hour , it’s the fuel pump belt and that one isn’t timed ,however it is timed on the D4

So wished to give a heads up the body doesn’t need to come off, if a garage tells u otherwise there telling u porkies

 

[gstuart]

Also meant to add, the D3 2.7 turbo can also be replaced without removing the body , not easily but can be done

 

[Guitar Mick]

Juesss ......... that's a lot of plumbing

 

[gstuart]

Juesss ......... that's a lot of plumbing

Indeed , it was good fun when I cleaned and blanked my egrs , left the egr pipes on and blanks are hidden for mot
purposes

 

[gstuart]

Also very fiddly when I installed a twin battery setup , there very power hungry , last about a month of not used

Plug mine into a ctek on my drive, installed a charging point on the front of the house and changer in hallway

 

[gstuart]

So tested the aircon today to try and find the leak, put 40psi in the system, nothing didn’t drop at all

Couldn’t get to the back of the condensor so will have to remove air inlet ducting etc to test it

Sprayed nearly every ac joint with soapy water

Might be a different story when I put it under vacuum

Tested the rig first in some water, there were a few leaks which were easily resolved

Do have a new condensor but prefer to find the leak before removing the old one

 

[gstuart]

Also removed the passengers side headlight , can see some condensation inside

On the back of the headlight there’s 3 x tube holes that are blanked so thinking of drilling the holes and installing some tubing on the back to help with the condensation

 

[gstuart]

Gotcha , found the ac leak , is between the condensor and cooling rad

Can just see the bubbles, so new condensor it is, Have one already

Needed to prove to myself 100% what was at fault

That’s saved a good few hundred quid of what garages were quoting me to look for the leak

Happy days

 

[gstuart]

Also tried My ultraviolet torch, can just see the soapy bubbles

 

[gstuart]

Well this is far as I’ve got

, can’t get those large T40 torx to budge , have soaked them in plus gas and will leave them over night

Any tips please apart from cutting them off with a dremel plse

 

[gstuart]

So the torx 40 is now knackered , do have an impact gun that’s 240 v / 450 nm

Wondering if that may help

The threads do protrude about 1/2 inch through so wondering if I can get a dremel on the 6 x torx bolts to clean the threads to aid there removal

Just taken a step back to try and work out what the best course of action is , got to now hunt for another torx bit

Any ideas please , pretty plse with a cherry on top, lol

 

[Colin Swan]

If you have room give the head of the Torx bolt a good couple of wacks then try to tighten slightly, then try to loosen, you might need to do it a few times, that is the method I was taught way back in the 60s, failing that a bit of heat if nothing flammable in the vicinity, and of course a good quality torx bit. Colin