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My Discovery 3 06. EST
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Jann448
 


Member Since: 29 Sep 2017
Location: Tallinn
Posts: 23

Estonia 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3
My Discovery 3 06. EST

Hy to all from Estonia.

So i bought myself my first disco 3 and LR. 8)
Having read through most of the forum and knowing all the tricks and hidden surprises. I still thought "why not". Becaus I needed a large, comfortable and practical machine ( We like to travel a lot and see places where there are not always regular roads).
The machine had seen some life before me, but nothing seemed crazy or impossible to fix.
There were some color defects, from stone stubs and years of use. Originally everything on it worked, except parking sensors.
All was good and life was beautiful Whistle
Until one day I began to notice tiny inconsistencies, starting was longer than it should ( it was geting a bit colder outside 2-3dec.). The right front corner sank, more than i liked. Did not want to switch to the sixth gear on road and some other minor things.
Then I checked the car in the local garage. To see what errors are coming out and so on.

and then "THE LIST" started... and my life got a bit more ineresting.
Not much came out with diagnostic but it started the story which I am going to tell you now.

So, the to do list:

All glow plugs
All filters
All oils plus other fluids
All bushes and rods
Brake maintenance plus rear brake pipes and hoses
Underside of the body ( rust and all other thing)
EGR blank

does not look much.. so lets get started.

First thing in ordes was glow plugs Evil or Very Mad
because I knew that it would be difficult for them and for me ( having read all these posts) Smile
But i didnt end up too bad. At least thats what i thought. 4 out of 6 and 2 broken. one above the thread and one below. It was still all doable or was it Evil or Very Mad




It seems that my old phone have failed me and lost all photos. Censored
But here is how she looks right now:





Ok so, gona remove the two plugs by drilling them. Of course, but one of them is hidden under the inlet manifold LHS. New plan.. removing the manifold...not so fast. Injectors as well.
The first two came out beautifully but the last one ( next to fire wall) it did not even move an inch.
I tried everything I got. I even ordered a special tool to removing it, but it broke Censored .

So what next. But of course it's related to "BODY OFF JOB" Thumbs Up








Some time later... about 4-5 h (my first time, next one will be half of that)



So the injector right. It was so stuck that it did not come off even whit that big hammer ( big black thingy in last picture).
There was a reason for that. The injector was literally rusted shut. I think someone may have had the engine washed or something like that.
But it had to come out! RIGHT, to the big guns...
I welded a large nut on top of the injector so that I could use a large air gun.
It took about 10-15 minutes of forward and backward shaking/turning until it gave in and started moving. Another 10 minutes of hammering with spetcial tool and there it was.

Here s some pictures:







Everything out of the way. I finally got to the glow plugs. This was only time when I used specialist help to remove 1 of the plugs (first one i got myself out) because he had tools i did not.
All new plugs in so the next thing was to check the exhaust cross over pipe.
They tend to rust and cause problems. Like i have read from this forum it s a hassle to do if the body is on.









Some cutting and welding time later:













Added a new heat resistant tape to keep things around it cooler. Original was a double wall pipe so i tried to keep it that way as much as possible. By welding the inner one to the outer so it would stay there. I think this system is to disperse the exhaust gases heat a bit better than just a normal one wall pipe would too.






To be continued! Arrow
 

Last edited by Jann448 on 11th Jan 2018 8:07 am. Edited 2 times in total 
Post #18988948th Jan 2018 8:23 am
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Jann448
 


Member Since: 29 Sep 2017
Location: Tallinn
Posts: 23

Estonia 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

All that done i moved to the under body and brake pipes.
Nothing special to talk about that. Just lots of grinding, cutting, painting and some more...

Before:













After:







  
Post #18993759th Jan 2018 7:13 pm
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TC179
 


Member Since: 19 Aug 2014
Location: uk
Posts: 145

England 

So, more or less a total re-build then! What do you do in your spare time?!
Looking good!
  
Post #18993839th Jan 2018 7:24 pm
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Jann448
 


Member Since: 29 Sep 2017
Location: Tallinn
Posts: 23

Estonia 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Thanks!
This is my spare time (right now most of it at least) Very Happy not that my other side is very happy with it Rolling Eyes . In everiday life im a sales guy ( car parts and so on).

Im a perfectionist when it comes to fixing or building my own things Whistle

Because it all started with just some tiny seconds more starting time than i liked.
Then i let it checked and glow plugs where all gone (2 out of 6 where working).

And so it went... just could not look away from all that other stuff that needed some care as well.
  
Post #189955210th Jan 2018 7:25 am
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lynalldiscovery
 


Member Since: 22 Dec 2009
Location: Maidstone
Posts: 7274

United Kingdom 2006 Discovery 3 TDV6 Metropolis LE Auto Bonatti GreyDiscovery 3

As the D3s age I can see cill rot being a big issue.
  
Post #189955310th Jan 2018 7:31 am
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Bunn
 


Member Since: 02 Jan 2018
Location: Near Berkeley, South Gloucestershire
Posts: 20

United Kingdom 2009 Discovery 3 TDV6 SE Auto Stornoway GreyDiscovery 3

Given that I know nothing about mechanics, and your rather comical writing style (love it!), this is really interesting! Keep it coming!

Photos alongside a commentary of what you're doing really gives me an understanding of what the various parts I'm ready about actually look like and how they function...

Cheers!
  
Post #189955410th Jan 2018 7:32 am
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Jann448
 


Member Since: 29 Sep 2017
Location: Tallinn
Posts: 23

Estonia 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

All body and brakes done.
Moved on to the back end ( all bushings and rods).

Man it was a piece of a ... to do. All was rusted so shut and all the bolts where rusted shut.
Luckily i had my good friend Power Cutter to cut that crap out.

It was not easy with all the old bushing as well.














Nothing more special about it actually. Just lots of hours of work.

Dont have the pictures but i made a new eccentric bolt on the RHS. Did not have time to wait a new one.
And all other necessary bolts i bought from special store ( special strengthened bolts and all).
 

Last edited by Jann448 on 10th Jan 2018 9:54 am. Edited 1 time in total 
Post #189958110th Jan 2018 8:36 am
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OJ
 


Member Since: 01 Oct 2017
Location: Loch Leven
Posts: 725

Scotland 

Great job Jann, nice workshop and tools, thank you for sharing your story
Thumbs Up
OJ
  
Post #189958710th Jan 2018 9:01 am
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Jann448
 


Member Since: 29 Sep 2017
Location: Tallinn
Posts: 23

Estonia 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Thanks for that. I have no idea if im going to tell my other side that if all of that is done. There is so many upgrades i want to do as well.

Side rails
Roof rack
winch
BF AT or something similar
The newer NAV system ( 2010-2012 one i think it was)
Maybe newer lights
CB radio
LED working light back and front.

Definitely a smaller bank robbery Laughing after all of that and fixing the main things.
  
Post #189960510th Jan 2018 9:54 am
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sweetpea54321
 


Member Since: 23 Nov 2015
Location: Bolton
Posts: 212

England 2005 Discovery 3 TDV6 S Manual Zambezi SilverDiscovery 3

Good effort Jann..... I'm impressed its looking to be a very professional job - keep up the good work

SP Thumbs Up
 Mods so far:

New wheel winch
Instrument upgrade (clock on dash)
D4 fascia + Garmin nuvi
LED side light, interior etc
New FL2 rear wheel arch seals
Parrot MKi9200 hands free kit 
 
Post #189962310th Jan 2018 10:28 am
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OJ
 


Member Since: 01 Oct 2017
Location: Loch Leven
Posts: 725

Scotland 

Jann448 wrote:
Thanks for that. I have no idea if im going to tell my other side that if all of that is done. There is so many upgrades i want to do as well.

Side rails
Roof rack
winch
BF AT or something similar
The newer NAV system ( 2010-2012 one i think it was)
Maybe newer lights
CB radio
LED working light back and front.

Definitely a smaller bank robbery Laughing after all of that and fixing the main things.


Don’t tell her everything, if you do she’ll work on you to get something for herself to the same value Rolling with laughter
  
Post #189970110th Jan 2018 2:41 pm
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Jann448
 


Member Since: 29 Sep 2017
Location: Tallinn
Posts: 23

Estonia 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

In the mean time i have done and took care of some other smaller and bigger problems.

Here s some air suspension relief valve Blocks:









Just checked them and cleaned.
Parking brake system was also checked and lubricated.

New key fobs bought and replaced:



Of course i all ready did that little Censored of wire as well ( LHS green and not doing what it should do) Censored and of course it did not happen a day after i bought the car Evil or Very Mad

One day i thought that im gonna check the FRH air suspension. Because it was doing funny thing i did not like.
Some times it tried to bow to "someone" too much ( overnight or so it was lower than others).
I even checked it in specialist shop with diagnostics and all. But nothing, they said it was normal.
Not for me thou, we will not bow for no one. OK maybe to significant other Bow down Mr. Green

So checking it i discovered that it was leaking between suspension shaft and upper suspension bushing
there:



and this came out of it:



replaced it with new O-rings and luckily i was able to change the broken green plastic(between the two O-rings) with soft copper washer. Of course, I hope it works. Will let you know !


Ye found another crazy washer duds fault as well. Evil or Very Mad
This is how my transmission control module looked:






Luckily it was just the pins that where oxidized. A bit of cleaning and filing and it should be all good now.

Just some stuff that is all ready in and some waiting its right time:








  
Post #189971510th Jan 2018 3:30 pm
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Jann448
 


Member Since: 29 Sep 2017
Location: Tallinn
Posts: 23

Estonia 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

All front end done now as well.







Plus pump belt and tensioner



So now it slowly is getting back together:

Some wires got new cover (the plastic and old tape was worn and broken).
All injectors got cleaned and new washers.
EGR planking part was done. So it would look like it s original.
New filter went in.

Had some problems when changing lower swing arms. The bolts where quite stuck like allot.
But no no i did not cut them off. I needed them. So lots of banging lubing and power hammering later i got them out Thumbs Up





Gonna thank in advance all the forum members. For making this job so much easier and bearable.

Keep those awesome post coming Thumbs Up Bow down

TBC
  
Post #190171015th Jan 2018 7:52 am
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Pip66
 


Member Since: 26 Sep 2016
Location: Ely.
Posts: 170

United Kingdom 2008 Discovery 3 TDV6 HSE Auto Tangiers OrangeDiscovery 3

Wow, thoroughly enjoyed reading through this. Please keep it coming. Thumbs Up
 2008 G4 D3 vehicle No 11. UK selections.
2003 G4 D2 vehicle No 125. South African workshop car. 
 
Post #190175515th Jan 2018 10:20 am
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Triplet3
 


Member Since: 26 Nov 2016
Location: Southampton
Posts: 320

England 2007 Discovery 3 TDV6 GS Manual Arctic FrostDiscovery 3

Good work Thumbs Up keep it going!
 1995 Discovery 1 300TDI
2006 Discovery 3 TDV6 - Gone
1979 Series 3 109" - Gone 
 
Post #190176415th Jan 2018 11:01 am
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