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ESF got a sound like a dump valve too UPDATE FIXED!!!!!!!!!!
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timmyt79
 


Member Since: 18 Oct 2016
Location: Pemrokeshire
Posts: 585

Wales 2005 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

Just looking at the work you have already done... Did you think about checkibg/replacing the intercooler?
I had VERY similar issues and turned out there was a split in my intercooler... New upgraded Rs500 one sorted it out 👍 😍
  
Post #206238619th Jun 2019 3:47 pm
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Thanks for the reply Timmy I’m guessing it could be as it’s one of the only places left to leak, how hard is it to fit (or should I say) make fit the rs500 intercooler other than the in and outlet need adapting
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #206240619th Jun 2019 4:59 pm
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

No one got a clue ?
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #206247819th Jun 2019 9:19 pm
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Pete K
 


Member Since: 15 Jan 2016
Location: GL
Posts: 10335

England 2005 Discovery 3 TDV6 HSE Auto Rimini RedDiscovery 3

if the turbo actuator is stuck one end, that can cause dump valve noises. But if you are certain its free.....


I had a new turbo jam up in less than a year. All the black stuff in the exhaust
  
Post #206249519th Jun 2019 10:19 pm
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Hi Pete I’ve completely checked the push rod it’s free with no resistance, they even plugged their diagnostics machine in and drove the car around reading the data all came back good . Would a air leak throw up this code
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #206258220th Jun 2019 9:34 am
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timmyt79
 


Member Since: 18 Oct 2016
Location: Pemrokeshire
Posts: 585

Wales 2005 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

Did you get the PM's I sent you previously?
As I have said, easy to replace once you have number etc off and as the pictures I sent you show, it's a tight fit but it does fit!
Looking at your posts it seems you have exhausted a lot of potential issues so I would save yourself more heartache trying to theorise what it could be and just get on and replace it! And in reply to your last post.. YES an air leak can and does produce the symptoms/fault codes you describe.
Not one for throwing good money after bad but personally I would be bitting bullet and ordering a new intercooler 💰😔
  
Post #206259120th Jun 2019 10:30 am
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Thanks will bite the bullet and get one, anything I should be considering before I start this ?
Will be doing it at work in a fabrication workshop so can’t think of anything I may need
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #206260220th Jun 2019 11:18 am
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timmyt79
 


Member Since: 18 Oct 2016
Location: Pemrokeshire
Posts: 585

Wales 2005 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

Nothing really that I can recall... Plenty of rags and some brake cleaner if your like me and a bit anal when it comes to cleaning hard to reach places that no one will ever see! 🙈
You will need a grinder and a bit of hammerite as you need to trim the crash bar fixings a little bit (will be obvious when you have it off) other than that some GOOD quality hose clamps and some new hoses (if you haven't already)
Good luck and feel free to message if you need any more help
  
Post #206260520th Jun 2019 11:23 am
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Whilst looking I’ve notice 2 types of rs500 inter cooler depths one is 45mm and another is 65-70mm so do I go for the deeper one ? Which did you have Timmy
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #206274320th Jun 2019 8:05 pm
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timmyt79
 


Member Since: 18 Oct 2016
Location: Pemrokeshire
Posts: 585

Wales 2005 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

Mmmm.. Can't remember off top of my head, will have a look back through and let you know asap
  
Post #206274420th Jun 2019 8:08 pm
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Thumbs Up
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #206274520th Jun 2019 8:08 pm
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timmyt79
 


Member Since: 18 Oct 2016
Location: Pemrokeshire
Posts: 585

Wales 2005 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

Just to clarify are you talking depth of the intercooler itself or the pipework?
Prob best if I just get under mine and measure when I come off night duty in the morning! 🙈
  
Post #206274620th Jun 2019 8:15 pm
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Yeah thanks I’m thinking front to back dim not the hose size as I can cut and tig weld the old one on. As I’m guessing it needs to extend a bit longer to pick up where the hoses are. From photos the cooler is further out in front of the radiator correct me if in wrong
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #206275020th Jun 2019 8:20 pm
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Update resolved

The cause was a number of issues,

Drivers side egr valve broken off causing a rattle inside like it was the tappets, allowing exhaust gasses to vent straight into the throttle body

Throttle body seals wear allowing a slight leak

Egr blank cover plates to throttle body were leaking slightly

Air intake pipe that sits vertically just behind radiator was to low to form a seal with the ducting that travels across the top of the radiator because the bracket that holds it to the cowl was snapped. This was causing the dump valve noise

The turbo and actuator were perfectly fine and with all the leaks happening before and after the boost it ment the car couldn’t make the numbers add up so it threw the above faults up

Hope this helps someone to resolve the same issue
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 


Last edited by Dazz360 on 6th Nov 2019 9:26 pm. Edited 2 times in total 
Post #20980126th Nov 2019 8:12 pm
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Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Thumbs Up
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #20980346th Nov 2019 9:23 pm
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