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Replacing DIII TDV6 TURBO - How to
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3
Replacing DIII TDV6 TURBO - How to

Subject : Replacing a turbo on a DISCO 3 TDV6

Specials tools :
- Un arrache rotule de bonne taille (truck or 4X4).
- E10 sleeve.
- Drill 6, 7,5, 8 long lenth, very high quality.
- Little drill (but powered Laughing ).
- Un pont ou une fosse.

Protection :
- Bien caler le véhicule, cette manip nécessite de démonter le bras de suspension supérieur avant gauche.


Pièces :
- 1 new turbo (bought on ebay : http://myworld.ebay.co.uk/qualityparts09

- 1 turbo/exaust gasket ESR3737 (delivered with the turbo)
- 1 syringe (10ml is good) (delivered with the turbo)
- 1 O-ring for the oil return tube LR006184

- 1 gasket for the begining of the oil return tube (delivered with the turbo)
- 2 screw to fix the turbo on the exaust pipe (motor side) 1372721

- 1 gasket (double) for the oil entry 1372726



Notes :
- wear some gloves, everything is compact in this car... Whistle Evil or Very Mad

Difficulty :
- The biggest difficulty is to drill the original gudgeon, it need to have some imagination et good tools. Wink
- 8/10.

Timing :
- 1 day and a half, working slowly but correctly ! (2 workers)

Rick Husband 🖕
 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 4th Apr 2024 7:21 pm. Edited 10 times in total 
Post #9490841st Jul 2012 8:01 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

1 - Lift the car to high position.




2 - Open the bonnet, remove the jack and lock it.

http://www.landmania.com/forum/showthread.php?t=81873


3 - Unplug the battery



4 - Lift the front left ot the car, and put it on a stay. Remove the wheel.


5 - Remove the under protections of the motor and the gearbox.

 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 1st Jul 2012 8:57 am. Edited 3 times in total 
Post #9490851st Jul 2012 8:01 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

6 - Remove the screw the thermic protection of the fuel filter on the cross-part. 10 mm sleeve.




7 - Loosen the 2 front screws and the central one of the fuel tank. 13 mm sleeve with extension.


8 - Loosen the fixing screws othe the cross-part. 15 mm sleeve, 18 mm wrench.




9 - Holt the gearbox with a jack.




10 - Remove the fixing screw of the gearbox.

 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 1st Jul 2012 9:11 am. Edited 3 times in total 
Post #9490871st Jul 2012 8:02 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

11 - Remove the cross-part.


12 - Loosen the screw of the exaust collar. 15 mm pipe wrench.



WD40 is my friend Whistle


13 - Remove the 3 screws fixing the exaust pire on the turbo. 19 mm sleeve with extension and gimbal.



It is also possible to access to 2 nuts under the fond fender :super: (in this case, a flat round ratchet si a good idea Wink )




14 - Remove the rubber attachment.



Le pot sort bien en tirant sur la partie arrière dans un premier temps.


15 - reassemble the cross-part, the gearbox screw, don't jam, to remove the jack to have more place to move.
 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 1st Jul 2012 11:19 am. Edited 2 times in total 
Post #9490881st Jul 2012 8:03 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

16 - Remove 4 screws of the large heatshield. 10 mm pipe wrench.




17 - Remove 2 screws of the small heatshield. 10 mm pipe wrench.




18 - Remove the turbo fixing sheet. 10 and 13 mm wrench.




19 - Remove the 2 screws and the gudgeon of the bracket. 10 and 13 mm wrench.




20 - Remove the bottom nut who fix the turbo on the exaust pipe. 13 mm wrench.



It is the nut who can be seen above the right gudgeon.
 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 1st Jul 2012 11:33 am. Edited 2 times in total 
Post #9490891st Jul 2012 8:03 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

21 - Remove the fixing screw of the heatshield. 10 mm wrench.




22 - We can stop caving and go outside Thumbs Up




23 - Remove fixing screw of the heatshield. 10 mm wrench.



The heatshield is in 3 parts.


24 - Remove the top attachment of the suspension arm control.



25 - Remove the nut of the anti roll bar link up. 9 and 18 wrench.



The 9 mm wrench is use to stop the rotation of the arm.
 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 1st Jul 2012 9:26 pm. Edited 3 times in total 
Post #9490901st Jul 2012 8:04 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

26 - Remove the screw on the brake pipe and separate the cables. 10 mm wrench.



27 - Remove the patella nut. 30 torx wrench and 18 mm wrench. Remove the patella axle with a special tool.

28 ) Remove 2 nuts on the top arm axles. 9, 18 and 21 mm wrench.



You can operate on top, with a magnet on a long arm to finish to remove the axle :super:


29 - We have some place to work now ! Thumbs Up




30 - Remove the little plastic part near the webasto exhaust. You can use a screwdriver

 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 1st Jul 2012 12:18 pm. Edited 3 times in total 
Post #9490911st Jul 2012 8:04 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

31 - Remove 2 screw of the direction column et remove the column. E10 sleeve.



You can remove the column on front bottom of the car Thumbs Up

The next pictures were taken with the column in place...


32 - Remove 2 screw of the heatshieldon the turbo. 8 mm wrench.




33 - Remove the inflow hose. 50 torx wrench



You can't use a sleeve here.


34 - You must go under the car now. Remove the screw of the bottom of the exhaust oil pipe. 8 mm wrench.




35 - Remove 2 screw on the top of the exhaust oil pipe. 30 torx sleeve withe long extention.
 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 1st Jul 2012 12:36 pm. Edited 3 times in total 
Post #9490921st Jul 2012 8:05 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

36 - Remove the exhaust oil pipe.


37 - Remove 2 screw on the bottom of the turbo. 10mm sleeve and extension.



It is easy to remove for the one who can be seen on the picture. The second one is realy difficult Evil or Very Mad We have won the battle with this screw in this way : you can proceed with a long extension on a 10 mm sleeve, you have a passageway between the radiator and the differential. Patience... Rolling Eyes


38 - Drill the gudgeon on the turbo.



Be sure to protect everything who don't like filing before drilling....
You have do drill on aprox 15 mm, diameter 8 mm.

Be sure to have some good quality long drill and a small drill but with power. I have use a pneumatic one.


39 - Loosen the 2 metal collar on air pipes.




40 - Unplug the command cable and extract the turbo Laughing .
 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 1st Jul 2012 12:51 pm. Edited 3 times in total 
Post #9490931st Jul 2012 8:05 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

41 - Guinness, shower, a good sleep to have a look the day after Thumbs Up


42 - Fit the turbo.

Take care to inject some oil with the syringe in the entry of the oil in the turbo.

Drill 2x 8 mm hole (same we have drill on the old turbo) to put 2 screws on place of the gudgeon.

Take a short 13 mm wrench to maintain the nuts on exhaust pipe side. Heads of the screws are E10.



43 - Proceed in the same way back to fit all parts in place... Mr. Green .

I have put some gease on scews on the cross-part, they bhave began to get rusty.
You have to change the nylstop nuts but I have use some glue (Loctite 243 / normal) for winting the new nuts.

When you start the motor the first time, don't accelerate, don't tutch the pedal for one minute, to be sure that some oil came in the turbo, with pressure, before it couldd start to turn on high speed.
 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 


Last edited by gecko_fr on 18th Jan 2014 8:35 pm. Edited 3 times in total 
Post #9490941st Jul 2012 8:06 am
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Biffysun
 


Member Since: 09 Jul 2011
Location: Central
Posts: 1790

Scotland 2016 Discovery 4 3.0 SDV6 SE Tech Auto Corris GreyDiscovery 4

Well done Thumbs Up Its a pure b Censored d of a job and you even had the patience to take pics! Thumbs Up
  
Post #9490971st Jul 2012 8:19 am
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Flack
 


Member Since: 06 Sep 2006
Location: Preston Lancashire
Posts: 6307

England 2007 Discovery 3 TDV6 XS Auto Stornoway GreyDiscovery 3

Good write up bud, its one of the worst jobs on the D3...


Flack
  
Post #9491051st Jul 2012 8:57 am
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NoDo$h
 


Member Since: 02 May 2006
Location: Finding new and exciting ways to milk badgers.
Posts: 19689

Ukraine 

Bow down
 I know it's not considered "kind" to say no these days, but no. Just no, ok? And if it's not ok, still no.  
Post #9491401st Jul 2012 10:23 am
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gecko_fr
 


Member Since: 26 Jul 2010
Location: Near Dijon
Posts: 127

France 2007 Discovery 3 TDV6 HSE Auto Stornoway GreyDiscovery 3

So, I have finish...

Excuse me for my bad english...

I expect that could help some guys who want to do this !

(if some English men want to correct my job in good english, I will be happy to read the correction in MP and remove my bad words Laughing )
 Stornoway Grey
Replacing DIII TDV6 TURBO - How to
Brake cross reference documentation
Bible sur les freins de Bodsy en français 
 
Post #9492171st Jul 2012 1:11 pm
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Disco_Mikey
 


Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20836

Scotland 2005 Discovery 3 TDV6 HSE Auto Cairns BlueDiscovery 3
Re: Replacing DIII TDV6 TURBO - How to

gecko_fr wrote:

- 2 screw to fix the turbo on the exaust pipe (motor side) 1372721



£12 per bolt! Shocked

Much better idea is a 40mm long bolt, from the front timing cover of a 300TDi Disco/Fender. 48p each Thumbs Up
 My D3 Build Thread

TDV8 Retrofit Build Thread 
 
Post #9492391st Jul 2012 2:34 pm
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