Voyager CRD 2.5 engine overhaul
 

Hello everyone, the warm weather is almost here and I am thinking of removing the engine and gearbox from my 2002/3 Voyager 2.5CRD. The mileage is about 155,000km or 100,000miles.

The to do list:

1. replace the turbo with a reconditioned one as my bearings are leaking oil
2. replace all sensors at the rear (turbo side) of the engine as these are probably losing their accuracy by now
3. replace crankshaft oil seals, both sides - the one on the gear box side is leaking
4. maybe replace the clutch plate
5. clean up rush on chassis and apply neverox rustproof
6. maybe replace the coolant heater pipes from the auxiliary heater as these are a bit rusty in places
7. replace any engine mounts that are failing

So far with this car, I have already replaced the egr valve, belts, pulleys, glow plugs, injectors, water pump and just purchased a new set of tires last winter.

Is there anything else I should be thinking of replacing or servicing?

Many thanks for any feedback, comments etc. Rgds, kkc

wow, that's quite a project you have there. I cannot add anything there, however for everyones benefit it would be good if you could document and photo and gotchas or techniques you learn in doing so, as a lot of what you're doing are done in smaller parts/sections by forum members who would be very grateful.

Good luck, and I look forward to your tips and tricks!

You should definitely replace the timing belt and water pump and unless your clutch isn't that old, also replace the clutch plate, pressure plate and release bearing.

Timing belt, water pump and clutch plate (+crankshaft oil seal + serpentine belt) is exactly what I did at around 200K km
I'm over 300K km now and still going strong with no major problems until now.