At Last The Big TD5 job

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raywin

raywin

Well-Known Member
Posts
3,808
Location
North Yorkshire
Since I bought my defender, I have been threatening to re build the engine, the cam shaft is damaged and I thought I might use this to trigger a full re build, I intend to do the rings the bottom end shells and all other bits that deserve attention although I can see that getting a bit expensive so with 121K miles on the clock here we go.

I decided to make a start yesterday


IMG_0466.JPG

Right you bugger you are having it
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Over time it has become quite scruffy in there cables tied up with tie wraps and pipes hanging down, I would love to see a picture under the bonnet of a TD5 with all pipes and cables in their correct place as when new.
IMG_0479.JPG

Took off the inlet manifold just to get better access to things (see what I mean about cables etc a right rats nest in there)
IMG_0478.JPG

The power steering pipe work looks shot, first item onn the extra costs list.
Spent the day pludding along disconnecting everthing but decided to wrap up and try a pint.
 
The split conduit all looks in good condition. Ours is a 2003 disco with 119k miles. The old engine is fubar and is in the scrapyard and I am going to have to put s replacement in. The conduit in ours is all crumbly and I need to replace it.
 
brianconwy said:
The split conduit all looks in good condition. Ours is a 2003 disco with 119k miles. The old engine is fubar and is in the scrapyard and I am going to have to put s replacement in. The conduit in ours is all crumbly and I need to replace it.
Click to expand...
Seems to me the looms in these vehicles go off after a time, I have a "new" loom to fit in mine which I bought from oe of the members on here, mine also had a tuning chip fitted which was scotch locked onto the injector wires at the red plug end, I removed the chip but the scotch locks had cut through the insulation, I also cut out the crank sensor cable and soldered in a new lead a couple of years ago.
Hope that the new loom will help it run more smoothly.

By the way hope you saved some of the bits from the old engine.
 
Just been through similar good luck , Take plenty of pics as you go it helps putting it all back together and don’t rush along too quick without bagging up and labelling. Good gloves keep your hands clean - black mamba don’t split
 
steve2286w said:
Just been through similar good luck , Take plenty of pics as you go it helps putting it all back together and don’t rush along too quick without bagging up and labelling. Good gloves keep your hands clean - black mamba don’t split
Click to expand...
Thanks, I am planning to take it steady I have plenty time to do it, just need to get the engine in the garage under cover.
How did yours go? Did it run better and make it worth all the effort?
 
Henry_b said:
My 183k TD5 prolly needs a refresh!
Not in any hurry though!

Look forward to the progress/.
Click to expand...
Bit frustrated by rain today but looking to get some of the stuff stripped off yesterday into the back of the defender and make room in the garage, then if I can get the engine out tomorrow should be able to move forward.
New engine stand should be here early next week, bore gauge was delivered today, new spring compressor due tomorrow.
Will post my progress if people want to see it.
Its exciting times at the moment.
 
raywin said:
Bit frustrated by rain today but looking to get some of the stuff stripped off yesterday into the back of the defender and make room in the garage, then if I can get the engine out tomorrow should be able to move forward.
New engine stand should be here early next week, bore gauge was delivered today, new spring compressor due tomorrow.
Will post my progress if people want to see it.
Its exciting times at the moment.
Click to expand...

Yep keep us posted! ;)
 
raywin said:
Will post my progress if people want to see it
Click to expand...

Peeps on here always love to see a tired engine given a new lease of life:)

With pics of course:)

Oh and don’t forget to write down any new swear words you make up:eek:

Good luck.

J
 
raywin said:
Seems to me the looms in these vehicles go off after a time, I have a "new" loom to fit in mine which I bought from oe of the members on here, mine also had a tuning chip fitted which was scotch locked onto the injector wires at the red plug end, I removed the chip but the scotch locks had cut through the insulation, I also cut out the crank sensor cable and soldered in a new lead a couple of years ago.
Hope that the new loom will help it run more smoothly.

By the way hope you saved some of the bits from the old engine.
Click to expand...
Yes, apart from the block, crankshaft and the piston that was destroyed. I fitted a crank sensor lead that is supposed to be an upgrade on the original and an injector haeness. The wire to the oil pressure switch on the oil cooler has snapped - so I need to fix that. All good fun.
 
Last edited:
Not only the cricket rained off yesterday, only managed to get some of the stuff out off the garage and stored it in the back of the defender, space is prety tight.
IMG_0483.JPG


So get stuck in today.
I took off the power steering pump and left it connected to the pipe work, took off the bell housing bolts left the top two in position then jack up the gear box to support it.

IMG_0485.JPG


I took the bolts out of the engine mounts to cut down the amount of lift needed to get the engine clear of the gear box, the bolts are a sod to get out, managed to break the brake vacuum pipe DAM need to start looking for a new one or a straight connector.


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OK time to check arround again and then get ready to lift it out, pull back the bonet with a light rope and use my patent bonnet protector to avoid scratching it.

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Bit of a struggle to get it clear single handed but out she comes

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I'm not sure but engines seem much bigger and heavier than when I was a lad, quite honestly I've had enough today so a good tidy up and get the engine onto some wooden blocks so that I can start to strip the auxiaries off it and put it onto the engine stand which arrived today.
At least I am not at the mercy of the weather now and hopefully the hard graft is done untill its time to put it back, feel I've earned a pint.

IMG_0495.JPG

IMG_0498.JPG
 
Looks a monster of an engine, I wish I had an engine stand when I did mine , forever rolling it around, Landry looks good nick underneath , what symptoms did you have with bad cam and how was it damaged
 
There is a lot more room at the back of the emgine on a defender. I had to take the bonnet off on the disco and just removed the first two radiators. The inlet manifold bolts were hard to get to. I think I will install the replacement motor with the inlet manifold in place and fit the exhaust manifold later. I am toying with the idea of fitting a new fuel pressure regulator while the engine is out and the oil pump pulley bolt. The serpentine belt looks in good condition. Is it worth me spending on a new one?
 
Am I right in thinking that the engine can only be mounted on a stand with the flywheel off? While I am changing the oil pump bolt, I already have a rear crankshaft seal and I could change that. The clutch I have kept from the old engine is only 3 months old so I might as well swap that.
 
raywin said:
Not only the cricket rained off yesterday, only managed to get some of the stuff out off the garage and stored it in the back of the defender, space is prety tight.
View attachment 187043

So get stuck in today.
I took off the power steering pump and left it connected to the pipe work, took off the bell housing bolts left the top two in position then jack up the gear box to support it.

View attachment 187045

I took the bolts out of the engine mounts to cut down the amount of lift needed to get the engine clear of the gear box, the bolts are a sod to get out, managed to break the brake vacuum pipe DAM need to start looking for a new one or a straight connector.


View attachment 187046

OK time to check arround again and then get ready to lift it out, pull back the bonet with a light rope and use my patent bonnet protector to avoid scratching it.

View attachment 187047

Bit of a struggle to get it clear single handed but out she comes

View attachment 187048

I'm not sure but engines seem much bigger and heavier than when I was a lad, quite honestly I've had enough today so a good tidy up and get the engine onto some wooden blocks so that I can start to strip the auxiaries off it and put it onto the engine stand which arrived today.
At least I am not at the mercy of the weather now and hopefully the hard graft is done untill its time to put it back, feel I've earned a pint.

View attachment 187049
View attachment 187050
Click to expand...
superb watching closely!
 
steve2286w said:
Yes it bolts to the rear of block
Click to expand...
It was a silly question really as I bolted the old block to the stand to remove parts before I got rid of it. I was hoping there was an alternative way of mounting but I doubt any fastening points on the front of the engine wouldn't be strong enmough even if there were four of them in convenient places. Do you think resting the engine on the rocker cover would damage it?
 
brianconwy said:
It was a silly question really as I bolted the old block to the stand to remove parts before I got rid of it. I was hoping there was an alternative way of mounting but I doubt any fastening points on the front of the engine wouldn't be strong enmough even if there were four of them in convenient places. Do you think resting the engine on the rocker cover would damage it?
Click to expand...
Yes. I wouldn't be doing that.
 
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