Bennehboy
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Balls, too late to post this tip, but if you run a 1mm slitting disk up the length of an old head bolt, it works as a perfect thread chaser.....
At Last The Big TD5 job
- Thread starter raywin
- Start date
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raywin
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Will try to, hope that I will have the luxury of standing back and firing it up.
I put quite a bit of time and effort into this and the one thing I dread is something stupid happening to negate all of that, dont expect a miracle but just hope it runs a bit better with the new camshaft and bearings.
Plan to make a couple of trips when it's up and running and just hope it feels reliable.
raywin
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Thanks for that, yes I've used that one in the desperate past, but quite honestly the threads were very free, I ran an old bolt down to the bottom of the threads virtualy with my finger and thumb, I put just a little molyslip thread paste on it just to be sure the block threads were not dry.
I've tightened up a few bolts in my time from heat expending turbine cover bolts to torquing impeller bolts, and the first bolts didn't feel right some were much tighter than others while some were tight then I suddenly relaxing
Second lot were even seeming to need a very similar effort for each bolt per stage.
Just one thing the first set were ordered as OEM and came in a blue bag.
Second lot looked much better, threads were very smooth,
lesson learned
Bennehboy
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AMC head bolts are also very nice.
raywin
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Mine were from LR direct.
One tip for anyone doing this is spend a bit on head bolts, it is cheaper.
raywin
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Short break in Ibiza, bit stormy at first but nice later, enjoyed having a happy hour pint ( 2 Euros ) sitting looking at the sea.
Back to reality now.
Way back I bought a pilot bush for the fly wheel, and put it in some oil but the original seemed OK, after a few things happened I decided I want to avoid any chance of taking this brute out again, so I fitted the bush, getting the old one out is a bit brutal so no pictures, I know the hydraulic trick but cant find anything the right diameter.
But heres a trick for you, the bushes are pourous so buy them well in advance and stand them in oil for a few week, hopefully will extend their life.
Put in a new centrifugal filter.
This is something I have often wondered about, I cant hear it run down when the engine stops but my hearing is prety poor, I looked at the old filter and I expected to see some sign of marking on the center bronze bush but it looks like the new one.
When the filter housing was off I shook it and you could hear the filter moving inside, in fact I was surprised at the clearance above the filter element it seemed to move too much for me,
Any thoughts anyone?
So I decided to get stuck in, sling the engine and ttry to get it out of the garage, I decided to leave the manifolds off to allow easier connection of pipes and cables, will find out later if this was a good idea.
This is a job for two men or one idiot.
Check the position of the bell housing and then I used the little pull lift to adjust the engine into roughly the same , I had to move the pull lift and the cord so that I could twist the engine on its long axis as well as tilt it back and forward.
Slowly slowly, a bit at a time, had to jack the gearbox up a bit
Ooops how did that get in there
Notice my faithfull old dummy bolts, made sets in 5, 6, 8 and 10 mm many years ago and they have been worth their weight in gold, put them in thebell housing bolt holes, to guide the engine and bell housing together.
Enough for today
Back to reality now.
Way back I bought a pilot bush for the fly wheel, and put it in some oil but the original seemed OK, after a few things happened I decided I want to avoid any chance of taking this brute out again, so I fitted the bush, getting the old one out is a bit brutal so no pictures, I know the hydraulic trick but cant find anything the right diameter.
But heres a trick for you, the bushes are pourous so buy them well in advance and stand them in oil for a few week, hopefully will extend their life.
Put in a new centrifugal filter.
This is something I have often wondered about, I cant hear it run down when the engine stops but my hearing is prety poor, I looked at the old filter and I expected to see some sign of marking on the center bronze bush but it looks like the new one.
When the filter housing was off I shook it and you could hear the filter moving inside, in fact I was surprised at the clearance above the filter element it seemed to move too much for me,
Any thoughts anyone?
So I decided to get stuck in, sling the engine and ttry to get it out of the garage, I decided to leave the manifolds off to allow easier connection of pipes and cables, will find out later if this was a good idea.
This is a job for two men or one idiot.
Check the position of the bell housing and then I used the little pull lift to adjust the engine into roughly the same , I had to move the pull lift and the cord so that I could twist the engine on its long axis as well as tilt it back and forward.
Slowly slowly, a bit at a time, had to jack the gearbox up a bit
Ooops how did that get in there
Notice my faithfull old dummy bolts, made sets in 5, 6, 8 and 10 mm many years ago and they have been worth their weight in gold, put them in thebell housing bolt holes, to guide the engine and bell housing together.
Enough for today
Attachments
raywin
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Today I continued to try and connect everything up, just plodding along trying to make it a bit neater under the bonnet.
I need a bit of help though.
I put in the new loom and all seems quite OK but the starter has two heavy cables which look as if they connect to it, but there is only one terminal, I coupled them up and took a picture.
Just wondered if any defender TD5 person may help me out here, does your starter motor connect like this?
Photo is taken under the vehicle.
I need a bit of help though.
I put in the new loom and all seems quite OK but the starter has two heavy cables which look as if they connect to it, but there is only one terminal, I coupled them up and took a picture.
Just wondered if any defender TD5 person may help me out here, does your starter motor connect like this?
Photo is taken under the vehicle.
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Have you not followed the other cable? Does the bigger one not come from the battery and the other go to the alternator? I'd have a look at mine (300Tdi) but I'm in Belfast this weekend. The Guinness is tremendous 
raywin
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Managed to find this on here (see attached file)
Seems the heavy red cable comes from the battery over the bell housing and connects to the same terminal as the alternator cable which is smaller.
So I think its OK, quote honestly it had to be the only place it would go but maybe I'm getting nervous.
Hope you enjoy the Guinness over there, must've quite expensive these days.
Seems the heavy red cable comes from the battery over the bell housing and connects to the same terminal as the alternator cable which is smaller.
So I think its OK, quote honestly it had to be the only place it would go but maybe I'm getting nervous.
Hope you enjoy the Guinness over there, must've quite expensive these days.
Hi Ray, yes that's how my starter is connected, please excuse the embarrassing state compared to yours, my fpr is very leaky and awaiting replacement!
Also re your post about hearing the centrifugal filter spinning down, I've noticed if I go to the local autoparts shop and buy their fram filters, I have great difficulty in hearing the spinning down, if I buy a mahle one from the local Landy garage it's really very audible, and I think its certainly worth spending a few extra pennies on high quality filters than not... I only use coopers, mahle or Mann now on mine, peace of mind!
Great build thread BTW, easy reading in bed with a cuppa!
Great build thread BTW, easy reading in bed with a cuppa!
raywin
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Also re your post about hearing the centrifugal filter spinning down, I've noticed if I go to the local autoparts shop and buy their fram filters, I have great difficulty in hearing the spinning down, if I buy a mahle one from the local Landy garage it's really very audible, and I think its certainly worth spending a few extra pennies on high quality filters than not... I only use coopers, mahle or Mann now on mine, peace of mind!
Great build thread BTW, easy reading in bed with a cuppa!
Thank so much for that, it's so embarrassing to suddenly think hang on was there one or two cables on here. it's nice to take your time and plod along if you have the chance but the memory isn't as sharp these days, with your picture I'm confident to go on.
Re the filter sounds like good advice I think the one removed was a mahle but I may try a LR one, in reality they should be good for two or three oil changes but I've been changing at 12 months.
Been a lot of hard work but if it runs a bit better then it's all been worth it.
BTW
Try a bosch FPR like the one on here seems much better and it has a pipe on it so that you can divert any spillage resulting from a failure.
Will try to find the source.
Found it:
https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/332308717053
Last edited:
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It's best to check with those cables. Nasty consequences if they're in the wrong place
raywin
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That's what was worrying me, a cable that size direct on the battery would cause the battery to explode if it was shorted.It's best to check with those cables. Nasty consequences if they're in the wrong place
In reality there is only the starter and the alternator, which have such heavy cables in that area, but a bit of self doubt was creeping in.
Funny thing no matter how many digital pictures you take, you never seem to have the one you need.
raywin
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Rain stopped play today, bit of a clean up but no serious progress.
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Nothing wrong with a little bit of self doubt. Measure twice, cut once sort of thing. Far better than being blasé and seriously melting stuff.
When I did my rebuild I took so many pictures it was unreal. I still had a frustrating number of times when I had several pictures of an area, but they didn't quite show what I needed to see
You can't take too many.
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Nothing wrong with a little bit of self doubt. Measure twice, cut once sort of thing. Far better than being blasé and seriously melting stuff.
When I did my rebuild I took so many pictures it was unreal. I still had a frustrating number of times when I had several pictures of an area, but they didn't quite show what I needed to see
And have a Cheat Sheet ...
Bits of masking tape labels ...
All of it ...
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Yes, I had a lot of masking tape labels. Should have used pen rather than pencil though
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Yes, I had a lot of masking tape labels. Should have used pen rather than pencil though
The Rise of the Sharpie ...
raywin
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I'm not allowed anything sharp.
